Single Layer Golf Ball Core Hardness Gradient Design
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Solution Overview
Problem
Existing golf ball designs fail to achieve a single layer core with a soft-to-hard hardness gradient from the surface to the center, which is desirable for optimal playing characteristics and manufacturing efficiency.
Innovation Solution
A single layer golf ball core with varying hardness regions, achieved by adjusting peroxide and antioxidant types and amounts, curing times, and temperatures, to create specific Shore C and Shore D hardness gradients within the core, allowing for a soft outer surface and a harder center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a hard core and soft cover design is used to achieve high spin rate and control, then spin rate and control are improved, but resiliency and distance are reduced
Solution Approach 1:
The patent applies local quality by creating distinct hardness zones within the core: an inner core region with first hardness, an outer core region with second hardness greater than the first, and an intermediate region with third hardness between the two. This gradient structure allows different regions to provide different functions - the harder outer region provides control while the softer inner region provides resiliency, resolving the contradiction between control and distance.
2Adaptability or versatility
If multiple core layers are used to achieve varying hardness regions, then playing characteristics are improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent segments the core into distinct hardness regions (inner core region, outer core region, and intermediate region) with varying hardness values. This segmentation allows for optimized playing characteristics in different zones while maintaining a single-layer construction that simplifies manufacturing compared to multiple separate layers.
Solution Approach 2:
The patent changes the physical parameter of hardness across different regions of the core by controlling crosslinking density and composition gradients. This allows for varying hardness (first hardness in inner region, second hardness in outer region) within a single continuous material structure, achieving complex playing characteristics without complex manufacturing.
3Ease of manufacture
If a single layer core with homogenous formulation is used, then manufacturing is simplified, but varying hardness regions cannot be achieved
Solution Approach 1:
The patent achieves local quality variations within a single-layer core by creating regions with different hardness values (inner core region with first hardness, outer core region with second hardness). This is accomplished through controlled gradients in crosslinking density and composition during the curing process, allowing precise hardness control in different zones while maintaining manufacturing simplicity.
Solution Approach 2:
The patent changes physical parameters (hardness, crosslinking density) across the core structure by controlling the curing process gradients. The outer core region is cured to achieve second hardness greater than the inner core region's first hardness, while the intermediate region has third hardness between the two. This parameter control is achieved through controlled exposure to heat and peroxide concentration gradients during manufacturing.
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 design enhances the golf ball's compression, spin, and feel while reducing manufacturing costs by eliminating the need for multiple core layers, offering improved control and distance without sacrificing performance.
Implementation Method 1
The cores can be heated and crosslinked to create certain characteristics, such as higher or lower compression, which can also impact the spin rate of the ball and/or provide better 'feel.'
Implementation Method 2
The cores can be heated and crosslinked to create certain characteristics
Data Source
AI summary
The invention is directed to a golf ball comprising: a single layer core and a cover layer disposed about the single layer core; the single layer core being formed from a substantially homogenous formulation and comprising a geometric center and an outer surface wherein the outer surface has a hardness greater than a hardness of the geometric center; the single layer core further comprising: an inner core region disposed about the geometric center; an outer core region disposed about the inner core region and adjacent the outer surface; and a boundary disposed between the inner core region and the outer core region at about 12 mm or less from the outer surface; wherein the boundary has a hardness that is greater than the hardness of the geometric center and greater than the hardness of the outer surface. In another embodiment, the boundary has a hardness that is greater than the hardness of the geometric center and less than the hardness of the outer surface.