Multi-Layer Golf Ball Graded Mantle Durability
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Solution Overview
Problem
Multi-layer golf balls with low core PGA compression and hard outer mantle layers face durability issues due to the conflicting requirements of maintaining durability and soft feel, as the hard outer mantle layers tend to suffer durability failures when combined with low core compressions.
Innovation Solution
The golf ball design incorporates a mantle construction with increasing flexural modulus and Shore D hardness from the core to the outer mantle layer, maintaining durability while retaining a soft feel by ensuring the core/inner mantle layer/intermediate mantle layer combined construct has a PGA compression of at least 30, and each successive layer has a higher flexural modulus and Shore D hardness, resulting in a five-piece golf ball with specific sound frequency and loudness characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard outer mantle layers are used in multi-layer golf balls, then impact durability is improved, but durability failures occur when combined with low core compressions
Solution Approach 1:
The patent applies parameter changes by systematically varying the PGA compression values across different layers. The core has low PGA compression (less than 70) for soft feel, while the mantle layers have progressively higher PGA compression values (at least 30, at least 40, at least 50) to provide durability. This gradient of compression parameters resolves the contradiction between soft feel and impact durability.
Solution Approach 2:
The patent uses composite materials by combining multiple layers with different material properties. Each layer (core, inner mantle, intermediate mantle, outer mantle) is made from materials with specific flexural modulus and Shore D hardness ranges that differ from adjacent layers. This composite structure allows the ball to exhibit both soft feel from the low-compression core and high impact durability from the hard outer mantle layers.
2Ease of operation
If low core PGA compression is used, then soft feel is improved, but impact durability deteriorates
Solution Approach 1:
The patent applies local quality by giving different regions (layers) of the golf ball different mechanical properties. The core region has low PGA compression and low flexural modulus for soft feel, while the mantle layers have progressively higher PGA compression and flexural modulus for durability. This spatial variation in material properties resolves the contradiction between soft feel and impact durability.
Solution Approach 2:
The patent resolves the contradiction by adding a dimensional aspect - creating a multi-layer spherical structure with radial variation in material properties. Instead of using a single uniform material, the invention distributes different compression and hardness properties across multiple concentric layers, allowing the ball to exhibit both soft feel and high impact durability simultaneously.
Data Source
AI summary
A golf ball comprising:(a) a core;(b) an inner mantle layer;(c) an intermediate mantle layer;(d) an outer mantle layer; and(e) at least one cover layer;wherein the core has a PGA compression of less than 70, and the core/inner mantle layer/intermediate mantle layer combined construct has a PGA compression of at least 30.