Foam Core Golf Ball with Density Gradient for Energy Transfer
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Solution Overview
Problem
Golf balls with foam cores tend to have low resiliency, resulting in shorter distances when hit, as they absorb impact rather than transferring energy effectively.
Innovation Solution
A golf ball core assembly featuring a foamed inner core layer and an outer core layer with specific gravity and hardness gradients, composed of highly neutralized polymer compositions, including acid copolymers and non-acid polymers, to enhance resiliency and energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a foam core is used in a golf ball, then the ball can absorb impact and provide comfort, but the resiliency decreases and distance is reduced
Solution Approach 1:
The core is divided into multiple layers with different foam densities - a lower density inner core layer and a higher density outer core layer. This segmentation allows the inner layer to absorb impact while the outer layer provides resiliency and energy return, resolving the contradiction between impact absorption and resiliency.
Solution Approach 2:
Different regions of the core have different density characteristics - the inner core has lower density for maximum impact absorption, while the outer core has higher density for energy return. This local variation in material properties allows both impact absorption and resiliency to be optimized in different zones of the same component.
2Object-affected harmful factors
If a foam core is used in a golf ball, then the ball can reduce stress on impact, but the energy transfer efficiency decreases
Solution Approach 1:
The core is segmented into inner and outer layers with different foam densities. The inner layer absorbs impact stress while the outer layer efficiently transfers energy to the cover, minimizing energy loss while still providing stress reduction.
Solution Approach 2:
The core uses a composite foam structure combining low density and high density foam materials in specific layers. This composite approach allows simultaneous optimization of stress reduction and energy transfer efficiency by leveraging the complementary properties of different foam densities.
3Strength
If a dual-layer core with density gradient is used, then resiliency and energy transfer are improved, but the manufacturing complexity increases
Solution Approach 1:
The core is divided into two distinct layers with different foam densities, creating a manageable level of complexity that can be manufactured using existing multi-layer molding techniques while achieving improved resiliency and energy transfer.
Solution Approach 2:
The foam density parameter is varied systematically from the inner layer to the outer layer, creating a density gradient that optimizes performance. This controlled parameter change achieves complex functionality through a relatively simple structural modification.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution improves the resiliency of golf balls, allowing for higher initial ball speeds and longer distance shots by optimizing the core's structure and materials to better absorb and release energy.
Implementation Method 1
Golf balls with foam cores tend to have low resiliency, resulting in shorter distances when hit, as they absorb impact rather than transferring energy effectively
Implementation Method 2
The solution improves the resiliency of golf balls, allowing for higher initial ball speeds and longer distance shots by optimizing the core's structure and materials to better absorb and release energy
Data Source
AI summary
Multi-layered golf balls containing a dual-core structure are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The outer core layer is preferably formed from a non-foamed composition selected from thermoset compositions and thermoplastic compositions. The core layers have different hardness and specific gravity levels. The specific gravity (density) of the foam inner core is preferably less than the density of the outer core layer.