Cross-linked Thermoplastic Foam Golf Ball Core
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Solution Overview
Problem
Existing foam core constructions for golf balls face issues with thermal stability and durability due to temperature fluctuations, leading to potential melting, collapse, and degradation of foam properties, affecting the core's resiliency and hardness.
Innovation Solution
A multi-piece golf ball design featuring a core assembly with a foamed inner core made from a cross-linked ethylene acid copolymer and a non-foamed outer core layer, where the inner core has a positive hardness gradient and is protected by a cross-linked thermoplastic composition to maintain thermal stability, and a multi-layered cover for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a foam core construction is used in golf balls, then the ball achieves desirable resiliency and rebound performance, but the foam core suffers from thermal instability leading to melting, collapse, and degradation at temperature fluctuations
Solution Approach 1:
The patent changes the chemical and physical parameters of the foam core material by using cross-linked thermoplastic compositions with specific glass transition temperatures and molecular structures. This modification allows the foam to maintain its cellular structure and mechanical properties across a wide temperature range while preserving desirable resiliency characteristics.
Solution Approach 2:
The patent employs composite material construction by combining cross-linked thermoplastic polymers with foaming agents to create a multi-phase material system. The cross-linked network provides thermal stability while the foam structure delivers resiliency, achieving both properties simultaneously in a single integrated core material.
2Ease of manufacture
If traditional foam materials are used in the core, then the manufacturing process is simple, but the foam core lacks durability and collapses under temperature stress
Solution Approach 1:
The patent modifies the manufacturing parameters by using cross-linked thermoplastic compositions that can be processed through standard injection molding techniques. The cross-linking occurs during or after molding, providing enhanced durability without requiring fundamentally different manufacturing equipment or processes, thus maintaining ease of manufacture while dramatically improving durability.
3Reliability
If the foam core is made softer to improve resiliency, then the ball achieves better rebound velocity, but the foam becomes more susceptible to thermal degradation and structural collapse
Solution Approach 1:
The patent achieves this balance by carefully controlling the glass transition temperature and molecular weight of the cross-linked thermoplastic foam. The cross-linking density and polymer chain flexibility are optimized to provide soft, resilient behavior at playing temperatures while maintaining structural integrity and resistance to thermal degradation across the full operating temperature range.
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 provides golf balls with improved resiliency, thermal stability, and durability over a wide temperature range, ensuring consistent performance and extended durability by maintaining the foamed core's structure and properties.
Implementation Method 1
the foam layer comprises a cross-linked thermoplastic, preferably an ethylene acid copolymer ionomer, composition
Implementation Method 2
a foamed inner core made from a cross-linked ethylene acid copolymer
Implementation Method 3
The core sub-structure located inside of the golf ball acts as an engine or spring for the ball
Data Source
AI summary
Golf balls having an inner core made of a foamed composition are provided. The core assembly preferably includes a foam inner core (center) and surrounding outer core layer. A cross-linked thermoplastic, preferably an ethylene acid copolymer ionomer, is used to form the foam composition. The core layers have different hardness gradients and specific gravity values. The ethylene acid copolymer is reacted with a metallic acrylate salt and peroxide free-radical initiator to form the cross-linked polymer. The foamed, cross-linked composition helps provide the inner core with good resiliency, thermal stability, and durability. Non-foamed thermoplastics or thermosets such as polybutadiene rubber may be used to form the outer core layer. The ball further includes a cover that may be multi-layered.