Adhesion Promoting Coating for Golf Ball Layer Bonding
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Solution Overview
Problem
Current golf balls face challenges in achieving strong adhesion between adjacent layers, particularly between zinc-containing or magnesium-containing rubber-based layers and ionomeric layers, which affects durability and resistance to impact.
Innovation Solution
The application of an adhesion promoting coating composed of a waterborne dispersion with an ethylene acid copolymer having an acid content of at least 15% by weight, which forms strong bonds with zinc-containing or magnesium-containing components and ionomeric materials, enhancing inter-layer adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a zinc-containing or magnesium-containing rubber-based layer is directly bonded to an ionomeric layer, then manufacturing simplicity is maintained, but adhesion strength between layers is insufficient
Solution Approach 1:
The patent introduces an intermediate adhesion promoter coating between the zinc-containing or magnesium-containing rubber-based layer and the ionomeric layer. This coating contains carboxylic acid groups that chemically bond to the metal-containing rubber layer and also bond to the ionomeric layer, thereby mediating the adhesion between the two layers and solving the insufficient bond strength problem without requiring fundamental changes to the layer structure.
Solution Approach 2:
The patent creates a composite interface structure by combining the metal-containing rubber layer, the adhesion promoter coating with carboxylic acid groups, and the ionomeric layer. This composite material approach at the interface enhances the overall adhesion strength by utilizing the complementary properties of each material layer, particularly the chemical reactivity of carboxylic acid groups with both the metal components and the ionomeric material.
2Reliability
If conventional layer bonding is used without adhesion promoter, then manufacturing process simplicity is maintained, but durability and resistance to impact force deteriorate
Solution Approach 1:
The adhesion promoter coating acts as a mediator that enhances the durability and impact resistance of the golf ball by creating a strong chemical bond between the core layer and the ionomeric layer. This intermediate layer prevents delamination under impact conditions while adding only a thin coating that can be applied through existing manufacturing processes, thus improving reliability with minimal impact on ease of manufacture.
Solution Approach 2:
The patent changes the chemical parameters of the interface by introducing a coating with specific carboxylic acid content (at least 15% by weight) and specific neutralization levels (10-70%). These parameter changes in the adhesion promoter coating significantly improve the bond strength and durability of the golf ball layers, allowing the structure to withstand impact forces that would otherwise cause failure in conventionally bonded layers.
3Strength
If high acid content copolymer is used in adhesion promoter coating, then adhesion strength to ionomeric layer is improved, but coating complexity and formulation difficulty increase
Solution Approach 1:
The patent specifies precise parameter ranges for the adhesion promoter coating, including acid content (at least 15% by weight), neutralization level (10-70%), and copolymer composition (ethylene and carboxylic acid components). By defining these parameters, the patent balances the need for high bonding strength to the ionomeric layer with the practical considerations of coating formulation and application, ensuring that the coating can be manufactured with controlled complexity.
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
This solution significantly improves the durability of golf balls by increasing the number of hits they can withstand before failing, reducing cracks and breakage, and maintaining resilience.
Implementation Method 1
strong bonding that results between at least one ethylene acid copolymer of the adhesion promoting coating and the Zn-containing components (such as zinc diacrylate ('ZDA') and/or zinc oxide ('ZnO'))
Implementation Method 2
ion-hopping that occurs between the ethylene acid copolymer(s) of the adhesion promoting coating and the ionomeric material of the outer layer molded thereabout
Implementation Method 3
the water dispersibility of the ethylene acid copolymer of the adhesion promoting coating where the acid content is 15% by weight or higher
Data Source
AI summary
Method of making a golf ball, the golf ball comprising a core, an outer layer and at least one adhesion promoting coating disposed between each of the core and the outer layer; the core comprising a rubber composition comprising at least one zinc-containing and/or magnesium-containing component; the outer layer comprising at least one ionomer; and the adhesion promoting coating comprising a waterborne dispersion comprised of at least one ethylene acid copolymer having an acid content of at least 15% by weight wherein the copolymer is at least partially neutralized with one or more neutralizing agent; wherein at least one neutralizing agent is selected from ammonia compounds and/or amine compounds. In a specific embodiment, the at least one neutralizing agent comprises i) mono and/or divalent metal compounds and ii) ammonia compounds and/or amine compounds.