Golf Ball Interlocking Multi-Layer Core Design
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Solution Overview
Problem
Existing golf ball technologies face challenges in maintaining core concentricity and flight symmetry, leading to issues like hooking or slicing during flight, which can affect the performance and alignment of the ball.
Innovation Solution
The golf ball design incorporates an inner core with through holes that allow the outer core material to flow and fill these holes during molding, ensuring interlocking layers and maintaining core symmetry, using distinct rubber formulations for each layer with varying hardness and Mooney viscosity to enhance concentricity and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-layer core construction is used without interlocking features, then manufacturing process is simpler, but core concentricity and flight symmetry deteriorate due to inner core shifting during curing
Solution Approach 1:
The outer core material is molded to surround and interlock with the inner core, creating a nested structure where the outer core penetrates through the inner core and locks it in place. This nesting approach ensures the inner core remains concentric within the outer core during curing, solving the flight symmetry problem while maintaining a relatively simple two-layer construction.
Solution Approach 2:
The core is divided into distinct segments (inner core and outer core) with different compositions and properties. The inner core provides resiliency while the outer core provides structure and interlocking capability. This segmentation allows each layer to be optimized for its specific function while working together to achieve overall core stability and concentricity.
2Reliability
If inner core is made softer for resiliency, then rebounding performance improves, but core stability and alignment deteriorate due to inner core shifting
Solution Approach 1:
Different regions of the core have different properties: the inner core is softer and more resilient for rebounding performance, while the outer core is harder and more rigid for structural stability. The interlocking interface between these regions with different local qualities ensures the soft inner core remains stable and aligned during curing, combining both resiliency and stability.
3Ease of manufacture
If outer core material flows freely during molding, then manufacturing process is simpler, but inner core alignment deteriorates due to shifting during curing
Solution Approach 1:
The inner core is positioned and secured within the outer core mold cavity before the outer core material is fully cured. The interlocking design is built into the mold structure, creating preliminary constraints that guide the outer core material flow and prevent inner core shifting during the molding and curing process, ensuring alignment while maintaining ease of manufacture.
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
This design enhances the manufacturing process to produce consistent and symmetrical multi-layer cores, improving the golf ball's flight stability and putting trajectory by preventing shifting of the inner core during curing, thus maintaining optimal performance and alignment.
Implementation Method 1
The outer core is formed from a second composition, different from the first composition. The outer core has a first portion that surrounds the inner core and a second portion that extends from the first opening to the second opening and thereby completely fills each of the through holes.
Data Source
AI summary
A golf ball has a core and a cover that surrounds the core. The core is a multi-layer component of the golf ball, having at least two core layers including an inner core and at least one outer core. The inner core is formed from a first composition and has a generally spherical shape and a spherical surface. The inner core defines one or more through holes that each extend from a first opening at the spherical surface to a second opening at the spherical surface. The outer core is formed from a second composition, different from the first composition. The outer core has a first portion that surrounds the inner core and a second portion that extends from the first opening to the second opening and thereby completely fills each of the through holes.