Foamed Silicone Golf Ball Core Thermal Stability

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Solution Overview

Problem

Existing golf ball foam cores face issues with thermal stability, resiliency, and durability due to the low heat resistance of some polyurethane foams, which can lead to adverse effects on the core's size, resiliency, and stiffness during molding processes.

Innovation Solution

The development of golf balls with a multi-piece construction featuring a solid core assembly, including a lightweight foamed silicone inner core and non-foamed silicone elastomer inner cover layer, along with a thermoset or thermoplastic outer cover layer, providing high elongation, tensile strength, chemical/fluid-resistance, and improved heat stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If polyurethane foam is used for the inner core, then the core provides cushioning and weight reduction, but the foam exhibits poor thermal stability and loses resiliency during molding

Engineering Contradiction:

Improvecore weightVSAvoidthermal stability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent changes the material parameter from polyurethane foam to silicone foam, which fundamentally alters the thermal stability characteristic while maintaining the lightweight and cushioning properties needed for the golf ball core

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure combining silicone foam with thermoset or thermoplastic outer core layers, creating a multi-material core assembly that leverages the lightweight properties of foam while the outer layers provide thermal stability and structural integrity

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If polyurethane foam is used for the inner core, then the core achieves desired cushioning properties, but the foam undergoes thermal degradation affecting core size and stiffness

Engineering Contradiction:

Improvecushioning propertiesVSAvoidcore size consistency

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent changes the material composition from polyurethane to silicone foam, which has superior thermal stability that prevents degradation during molding, thereby maintaining consistent core size and stiffness while preserving cushioning properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermally unstable polyurethane foam with silicone foam that maintains its structural integrity throughout the molding process, eliminating the need for corrective measures to compensate for thermal degradation

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If conventional foam materials are used, then manufacturing is simpler, but the foam lacks durability and resiliency over time

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcore durability

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent creates a composite core structure where silicone foam provides durability and resiliency, while the thermoset or thermoplastic outer layers enhance structural stability and protect the foam, resulting in a long-lasting core assembly

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material properties by using silicone foam with superior elastic recovery and thermal stability, ensuring the core maintains its resiliency and durability throughout the golf ball's service life

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 solution enhances the thermal stability and maintains resiliency and durability of the golf ball core, ensuring consistent performance and longevity without thermal degradation, while also offering improved chemical and fluid resistance.

Implementation Method 1

a lightweight foamed silicone inner core

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

at least one layer made from a non-foamed silicone elastomer composition... desirable ball playing performance properties... resiliency

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

improved heat stability... without thermal degradation

Methodology Applied

Scientific EffectThermal stability:

Implementation Method 4

rebound velocity to its initial incoming velocity... coefficient of restitution... higher rebound velocity have a higher COR value

Methodology Applied

Scientific EffectEnergy absorption:

Data Source

PatentUS11583731B2Golf balls having layers made of silicone elastomers

Publication Date: 2023.02.21 ACUSHNET CO

AI summary

Multi-layered golf balls having at least one layer made of a foamed silicone composition are provided. Multi-layered golf balls having at least one layer made of non-foamed silicone elastomer composition also are provided. For example, three-piece, four-piece, and five-piece golf balls containing different core and cover structures can be made. The foamed silicones have good thermal stability and durability without sacrificing resiliency. The non-foamed silicone elastomers have high elongation, tensile strength, chemical/fluid-resistance, and weatherability properties. These compositions can be used to form any layer, for example, core, intermediate, or cover, in the golf ball.