Thermoplastic Golf Ball Cover Crosslinking for Scuff Resistance
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Solution Overview
Problem
Existing golf ball technologies face challenges in achieving excellent scuff resistance, spin properties, feel on approach shots, discoloration resistance, and productivity, particularly due to issues with thermoplastic polyurethane materials such as variability in compounding ratios, unreacted isocyanate groups causing seizing and solidification, and solvent-induced deformations.
Innovation Solution
A golf ball design with an outermost layer made of thermoplastic materials like polyurethane or polyurea, where the absorbance peak heights near 1512 cm−1 measured by FT-IR/ATR spectroscopy show a difference of at least 0.02 between the outside and inside portions, indicating controlled crosslinking, and treated with an isocyanate compound free of organic solvents to enhance scuff resistance and spin performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset polyurethane materials are used for golf ball covers, then scuff resistance and spin properties are improved, but productivity deteriorates due to long molding time and difficulty in controlling the thermosetting process
Solution Approach 1:
The patent changes the fundamental parameter of the polyurethane material from thermoset to thermoplastic type, enabling the use of injection molding which dramatically reduces molding time while maintaining the desired scuff resistance through controlled crosslinking in the outermost layer
Solution Approach 2:
The patent creates a composite structure with the outermost layer containing crosslinked polyurethane or polyurea resin (providing scuff resistance) and the inner layers using thermoplastic polyurethane (enabling efficient molding), thus combining the advantages of both material types
2Productivity
If thermoplastic polyurethane materials are used for golf ball covers, then productivity and ease of molding are improved, but scuff resistance and spin properties deteriorate compared to thermoset materials
Solution Approach 1:
The patent applies local quality by creating an outermost layer with different properties (crosslinked polyurethane or polyurea resin) from the inner layers (thermoplastic polyurethane), providing scuff resistance where it is most needed while maintaining overall productivity
Solution Approach 2:
The patent performs preliminary crosslinking of the outermost layer before final molding, ensuring that the scuff-resistant properties are established in advance while the thermoplastic inner layers remain moldable
3Productivity
If isocyanate mixture is charged directly into the molding machine, then productivity is improved by avoiding secondary treatment, but uniformity deteriorates due to variability in compounding ratio and burn contaminants arise
Solution Approach 1:
The patent uses an isocyanate group-containing compound as an intermediary that reacts with the polyol components during molding to form the desired crosslinked structure, avoiding the need to charge pre-mixed isocyanate mixtures while ensuring uniform reaction and eliminating burn contaminants
Solution Approach 2:
The patent replaces the mechanical mixing approach (dry blending) with a chemical reaction approach where the isocyanate group-containing compound reacts in situ during molding, ensuring uniform distribution and composition without variability in compounding ratio
4Strength
If secondary treatment with isocyanate compound is applied to thermoplastic resin covers, then scuff resistance is improved, but productivity deteriorates due to additional treatment steps and solvent-induced deformations occur
Solution Approach 1:
The patent merges the crosslinking reaction with the molding process itself by incorporating the isocyanate group-containing compound into the resin composition, eliminating the need for separate secondary treatment steps and avoiding solvent-induced deformations
Solution Approach 2:
The patent extracts the harmful organic solvent from the treatment process by using compounds that react without requiring solvents, thereby eliminating the source of deformations while maintaining scuff resistance improvement
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 results in improved scuff resistance, spin performance, feel on approach shots, and discoloration resistance while maintaining high productivity by controlling crosslinking reactions and avoiding solvent-induced issues, leading to enhanced golf ball properties.
Implementation Method 1
the degree of crosslinking due to urethane bonds is varied between an outside portion and an inside portion of the cover
Implementation Method 2
the thermoplastic outermost layer and a polyisocyanate compound with a specific reaction product
Implementation Method 3
letting the absorbance peak heights near 1512 cm−1 measured by the attenuated total reflectance method in Fourier transform infrared absorption spectroscopy
Data Source
AI summary
The invention provides a golf ball having a core and a cover of one or more layer encasing the core, wherein the cover has an outermost layer molded of a thermoplastic material selected from the group consisting of polyurethane, polyurea and mixtures thereof and, letting the absorbance peak heights near a wave number of 1512 cm−1 measured by the attenuated total reflectance method in Fourier transform infrared absorption spectroscopy (FT-IR/ATR spectroscopy) at an outside portion and an inside portion of the outermost cover layer be respectively P1 and P2, the value P1-P2 is at least 0.02.