Golf Ball Intermediate Layer Spin Control
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Solution Overview
Problem
Golf balls with high-rigidity ionomer resins in the intermediate layer face challenges in achieving both increased distance and durability to repeated impact, often compromising on spin rate and feel during shots with drivers and long/middle irons.
Innovation Solution
A golf ball design featuring a rubber core with a thermoplastic resin composition for the intermediate layer, including a magnesium salt of an ethylenically unsaturated carboxylic acid copolymer, and a polyurethane resin composition for the outermost layer with specific Shore D hardness, which controls spin rate and enhances durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a high-rigidity ionomer resin is used in the intermediate layer to increase distance, then the spin rate on driver shots is reduced, but the durability to repeated impact worsens
Solution Approach 1:
The patent applies parameter changes by precisely controlling the flexural rigidity of the ionomer resin in the intermediate layer to be within 340-410 MPa and the thickness to be within 0.7-1.2 mm. This optimization of physical parameters allows the intermediate layer to provide sufficient rigidity for reducing spin rate and increasing distance, while maintaining adequate durability to repeated impact through the balanced parameter range.
Solution Approach 2:
The patent employs composite materials by combining ionomer resin in the intermediate layer with polyurethane resin in the outermost layer. This multi-material construction allows each layer to perform its specific function: the ionomer resin provides rigidity for distance control, while the polyurethane resin provides softness for spin control on approach shots and durability, resolving the contradiction through material composition.
2Reliability
If the intermediate layer thickness is increased to enhance durability, then the durability to repeated impact improves, but the feel at impact on driver shots worsens
Solution Approach 1:
The patent resolves this contradiction through parameter optimization by limiting the intermediate layer thickness to 0.7-1.2 mm. This controlled thickness range provides sufficient material for durability while preventing excessive thickness that would deteriorate impact feel. The parameter boundary ensures both durability and acceptable feel are achieved simultaneously.
Solution Approach 2:
The patent applies local quality by creating different layer structures with specific properties at different locations. The intermediate layer has controlled thickness and rigidity for durability, while the outermost layer has soft polyurethane material for feel and spin control. Each layer's localized properties contribute to overall performance without compromising the other.
3Ease of operation
If a soft polyurethane resin is used in the outermost layer to increase spin rate on approach shots, then controllability improves, but the durability to repeated impact may be compromised
Solution Approach 1:
The patent uses composite materials to resolve this contradiction by combining soft polyurethane resin in the outermost layer with rigid ionomer resin in the intermediate layer. The polyurethane provides softness for high spin rate and controllability on approach shots, while the ionomer intermediate layer provides structural support and durability to repeated impact, allowing both softness and durability to coexist.
Solution Approach 2:
The patent applies local quality by assigning different material properties to different layers: the outermost layer uses soft polyurethane for spin and controllability, while the intermediate layer uses rigid ionomer for durability. This spatial differentiation of material properties allows each layer to optimize its local function without compromising overall ball performance.
Data Source
AI summary
In a golf ball having a rubber core and an intermediate layer and outermost layer which encase the core, the intermediate layer is formed of a thermoplastic resin composition which has a flexural rigidity of 400 to 500 MPa and a melt flow rate of 15 g/10 min or less and includes 50 to 100 wt % of a magnesium salt of an ethylenically unsaturated carboxylic acid copolymer, the outermost layer is formed of a polyurethane resin composition having a Shore D material hardness of 55 or less, and the golf ball has a deflection within a given range. Compared with conventional golf balls containing the high-rigidity ionomer resins hitherto used as intermediate layer materials, this ball suppresses the spin rate on shots with a driver and long and middle irons, enabling an increased distance to be obtained, and also has a high durability to repeated impact.