Multi-layer Golf Ball Cover with Thermoset Intermediate Layer
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Solution Overview
Problem
Current golf balls, particularly solid constructions, lack the spin and feel characteristics of wound balls while being difficult and expensive to manufacture, and existing multi-layer balls are costly and hard to produce with optimal playing characteristics.
Innovation Solution
A golf ball design featuring a three-layer cover with a thermoplastic inner cover layer, a thermoset intermediate cover layer made from liquid rubber, and a thermoset polyurethane or polyurea outer cover layer, utilizing materials like polybutadiene rubber and metallic salts of carboxylic acids to achieve desired hardness and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wound golf balls are used to achieve spin and feel characteristics, then playing characteristics are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The golf ball is divided into multiple layers with distinct functions: a core layer for elasticity, an intermediate cover layer for spin control, and an outer cover layer for feel characteristics. This segmentation allows each layer to be optimized independently while maintaining overall performance, resolving the contradiction by achieving wound-ball characteristics through layered construction rather than actual winding.
Solution Approach 2:
The patent uses composite materials with different properties in each layer: the core uses elastomeric material for resilience, the intermediate layer uses ionomeric or polyurethane for spin control, and the outer layer uses thermoplastic or thermoset materials for feel. This composite approach replicates the performance of wound balls using solid construction, eliminating manufacturing complexity while preserving playing characteristics.
2Reliability
If multi-layer solid golf balls are constructed to improve playing characteristics, then performance is enhanced, but manufacturing cost and difficulty increase
Solution Approach 1:
The patent optimizes playing characteristics by adjusting parameters such as layer thickness, material hardness (Shore A 40-80 for intermediate layer, Shore D 60-80 for outer layer), and material composition rather than complex manufacturing processes. This allows standard manufacturing equipment to produce high-performance balls, reducing cost and difficulty while maintaining enhanced playing characteristics.
3Reliability
If the intermediate cover layer is made from liquid rubber latex material, then spin characteristics are improved, but material processing complexity increases
Solution Approach 1:
The intermediate cover layer uses liquid rubber latex material that is applied in liquid form and then cured to a solid state. This phase transition from liquid to solid simplifies processing compared to handling solid rubber, as the liquid state allows for easier coating and conforming to the core, while the cured solid provides the desired spin characteristics.
Solution Approach 2:
The patent replaces mechanical mixing and handling of solid rubber with chemical curing processes. The liquid latex material is applied and then cured through chemical reaction (vulcanization or crosslinking), eliminating the need for complex mechanical processing steps and reducing overall processing complexity while maintaining spin performance.
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 three-layer cover construction enhances the golf ball's playing characteristics, such as compression, velocity, and spin, while reducing manufacturing complexity and costs, offering a more affordable option with improved performance.
Implementation Method 1
The liquid rubber composition may further include a crosslinking agent comprising one or more metallic salts of a carboxylic acid
Data Source
AI summary
A golf ball including a core and a cover including a thermoplastic inner cover layer having a material hardness of 60 to 80 Shore D; a thermoset outer cover layer comprising a castable polyurea and having a material hardness of 20 to 60 Shore D; and a thermoset intermediate cover layer disposed between the inner and outer cover layers and having a hardness substantially the same as the inner cover layer hardness and greater than the outer cover layer hardness. The inner cover includes one or more high- or low-acid ionomers and, optionally, a maleic anhydride modified polyolefin. The intermediate layer is formed from a castable liquid polybutadiene rubber.