Golf Ball Dual-Layer Core Foam Thermoset Resiliency
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Solution Overview
Problem
Golf balls with foam cores tend to have low resiliency, resulting in shorter distances when hit, as they do not effectively maximize initial ball speed and COR values, which are crucial for longer shots.
Innovation Solution
A dual-layered golf ball design featuring a foamed polyurethane inner core and a non-foamed thermoset outer core layer with specific gravity and hardness gradients, optimizing the core's structure to enhance resiliency and COR values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a foam core is used in golf balls, then the ball weight is reduced and manufacturing cost decreases, but the resiliency and COR values are lowered, resulting in shorter distances
Solution Approach 1:
The core is divided into two distinct layers: an inner foam core layer and an outer thermoset core layer. This segmentation allows each layer to perform its specialized function - the foam layer reduces weight while the thermoset layer maintains resiliency and COR values, resolving the contradiction between weight reduction and strength preservation.
Solution Approach 2:
The patent combines two different materials - foam and thermoset resin - into a composite core structure. The foam provides weight reduction benefits while the thermoset material contributes high resiliency and COR properties, achieving both lightweight construction and high performance simultaneously.
2Ease of manufacture
If a foam core is used in golf balls, then manufacturing cost decreases, but the initial ball speed and COR values are not maximized, limiting shot distance
Solution Approach 1:
The core is segmented into two functional layers where the inner foam layer provides cost-effective weight reduction and the outer thermoset layer delivers high-speed performance characteristics, allowing the ball to achieve maximum initial speed while maintaining manufacturing efficiency.
Solution Approach 2:
Different regions of the core have different material properties optimized for their specific functions. The inner foam region provides economical weight savings while the outer thermoset region provides localized high-performance characteristics for maximum ball speed generation upon impact.
3Strength
If the core hardness is increased to improve resiliency, then COR values improve, but the ball feels too hard and loses comfort during impact
Solution Approach 1:
The core is segmented into two layers with different hardness characteristics. The inner foam layer provides a softer, more comfortable impact feel while the outer thermoset layer provides the harder, more resilient surface for high COR values, resolving the contradiction between resiliency and comfort.
Solution Approach 2:
Different regions of the core have different hardness properties - the inner foam region is softer for comfort while the outer thermoset region is harder for resiliency. This local differentiation allows the ball to provide both comfort during impact and high performance in terms of COR and distance.
Data Source
AI summary
Multi-piece golf balls containing a dual-core structure are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The outer core layer is preferably formed from a non-foamed thermoset composition such as polybutadiene rubber. The inner and outer core layers can have different hardness gradients. Preferably, the specific gravity (density) of the foam inner core is less than the density of the outer core layer. The ball further includes a cover of at least one layer and may include at least one casing layer. The core structure and resulting ball have relatively good resiliency.