Multi-layered Golf Ball Core with Foam and Thermoset Layers
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Solution Overview
Problem
Golf balls with foam cores tend to have low resiliency, resulting in short distances traveled after being hit, as they lack improved rebounding performance.
Innovation Solution
A multi-piece golf ball design featuring a solid core with three layers: a foamed inner core, a non-foamed intermediate thermoset layer, and a non-foamed outer thermoset layer, each with specific gravity and hardness gradients, optimized to enhance resiliency and playing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a foam core is used in golf balls, then the ball weight is reduced and manufacturing cost is lowered, but the resiliency and rebounding performance deteriorate, resulting in shorter flight distance
Solution Approach 1:
The core is divided into multiple layers with different materials: an inner foam core layer surrounded by outer thermoset rubber layers. This segmentation allows the foam to provide weight reduction while the thermoset layers contribute resiliency and rebounding performance, resolving the contradiction between lightweight construction and elastic strength.
Solution Approach 2:
The patent uses composite material construction combining foam (for low density and weight reduction) with thermoset rubber layers (for high resiliency and rebounding). This composite approach allows the ball to achieve both reduced weight and improved strength characteristics that neither material could provide alone.
2Ease of manufacture
If a foam core is used in golf balls, then manufacturing cost is reduced, but the rebounding performance and flight distance deteriorate
Solution Approach 1:
The core is segmented into an inner foam layer (easier and cheaper to manufacture) and outer thermoset rubber layers (provide superior rebounding performance). This segmentation allows cost-effective manufacturing while maintaining high-performance characteristics in the critical outer layers that directly contact the club face.
Solution Approach 2:
The composite structure combines inexpensive foam material with performance-oriented thermoset rubber, achieving a balance between manufacturing cost and rebounding performance. The foam provides cost-effective weight reduction while the thermoset layers deliver the necessary elastic response for long flight distance.
3Strength
If the core hardness is increased to improve durability, then the resiliency improves, but the feel and comfort for recreational players deteriorates
Solution Approach 1:
Different regions of the core have different hardness characteristics: the inner foam core provides softness and comfort for recreational players, while the outer thermoset rubber layers provide hardness and durability. This local differentiation of material properties allows the ball to satisfy both recreational and professional player requirements simultaneously.
Solution Approach 2:
The composite construction combines soft foam material in the inner core (providing comfort and ease of operation) with harder thermoset rubber in the outer layers (providing durability and resiliency). This material combination resolves the contradiction between hard durability and soft feel by assigning different material properties to different functional zones of the ball.
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 multi-layered core construction improves the golf ball's resiliency and playing performance, allowing for higher initial ball speed and longer distance shots while maintaining durability and control.
Implementation Method 1
the inner core has a diameter in the range of about 0.100 to about 1.100 inches and a specific gravity (SGinner)
Implementation Method 2
an intermediate layer comprising a first thermoset material, wherein the intermediate layer is disposed about the inner core
Data Source
AI summary
Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.