Self-aligning Golf Ball Core with Protrusions
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Solution Overview
Problem
The challenge in forming a golf ball sub-assembly lies in achieving sufficient adhesion between the core body and the casing layer, particularly with foamed materials, where premature or delayed plunging of the core body into the foamed casing layer material can result in displacement or insufficient support, and ensuring reliable centering within the casting mold.
Innovation Solution
A self-aligning core body with protrusions is used, allowing for immediate plunging into a foamed casing material with a viscosity of 5,000 cp-50,000 cp, which contacts the mold surface to center the core body, and is then cured to form a concentric casing layer, using techniques like silane treatment for adhesion promotion and double-shot casting methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the core body is plunged into the foamed casing layer material, then the core body is centered relative to the casting mold, but the core body may be displaced if plunging is performed too late
Solution Approach 1:
Protrusions are formed on the core body in advance before plunging, creating pre-positioning features that will engage with the casting mold interior surface to ensure accurate centering during the plunging operation
Solution Approach 2:
The protrusions on the core body automatically engage with the casting mold interior surface during plunging, enabling self-centering without requiring external monitoring or adjustment mechanisms
2Manufacturing precision
If the core body is plunged prematurely into the foamed casing layer material, then the core body is centered, but the viscosity of the foamed casing layer material has not reached a sufficient viscosity
Solution Approach 1:
The protrusions provide automatic centering functionality that works independently of the foamed casing layer material's viscosity state, eliminating the need to monitor and control the timing of plunging relative to material curing
3Measurement precision
If active monitoring of the curing or foaming of the foamed casing layer material is performed, then the target curing state can be determined, but the process complexity and cycle time increase
Solution Approach 1:
The protrusions enable self-centering through automatic engagement with the casting mold interior surface, eliminating the need for active monitoring systems to detect curing state or control plunging timing
Solution Approach 2:
The centering function is extracted from the foamed casing layer material curing process and transferred to the core body protrusions, allowing plunging to occur immediately without monitoring the material's viscosity or curing state
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 method ensures improved concentricity and adhesion between the core body and the casing layer, reduces the complexity of timing requirements, and allows for immediate centering without additional cycle time, enhancing the manufacturing efficiency and structural integrity of the golf ball sub-assembly.
Implementation Method 1
at least a subset of the plurality of protrusions contacts the interior surface of the at least one first casting mold to center the core body relative to the at least one first casting mold
Implementation Method 2
curing the foamed casing material such that the foamed casing material fills a void defined between the core body and the at least one first casting mold
Data Source
AI summary
A golf ball sub-assembly is provided that is formed from a core body and a foamed casing layer. The core body has a non-spherical profile due to the presence of centering elements, which can be provided in the form of protrusions or other types of structures on the outer surface of the core body. A foamed material is used for the casing layer. The core body can be plunged into a casting mold including the foamed material prior to the foamed material reaching a viscosity level that is typically required for the core body to be properly situated within the casting mold. A method of forming a golf ball using a core body having protrusions is also disclosed herein. The protrusions promote concentricity and therefore the method does not require targeting a specific viscosity of a foamed casing material when plunging the core body within the casting mold.