Multi-layer Golf Ball Core with Hardness Gradient
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Solution Overview
Problem
There is a need for a golf ball with a very high positive gradient core, specifically a very soft, low compression inner core layer formed from an unfoamed composition that provides good durability and contributes to spin reduction.
Innovation Solution
A golf ball design featuring a core with a solid inner core layer made from an unfoamed thermoplastic composition and an outer core layer formed from a thermoset composition, where the inner core layer has a center Shore C hardness of 50 or less and the outer core layer has a thickness of 0.200 inches or greater with an outer surface Shore C hardness at least 40 points greater than the inner core layer, creating a steep positive hardness gradient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a soft inner core layer is used to reduce spin, then spin control is improved, but durability deteriorates
Solution Approach 1:
The core is divided into multiple layers with different hardness properties: a soft inner core layer (Shore C hardness 30-50) for spin control and a hard outer core layer (Shore C hardness 70-90) for durability. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between spin reduction and durability.
Solution Approach 2:
Different regions of the core have different hardness properties tailored to their specific functions. The inner core layer is made soft (lower Shore C hardness) to reduce spin on full shots, while the outer core layer is made hard (higher Shore C hardness) to provide durability and resistance to deformation. This local differentiation of material properties resolves the contradiction between spin control and durability.
2Reliability
If a hard outer core layer is used to improve durability, then durability is improved, but spin control deteriorates
Solution Approach 1:
The core is segmented into functional layers where the outer core layer provides durability through its hard properties (Shore C hardness 70-90) while the inner core layer handles spin control. This segmentation allows the hard outer layer to protect against damage without interfering with the spin-reducing function of the soft inner layer.
Solution Approach 2:
The outer core layer is specifically designed with hard material properties (higher Shore C hardness) localized to the outer region of the core, where durability is most needed. This localized hardness provides protection and resistance to deformation without preventing the inner soft layer from controlling spin effectively.
3Object-generated harmful factors
If a soft inner core layer is used to reduce spin, then spin control is improved, but compression control deteriorates
Solution Approach 1:
The core is segmented into compression-bearing and spin-control zones. The outer core layer with higher Shore C hardness (70-90) and greater thickness (0.15-0.30 inches) provides the primary compression resistance, while the inner core layer with lower Shore C hardness (30-50) and smaller diameter (0.80-1.10 inches) focuses on spin reduction. This segmentation resolves the contradiction by assigning compression control to the hard outer layer and spin control to the soft inner layer.
Solution Approach 2:
Different regions of the core have different compression characteristics: the outer core layer is designed with hard material properties and greater thickness to bear compression loads, while the inner core layer is designed with soft material properties optimized for spin control. This local differentiation of compression properties resolves the contradiction between spin reduction and compression control.
4Reliability
If a hard outer core layer is used to improve durability, then durability is improved, but compression resistance deteriorates
Solution Approach 1:
The core is segmented into functional zones where the outer core layer (Shore C hardness 70-90, thickness 0.15-0.30 inches) is specifically designed to bear compression loads and provide durability, while the inner core layer handles spin control. This segmentation ensures that the hard outer layer's primary function is compression resistance, resolving the contradiction between durability and compression control.
Solution Approach 2:
The outer core layer is designed with localized hard material properties (higher Shore C hardness) and greater thickness in the region where compression resistance is most needed. This localized hardness and thickness distribution optimizes the outer layer's ability to resist compression while maintaining durability, resolving the contradiction between these two parameters.
Data Source
AI summary
A golf ball comprising a core and a cover, wherein the core consists of: a solid inner core layer formed from an unfoamed thermoplastic composition and having a diameter of 1.10 inch or less and a center Shore C hardness (Hcenter) of 50 or less, one or more optional intermediate core layers, and an outer core layer formed from an unfoamed thermoset composition and having a thickness of 0.200 inches or greater and an outer surface Shore C hardness (Houter surface) of 70 or greater, wherein Houter surface>Hcenter, and Houter surface−Hcenter≧40.