Golf Ball Dual-Core Deflection Differential Design
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Solution Overview
Problem
Existing golf ball manufacturing methods fail to achieve optimal resilience and durability while maintaining playability, as they often rely on single-layer covers that do not adequately balance coefficient of restitution and hardness.
Innovation Solution
A dual-core configuration with a polybutadiene inner core and a thermoset or thermoplastic outer core layer, combined with a multi-layer cover comprising a low acid ionomer blend inner layer and a polyurethane outer layer, enhances resilience and durability through improved coefficient of restitution and compression characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer cover is used, then the manufacturing process is simple, but the coefficient of restitution and hardness cannot be adequately balanced
Solution Approach 1:
The cover is divided into two distinct layers: an inner layer comprising a low acid ionomer blend and an outer layer comprising polyurethane. This segmentation allows each layer to be optimized for specific properties - the inner layer for coefficient of restitution and the outer layer for hardness and durability - thereby resolving the contradiction between manufacturing simplicity and performance balance.
Solution Approach 2:
The patent employs composite materials by combining low acid ionomer blend and polyurethane in a multi-layer cover structure. This composite approach enables the integration of materials with complementary properties, achieving both high coefficient of restitution and adequate hardness simultaneously, which cannot be accomplished with a single material layer.
2Reliability
If the core is made softer to increase resilience, then the coefficient of restitution improves, but the compression and durability are compromised
Solution Approach 1:
The core is segmented into an inner core center and an outer core layer with different material properties. The inner core center uses a softer material (such as polybutadiene) to provide high coefficient of restitution, while the outer core layer uses a harder material (such as thermoset or thermoplastic) to provide compression and durability. This segmentation resolves the contradiction by assigning different functional requirements to different segments.
Solution Approach 2:
The dual-core structure combines softer and harder materials in a composite configuration. The inner core center material and outer core layer material work together to provide both high coefficient of restitution (from the softer inner layer) and adequate compression/durability (from the harder outer layer), resolving the contradiction through material composite design.
3Strength
If the cover is made thicker to increase durability, then the hardness improves, but the spin rates and playability are reduced
Solution Approach 1:
The cover is segmented into an inner layer and an outer layer with different thicknesses and material properties. The inner layer (low acid ionomer blend) provides a thinner profile that allows for high spin rates and playability, while the outer layer (polyurethane) provides the necessary durability and hardness. This segmentation resolves the contradiction by distributing different functional requirements across different layers.
Solution Approach 2:
The multi-layer cover uses composite materials where the inner low acid ionomer blend layer and outer polyurethane layer work together to achieve both durability and playability. The composite structure allows the thinner inner layer to maintain spin characteristics while the outer layer provides protective durability, resolving the contradiction between thickness-related durability and spin-related playability.
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 dual-core and multi-layer cover design results in golf balls with increased travel distance, enhanced durability, and improved playability, meeting U.S.G.A. standards for initial velocity while providing a softer feel and higher spin rates.
Implementation Method 1
The inner core center comprises a polybutadiene material and has a deflection of greater than 0.175 inch under a load of 200 pounds
Data Source
AI summary
A golf ball comprising a core comprising an inner core center and an outer core layer disposed over the inner core center. The inner core center has a deflection of greater than 0.210 inch under a load of 100 kilograms and the core has a deflection ranging from 0.120 inch to 0.095 inch under a load of 100 kilograms. A mantle layer is disposed over the core and a cover is disposed over them mantle.