Golf Ball Dual-Layer Core Balancing Resiliency and Feel
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Solution Overview
Problem
Golf balls with foam cores tend to have low resiliency, resulting in short distances traveled after being hit, while harder balls provide better distance but with an uncomfortable feel and reduced control.
Innovation Solution
A multi-layered golf ball design featuring a non-foamed inner core and a foamed outer core layer with specific gravity and flex modulus differences, using thermoset or thermoplastic materials for the inner core and a foamed polyurethane composition for the outer core, allowing for a balance of resiliency and soft compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a foam core is used in golf balls, then soft compression and resiliency are improved, but distance traveled deteriorates
Solution Approach 1:
The core is divided into two distinct layers: an inner non-foamed core layer and an outer foamed core layer. The inner core layer (made of polybutadiene or similar rubber) provides high resiliency and rebound velocity, while the outer foamed core layer (made of polyurethane foam) provides soft compression and feel. This segmentation allows each layer to contribute its superior properties without compromising the other.
Solution Approach 2:
The dual-layer core combines two different materials with complementary properties: a dense non-foamed rubber material for elastic energy storage and release, and a lighter foamed polyurethane material for softness and compression control. This composite structure achieves a balance between resiliency and soft feel that neither material could provide alone.
2Speed
If harder ball materials are used, then distance is improved, but feel and control deteriorate
Solution Approach 1:
Different regions of the core have different material properties optimized for their specific functions. The inner core layer has high density and high elastic modulus for maximum rebound velocity and distance, while the outer core layer has lower density and lower elastic modulus for soft compression and player feel. This local differentiation of material properties allows the ball to achieve both distance and control.
Data Source
AI summary
Multi-layered golf balls having a dual-layered core and cover of at least one layer are provided. The dual-core construction includes a non-foamed inner core (center) made of a thermoplastic or thermoset composition such as polybutadiene rubber. An outer core layer comprising a foamed composition, such as polyurethane foam, is disposed about the inner core. In one version, the foamed outer core layer is made of a relatively soft foam composition having low flex modulus and density. The foamed outer core layer may specific gravity gradient within the layer, wherein the outer surface specific gravity is greater than the midpoint specific gravity. A cover may be disposed about the core structure. For example, an inner cover made of ethylene acid copolymer ionomer and outer cover made of polyurethane may be used.