Golf Ball Intermediate Layer Resin Composition
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Solution Overview
Problem
Existing golf balls face challenges in achieving acceptable flight performance, controllability, and durability to cracking under repeated impact, particularly due to issues with laminar separation during high-speed injection molding and the difficulty in creating a thin cover using certain materials.
Innovation Solution
A golf ball design incorporating a core, an outermost cover layer, and intermediate layers with a specific resin composition that balances the melt viscosities of ionomers and thermoplastic polyester elastomers, including a mixture of metal ion-neutralized olefin-unsaturated carboxylic acid random copolymers, thermoplastic elastomers, and thermoplastic block copolymers, along with organic acids and metal ion sources, to prevent laminar separation and ensure durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-ionomeric material having a high melt viscosity is used in the cover material, then resilience is improved, but it becomes difficult to achieve a thin cover by injection molding
Solution Approach 1:
The patent uses a composite resin composition combining ionomer and thermoplastic polyester elastomer in specific proportions (50-80/50-20/4-20 weight ratio of base polymer/thermoplastic elastomer/thermoplastic block copolymer). This composite approach allows achieving both high resilience and successful thin cover injection molding by balancing the properties of individual components.
Solution Approach 2:
The patent controls the melt viscosity ratio of component (b) to component (a) within 0.4≦(b)/(a)≦1.5 at specific conditions (240°C, shear rate of 6,000 sec⁻¹). This parameter control ensures proper flow characteristics during injection molding while maintaining resilience, enabling thin cover production without manufacturing difficulties.
2Productivity
If high-speed injection molding is carried out, then productivity is improved, but laminar separation occurs lowering the durability of the ball
Solution Approach 1:
The patent employs a three-component resin composition (base polymer, thermoplastic elastomer, and thermoplastic block copolymer with reactive end blocks) where the components work synergistically. The thermoplastic block copolymer with functional groups creates strong interfacial bonding between components, preventing laminar separation during high-speed injection and ensuring high durability.
Solution Approach 2:
The thermoplastic block copolymer containing end blocks modified by functional groups acts as an intermediary that enhances compatibility between the ionomer and thermoplastic polyester elastomer. This intermediary component prevents laminar separation by creating strong interfacial adhesion, allowing high-speed injection molding without compromising durability.
3Adaptability or versatility
If a thin intermediate layer is used, then the golf ball achieves acceptable flight performance and controllability, but durability to cracking under repeated impact is compromised
Solution Approach 1:
The patent uses a composite resin composition in the intermediate layer with specific proportions of base polymer, thermoplastic elastomer, and thermoplastic block copolymer. This composite structure provides both the thinness needed for good flight performance and controllability, and the internal bonding strength required for high durability to cracking under repeated impact.
Solution Approach 2:
The thermoplastic block copolymer with reactive end blocks serves as an intermediary that creates strong interfacial bonding between the base polymer and thermoplastic elastomer in the intermediate layer. This strong bonding prevents cracking under repeated impact while maintaining the thin layer thickness necessary for acceptable flight performance and controllability.
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 solution provides golf balls with excellent flight performance, controllability, and enhanced durability to cracking, while allowing for the production of thin intermediate layers through high-speed injection molding without compromising durability.
Implementation Method 1
a thermoplastic block copolymer containing end blocks modified by a functional group having reactivity with an ionomer resin
Implementation Method 2
a metal ion neutralization product of an olefin-unsaturated carboxylic acid random copolymer and/or a metal ion neutralization product of an olefin-unsaturated carboxylic acid-unsaturated carboxylic acid ester random copolymer
Data Source
AI summary
The present invention provides a golf ball composed of a core, an outermost cover layer and one or more intermediate layer therebetween. At least one intermediate layer includes a mixture composed of a base polymer made of, in a specific ratio, (a) a metal ion neutralization product of an olefin-unsaturated carboxylic acid random copolymer and/or a metal ion neutralization product of an olefin-unsaturated carboxylic acid-unsaturated carboxylic acid ester random copolymer, (b) a thermoplastic elastomer selected from the group consisting of thermoplastic polyester elastomers, thermoplastic block copolymers and thermoplastic polyurethanes, and (c) a thermoplastic block copolymer containing end blocks modified by a functional group having reactivity with an ionomer resin, both end blocks being formed of different comonomers. The mixture also includes (e) an organic acid of 18 to 40 carbons or a derivative thereof, and (f) a metal ion source selected from the group consisting of alkali metals, alkaline earth metals and transition metals. The mixture has an optimized ratio between the melt viscosities of (b) and (a) as measured under a shear rate of 6,000 sec−1 and 240° C. in accordance with JIS K-7199. The golf ball of the invention has a flight and control performance acceptable for use by professional golfers and skilled amateurs, and also has an excellent durability to cracking under repeated impact.