Golf Ball Double Network Polymer Springy Feel
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Solution Overview
Problem
Conventional golf balls that are stretched to achieve a stiffer feel often induce crystallinity in the polymer network, which is undesirable for golfers preferring a springy feel, as there is a lack of materials that can benefit from stretching without crystallization.
Innovation Solution
A golf ball with a double network cross-linked composition comprising a mixture of a base thermoplastic polymer composition and a double network polymer composition, where the polymer composition is elongated during a partial cure state to create a springy rather than stiff thermoset layer, using materials like ionomers, polyurethanes, and polyurethane-polyurea hybrids, and incorporating particulates that are elongated up to 200% to enhance resilience and modulus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cross-linked polymeric bands are stretched to produce a stiffer material, then the material becomes stiffer, but crystallinity is induced within the polymer network which is undesirable for springy feel
Solution Approach 1:
The patent changes the physical state parameter of the polymer from fully cured to partially cured during the stretching process. This parameter change allows the polymer to be elongated without inducing crystallinity, as the partial cure state maintains molecular mobility that prevents crystal formation while still providing structural integrity for the desired springy feel.
Solution Approach 2:
The patent creates a composite material system combining base thermoplastic polymer with thermoset polymer composition in a double network cross-linked structure. This composite approach allows the thermoplastic component to provide flexibility and prevent crystallization while the thermoset component provides strength and structural stability, achieving both springy feel and durability.
2Strength
If polymer composition is elongated during partial cure state, then springy feel is achieved without crystallinity, but manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by partially curing the polymer composition before the stretching operation. This preliminary curing step creates a semi-rigid state that maintains shape during elongation while preventing crystallization. The partial cure is achieved by controlling temperature and time parameters before applying mechanical stress, simplifying the overall process by preventing the need for post-stretching crystallization control.
Solution Approach 2:
The patent introduces dynamics by implementing a multi-stage curing process where the polymer transitions from uncured to partially cured to fully cured states at different process stages. This dynamic approach allows optimization of each stage: the partial cure stage enables stretching without crystallization, while the final cure stage maximizes strength, thereby managing process complexity through staged optimization.
3Reliability
If double network cross-linked composition is used, then resilience and durability are improved, but material formulation complexity increases
Solution Approach 1:
The patent employs composite materials by formulating a double network cross-linked composition consisting of two distinct polymer networks: a thermoplastic polymer matrix and a thermoset polymer cross-linked network. The thermoplastic phase provides flexibility and impact resistance, while the thermoset phase provides structural strength and durability. This composite structure achieves enhanced reliability without requiring a completely new material system, as both components are conventional polymers used in golf ball manufacturing.
Solution Approach 2:
The patent applies local quality by creating regions with different cross-linking densities and polymer compositions within the cover layer. The double network structure creates local variations where thermoplastic-rich regions provide resilience and thermoset-rich regions provide durability. This local differentiation allows the material to exhibit both springy feel and high durability without requiring uniform complexity throughout the entire material formulation.
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 a golf ball with improved resilience and durability, providing a springy feel without inducing crystallinity, allowing for tailored playing characteristics such as spin and feel by varying the composition and layer structure.
Implementation Method 1
the polymer composition is elongated during a partial cure state to create a springy rather than stiff thermoset layer
Implementation Method 2
a double network cross-linked composition comprising a mixture of a base thermoplastic polymer composition and a double network polymer composition
Data Source
AI summary
Golf ball comprising at least one layer consisting of a double network cross-linked composition comprising a mixture of a base thermoplastic polymer composition and a double network polymer composition. The double network polymer composition comprises a plurality of particulates of a polymer composition that is elongated from 10% to 200%, or at least 50%, or at least 100% or at least 150% or 200% or greater during a partial cure state.