Golf Ball Multi-Layer Cover Manufacturing Process
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Solution Overview
Problem
Conventional golf ball manufacturing processes, such as compression and injection molding, face challenges in producing golf balls with very thin cover layers due to issues like core deformation, poor concentricity, and inconsistency in cover layer thickness and contouring.
Innovation Solution
A process involving the formation of hemispherical half shells with specific thickness and contour characteristics, followed by the dispensing and curing of thermoset composition to create uniform or non-uniform inner cover layers, ensuring better alignment and consistency between cover layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional compression or injection molding processes are used to manufacture golf balls with very thin cover layers, then the manufacturing process is simple and widely applicable, but quality control issues arise including poor concentricity, lack of matability, and inconsistency in cover layer wall thickness
Solution Approach 1:
The manufacturing process is divided into separate stages: first forming the inner cover layer with uniform thickness, then forming the outer cover layer independently, and finally bonding them together. This segmentation allows each layer to be optimized separately, ensuring precise thickness control and concentricity that cannot be achieved in conventional single-step molding processes.
Solution Approach 2:
The inner cover layer is formed and cured first before forming the outer cover layer. This preliminary action establishes a stable foundation with precise thickness and concentricity, which then serves as a mold for the outer layer, ensuring proper alignment and eliminating the quality control issues associated with conventional simultaneous molding methods.
2Ease of manufacture
If high pressure is applied during compression molding to form thin cover layers, then the cover layer can be formed, but the core is severely deformed causing blow out, core shifting, and loss of roundness
Solution Approach 1:
The cover formation process is segmented into two independent stages: first forming the inner cover layer with controlled pressure, then forming the outer cover layer separately. This segmentation prevents excessive pressure from deforming the core, as each layer is formed with appropriate pressure levels that do not compromise core structural integrity.
Solution Approach 2:
The inner cover layer acts as a cushioning layer formed beforehand, protecting the core from excessive pressure during the formation of the outer cover layer. This preliminary layer absorbs and distributes pressure evenly, preventing core deformation, blow out, and structural damage that would occur with direct high-pressure molding.
3Ease of manufacture
If retractable pins are used in RPIM process to center the core under high pressure, then the core can be positioned, but the core is pinched causing similar deformation issues including blow out and core shifting
Solution Approach 1:
The core positioning and cover formation is segmented into separate operations. The core is first positioned and secured in the mold, then the inner cover layer is formed independently, followed by the outer cover layer. This eliminates the need for retractable pins to pinch the core under pressure, preserving core structural integrity while maintaining precise positioning.
Solution Approach 2:
The core is preliminarily positioned and secured in the mold before any cover layer formation begins. This preliminary positioning establishes a stable foundation that prevents core movement during subsequent cover layer formation, eliminating the need for pinching mechanisms that would compromise core integrity.
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 process reliably produces golf balls with improved concentricity, matability, and contouring between cover layers, enhancing the alignment of dimples and overall quality of the golf ball.
Implementation Method 1
dispensing an uncured liquid thermoset composition into the hemispherical cavity of the first half shell
Implementation Method 2
forming first and second substantially hemispherical half shells having a non-uniform thickness and comprising a thermoplastic composition
Data Source
AI summary
Process for making golf ball having multi-layered cover having a very thin outermost cover layer comprising: providing first and second substantially hemispherical half shells comprising a thermoplastic composition; dispensing uncured liquid thermoset composition into a hemispherical cavity of first half shell; inserting first half of a core subassembly into hemispherical cavity and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer; dispensing the uncured liquid thermoset composition into hemispherical cavity of second half shell; inserting second half of core subassembly into hemispherical cavity of second half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer and thereby mating the first and second half shells; curing thermoset inner cover layer; and forming dimples in the outer surfaces of mated first and second half shells.