Golf Ball Embossing Die Geometry for Clear Single-Layer Dimples
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Solution Overview
Problem
Existing embossing methods struggle to effectively replicate the patterns of golf balls, and the patterns are not always well-defined or easy to apply to a single layer without damaging it, and often require post-processing to achieve an authentic representation.
Innovation Solution
A specialized embossing die with convexly curved tips on a cylindrical or conically tapered body is used to create concave depressions with cylindrical or conical walls and bridges, allowing for a gentle demolding process that replicates the golf ball pattern with clear, durable indentations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional embossing methods are used, then the embossing process can be applied to material layers, but the pattern is not well-defined and requires post-processing
Solution Approach 1:
The embossing die is segmented into multiple functional parts: a convexly curved tip for creating the concave base, a cylindrical or conically tapered body for forming the depression walls, and edge features for defining the outer diameter. This segmentation allows each part to perform its specific function effectively, creating a well-defined pattern in a single embossing operation without requiring post-processing.
Solution Approach 2:
The embossing die is designed with pre-configured geometric features (convex tip, cylindrical body, edge transitions) that automatically form the complete golf ball pattern structure during the embossing process itself. The preliminary design of the die geometry ensures that the concave base, depression walls, and bridges are formed in one step, eliminating the need for subsequent post-processing operations.
2Ease of operation
If conventional embossing dies are used, then embossing can be performed, but the material is damaged during demolding
Solution Approach 1:
The embossing die features a convexly curved tip in the manner of a spherical cap. This curved geometry allows the die to be easily pressed into the material and smoothly withdrawn without causing damage. The spherical cap shape distributes stress evenly and prevents sharp edges from tearing or nicking the material during demolding, enabling a gentle extraction process.
3Illumination intensity
If the embossing die tip protrudes more, then the golf ball pattern is more visible, but the embossing depth increases
Solution Approach 1:
The embossing die is designed with different local features: the tip protrudes by 0.3 to 1 mm to create visible concave bases for the golf ball pattern, while the cylindrical or conically tapered body controls the embossing depth to form depression walls with proper height. This local differentiation allows the pattern to be visually prominent while maintaining precise control over the embossing depth and wall formation.
Data Source
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AI summary
A material (9a, 9b) with a golf ball-like embossing pattern, comprising a plurality of embossing depressions (18a, 18b) arranged in the material (9a, 9b), is characterized, with regard to the task of representing a golf ball pattern in a defined, material-conserving, flexible and authentic manner on the surface of a material, in that an embossing depression (18a, 18b) has a concave base (19a, 19b) which transitions into a depression wall (20a, b) that is at least partially cylindrical or conical and/or into a bridge (21a, b) between the embossing depressions (18a, 18b) and/or into a bridging surface (23b) which connects two concave bases (19b). Furthermore, an embossing die (10a, 10b) and a method by which such a material can be produced are disclosed.