Golf Ball Foam Core Hardness Gradient Design
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Solution Overview
Problem
Golf balls with foam cores have low resiliency, resulting in short distances traveled after being hit, as they tend to absorb impact rather than rebound effectively, limiting the potential for longer shots.
Innovation Solution
A golf ball design featuring a dual-layer core assembly with a foamed inner core and a non-foamed thermoset or thermoplastic outer core layer, where the foamed inner core has regions of different hardness and density gradients, and the outer core layer is made from materials like polybutadiene rubber, enhancing rebound performance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a foam core is used in a golf ball, then the ball absorbs impact better, but the resiliency decreases and the ball travels shorter distances
Solution Approach 1:
The core is divided into two distinct layers: an inner foamed core layer and an outer non-foamed core layer. This segmentation allows each layer to perform its specialized function - the foamed inner layer absorbs impact while the solid outer layer provides resiliency and rebound, resolving the contradiction between impact absorption and resiliency.
Solution Approach 2:
Different regions of the core have different material properties. The inner foamed region has high impact absorption capability while the outer non-foamed region has high resiliency. This local differentiation of material qualities allows the core as a whole to achieve both impact absorption and resiliency simultaneously.
2Ease of manufacture
If a foam core with uniform hardness is used, then manufacturing is simpler, but the rebound performance is insufficient
Solution Approach 1:
The core is segmented into two layers with different material compositions and hardness levels. The inner foamed layer and outer non-foamed layer each contribute to optimal rebound performance, achieving superior rebound characteristics that cannot be obtained with a uniform hardness core.
Solution Approach 2:
The core uses composite materials - a combination of foamed material and solid thermoplastic or thermoset material. This composite construction provides both the manufacturing advantages of molded cores and the enhanced rebound performance of varied hardness profiles.
3Reliability
If a dual-layer core with different hardness regions is used, then the resiliency and rebound performance improve, but the device complexity increases
Solution Approach 1:
The core is divided into two functional layers that can be manufactured separately and then assembled. This segmentation enables each layer to be optimized for its specific function while simplifying the overall manufacturing process through modular construction.
Solution Approach 2:
The inner foamed core layer is nested within the outer non-foamed core layer, forming a concentric dual-layer structure. This nested arrangement achieves complex functionality with a simple spherical geometry, minimizing structural complexity while maximizing performance.
4Manufacturing precision
If the foam in the outer region of the inner core is collapsed, then the hardness gradient is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The foamed inner core layer is manufactured with a controlled hardness gradient from the beginning, with the outer region having higher hardness than the center. This preliminary creation of the hardness gradient eliminates the need for subsequent collapsing steps, simplifying the manufacturing process while achieving precise hardness control.
Solution Approach 2:
The foam manufacturing parameters (such as blowing agent distribution, curing conditions, or density gradients) are adjusted during the molding process to create the desired hardness gradient in the inner core layer. This parameter control during manufacturing achieves precise hardness distribution without additional processing steps.
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-layer core construction improves the resiliency and durability of the golf ball, allowing for higher initial ball speed and longer distance shots by creating a positive hardness and density gradient across the core assembly.
Implementation Method 1
The foam center preferably includes a fully-foamed region and a partially or completely-collapsed foam region. The hardness of the fully-foamed region is different than the hardness of the collapsed foam region.
Implementation Method 2
The dual-layer core construction improves the resiliency and durability of the golf ball, allowing for higher initial ball speed and longer distance shots by creating a positive hardness and density gradient across the core assembly.
Data Source
AI summary
Golf balls having a multi-layered core made of a foamed composition are provided. The core preferably has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition is used to form the foam center. The foam inner core preferably includes a fully-foamed center region and a partially or completely-collapsed foam outer region. The hardness of the fully-foamed region is different than the hardness of the collapsed foam region. Non-foamed thermoset or thermoplastic materials such as polybutadiene rubbers or ethylene acid copolymer ionomer may be used to form the outer core layer. The ball further includes a cover that may be multi-layered. The foam cores have good resiliency.