Foamed Intermediate Layer Golf Ball with Specific Gravity Gradient
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Solution Overview
Problem
Existing golf ball compositions face challenges in achieving stability and durability of foamed layers over a wide temperature range, with difficulties in adjusting specific gravity without compromising impact durability and resiliency.
Innovation Solution
A multi-layered golf ball design featuring a non-foamed inner core and a foamed intermediate layer made from a thermoset composition, using a mixture of polyisocyanate, polyol, and curing agent compounds with water as a blowing agent, allowing for adjustable specific gravity and hardness gradients while maintaining impact durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a foamed composition is used to form an intermediate layer in golf balls, then specific gravity can be adjusted and resiliency is improved, but stability and durability over a wide temperature range are compromised
Solution Approach 1:
The patent uses a composite material system consisting of polyisocyanate, polyol, and curing agent compounds to form the foamed intermediate layer. This composite composition provides both the desired foamed structure for weight adjustment and the thermal stability needed for durability across temperature ranges, resolving the contradiction between adjustability and temperature stability.
Solution Approach 2:
The patent adjusts the specific gravity and hardness parameters of the intermediate layer by modifying the composition ratios of polyisocyanate, polyol, and curing agents, along with controlling foam cell structure. These parameter changes allow optimization of both resiliency and temperature stability simultaneously.
2Quantity of substance
If the specific gravity of the foamed intermediate layer is adjusted, then ball performance is optimized, but impact durability may be compromised
Solution Approach 1:
The patent creates local quality variations within the intermediate layer through controlled foaming, where the foam cell structure and density are optimized in specific regions. This allows the outer regions to maintain durability while inner regions provide weight adjustment, resolving the contradiction between specific gravity optimization and impact durability.
Solution Approach 2:
The composite formulation of polyisocyanate, polyol, and curing agents creates a multi-phase material structure where different components contribute different properties. The foam structure provides weight adjustment while the cross-linked polymer matrix maintains impact durability, allowing independent optimization of specific gravity and strength.
3Strength
If hardness gradients are introduced in the intermediate layer, then resiliency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent creates dynamic hardness gradients within the intermediate layer by controlling the foaming process parameters during manufacturing. The gradient structure allows the material to be softer at certain depths for resiliency while harder at others for durability, achieving enhanced performance without requiring multiple discrete layers or complex assembly steps.
Solution Approach 2:
The hardness gradient is achieved by systematically varying the composition and foaming parameters through the thickness of the intermediate layer. By controlling factors such as cross-linking density and cell structure at different positions, the patent creates a continuous hardness transition that optimizes resiliency while maintaining manufacturability through a single-cure process.
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 provides golf balls with improved resiliency, impact durability, and adjustable specific gravity, ensuring consistent performance across varying temperatures and conditions.
Implementation Method 1
a foamed composition, for example, polyurethane foam, is cast over the core to form an intermediate layer
Implementation Method 2
a foamed composition, for example, polyurethane foam, is cast over the core to form an intermediate layer
Data Source
AI summary
Multi-layered golf balls having a core, intermediate layer, and cover are provided. The ball includes a non-foamed inner core (center) made of a thermoplastic or thermoset composition such as polybutadiene rubber. An intermediate layer comprising a foamed composition, such as polyurethane foam, is disposed about the inner core. The foamed intermediate layer may have a specific gravity gradient within the layer, wherein the outer surface specific gravity is greater than the midpoint specific gravity. Ball constructions having two intermediate layers, wherein at least one layer is a foamed layer can be made. A cover having at least one layer is disposed about the intermediate layer.