Golf Ball Intermediate Layer and Cover Hardness for Distance
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Solution Overview
Problem
Conventional golf balls with conventional dimples experience a loss of distance due to insufficient lift and drop in trajectory at low spin rates, and existing internal constructions with multiple layers do not adequately improve rebound and distance traveled.
Innovation Solution
A golf ball design featuring a core, an intermediate layer made of a heated mixture of olefin-unsaturated carboxylic acid random copolymers, non-ionomeric thermoplastic elastomers, fatty acids, and basic inorganic metal compounds, and a cover with specific hardness and thickness differences, along with a dimple design that maintains lift in the low-velocity region, reducing spin rates and enhancing distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional dimples are used on a golf ball, then the ball structure is simple and easy to manufacture, but the ball experiences insufficient lift and drop in trajectory in the low-velocity region after passing through the highest point, resulting in loss of distance
Solution Approach 1:
The patent applies parameter changes by modifying the dimple geometry parameters (depth, diameter, shape factors) to optimize aerodynamic performance. Specifically, the dimple depth-to-diameter ratio and other geometric parameters are adjusted to maintain lift in the low-velocity region, allowing the ball to travel farther without complicating the manufacturing process
2Productivity
If a golf ball is hit at low spin rate with conventional construction, then the coefficient of drag is reduced and distance increases, but the rebound decreases due to the cover material enclosing the intermediate layer
Solution Approach 1:
The patent employs composite materials by combining specific cover materials (ionomer resins or thermoplastic elastomers with defined hardness ranges) with intermediate layer materials (highly neutralized polymers with specific resin components). This composite construction maintains rebound properties while enabling low spin rate performance and extended distance
Solution Approach 2:
The patent applies local quality by creating a multi-layer construction where each layer has specific local properties: the cover layer has controlled hardness (50-70 Shore D) for rebound, the intermediate layer has specific material composition for spin control, and the core provides foundational elasticity. This localized optimization of material properties throughout the ball structure resolves the contradiction between rebound and distance
3Ease of manufacture
If the hardness and thickness of the cover and intermediate layer are not optimized, then the manufacturing process is simpler, but the synergistic effects between layers are insufficient, resulting in decreased rebound and reduced distance
Solution Approach 1:
The patent systematically optimizes critical parameters including cover hardness (50-70 Shore D), intermediate layer hardness (40-60 Shore D), layer thickness ratios, and material composition (degree of neutralization, resin content). These parameter changes create synergistic effects between layers that maximize both rebound and distance without significantly complicating manufacturing
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 golf ball achieves improved rebound and reduced spin rates, resulting in increased distance traveled by maintaining lift and synergistic effects between the intermediate layer and cover, enhancing aerodynamic performance.
Implementation Method 1
by using a highly neutralized polymer having a high resilience as the intermediate layer-forming material in order to maintain the rebound of the overall ball
Implementation Method 2
when a dimple design which does not lose lift in the low-velocity, low-spin region of the ball trajectory is provided on the outside surface of a golf ball
Implementation Method 3
enabling the ball to travel a longer distance... by using a highly neutralized polymer having a high resilience as the intermediate layer-forming material in order to maintain the rebound of the overall ball and by also setting the hardnesses and thicknesses of the cover and the intermediate layer in specific ranges
Data Source
AI summary
The invention provides a golf ball composed of a core, a cover having a plurality of dimples on an outside surface thereof, and an intermediate layer disposed between the core and the cover. The intermediate layer is formed of a highly neutralized resin material, and has a Shore D hardness below 50 and a thickness of at least 1.7 mm but not more than 6.0 mm. The cover and the intermediate layer have a difference in Shore D hardness therebetween (cover Shore D hardnessāintermediate layer Shore D hardness) of from 13 to 35. The cover and the intermediate layer have a combined thickness greater than 3 mm. The ball as a whole has a deflection, when compressed under a final load of 130 kgf from an initial load of 10 kgf, of at least about 2.0 mm but not more than about 4.0 mm. The golf ball, through a combination of dimples which do not cause a loss of lift in the low-velocity, low-spin rate region of the ball trajectory and a low-spin construction, travels farther and is therefore beneficial for competitive use by both skilled and amateur golfers.