Foamed Golf Ball Core with Nanoclay Dispersion
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Solution Overview
Problem
Existing golf ball compositions face challenges in uniformly dispersing nano-materials, leading to agglomerates that negatively affect physical properties such as compression strength and resiliency, which are crucial for achieving high initial ball speed and distance.
Innovation Solution
A multi-piece golf ball design featuring a dual-layered core with a foamed inner core and a non-foamed thermoset or thermoplastic outer core layer, where the inner core comprises a polyurethane foam composition with mineral filler particulate, including nanoclay particles, to enhance dispersion and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If nano-materials are added to enhance mechanical properties, then resiliency and compression strength are improved, but uniform dispersion is difficult to achieve due to agglomerate formation
Solution Approach 1:
The patent uses a multi-component foam composition comprising polyol, polyisocyanate, blowing agent, and nanoclay particulate that creates a composite material system. The nanoclay particles (1-100 nm) are dispersed within the foam matrix formed by the reaction of polyol and polyisocyanate, creating a composite structure that provides both the mechanical strength enhancement from the nano-materials and the uniform dispersion through the foam formation process
Solution Approach 2:
The patent changes the physical and chemical parameters of the system by controlling the foam expansion process, temperature, and curing conditions to transform the nanoclay-containing mixture into a uniformly dispersed foam structure. The blowing agent creates gas bubbles that distribute the nanoclay particles uniformly throughout the expanding foam matrix, preventing agglomerate formation
2Speed
If dual-layered core structure is implemented, then initial ball speed and distance are enhanced, but manufacturing complexity increases
Solution Approach 1:
The golf ball core is segmented into two distinct layers: an inner core layer made of traditional rubber material and an outer core layer made of the nanoclay-reinforced foam composition. This segmentation allows each layer to contribute different properties - the inner layer provides foundational resiliency while the outer layer with nanoclay particles enhances compression strength and energy return, resulting in higher initial ball speed
Solution Approach 2:
The patent merges two different material systems - traditional rubber core material and nanoclay-reinforced foam - into a single dual-layered core structure. The foam layer is applied over or bonded to the rubber core, combining the proven performance of rubber with the enhanced mechanical properties of nanoclay foam to achieve superior ball speed and distance
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 achieves improved dispersion and mechanical properties of nano-materials, resulting in enhanced resiliency and durability, allowing for higher initial ball speed and greater distance shots.
Implementation Method 1
improved dispersion and mechanical properties of nano-materials
Implementation Method 2
enhanced resiliency and durability, allowing for higher initial ball speed
Data Source
AI summary
Multi-piece golf balls having a solid core made of a foamed composition and a cover are provided. Preferably, the core is dual-layered having has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition containing mineral filler particulate, for example, nanoclay particles, is used to form the foam center. The concentration of clay particulate is preferably in a range of 0.1 to 60% by weight. The surrounding outer core layer may be made from non-foamed or foamed compositions. For example, polybutadiene rubber or highly neutralized olefin acid copolymers may be used in the outer core layer. The core layers have different hardness gradients and specific gravity values.