Foam Core Golf Ball Resiliency via Composite Structure

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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 fail to maintain initial velocity and energy transfer effectively, limiting their performance in long-distance shots.

Innovation Solution

A golf ball design featuring a foamed polyurethane inner core with a positive or zero hardness gradient and a thermoset or thermoplastic outer core layer, optimized with a highly neutralized polymer composition to enhance rebound and durability, incorporating specific hardness and density gradients to improve resiliency and energy retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a foam core is used in golf balls, then the ball weight is reduced and manufacturing cost decreases, but resiliency and coefficient of restitution are significantly reduced

Engineering Contradiction:

Improveball weightVSAvoidresiliency

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses a composite material system consisting of a foamed polyurethane inner core combined with a thermoset or thermoplastic outer core layer. This composite structure allows the inner foam core to provide weight reduction while the outer layer compensates for resiliency loss, achieving a balance between lightweight design and acceptable rebound performance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating a hardness gradient within the inner core layer, where the hardness varies from the center to the outer surface. This gradient structure (with specific hardness ranges at different depths) allows the core to optimize both weight and resiliency locally - softer regions provide compression and energy storage while harder regions maintain structural integrity and rebound

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If a foam core is used in golf balls, then manufacturing cost decreases, but energy transfer and initial velocity maintenance are insufficient

Engineering Contradiction:

Improvemanufacturing costVSAvoidenergy transfer

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The composite structure of foamed inner core plus thermoset/thermoplastic outer core layer creates a cost-effective solution that maintains energy transfer capability. The foam provides cost advantage through reduced material usage and simplified manufacturing, while the outer layer ensures sufficient energy transfer efficiency during club impact

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes energy transfer by carefully controlling the density and hardness parameters of the foamed core. The inner core density is maintained between 0.04-0.20 g/cm³ and hardness between 10-50 Shore C, with specific gradient profiles that maximize elastic recovery and energy return while minimizing material cost

Inventive Principle:

Principle #35Parameter changes

3Reliability

If hardness gradient is increased in inner core, then resiliency improves, but manufacturing precision requirements increase

Engineering Contradiction:

ImproveresiliencyVSAvoidhardness gradient control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent defines specific parameter ranges for the hardness gradient to balance resiliency improvement with manufacturing feasibility. The inner core hardness transitions from 10-50 Shore C at the center to 20-60 Shore C at the outer surface, with controlled gradient rates that achieve performance goals while remaining manufacturable using conventional injection molding and foaming processes

Inventive Principle:

Principle #35Parameter changes

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 design significantly increases the golf ball's resiliency and coefficient of restitution, allowing for higher initial ball speed and longer distances, while maintaining durability and control, particularly in long-distance shots.

Implementation Method 1

The inner core layer has an outer surface hardness and a center hardness to provide a positive or zero hardness gradient... significantly increases the golf ball's resiliency and coefficient of restitution

Methodology Applied

Scientific EffectElasticity: Elasticity