Golf Ball Ionomer Masterbatch for Homogeneous Polymer Blending
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Solution Overview
Problem
The challenge lies in manufacturing golf balls that incorporate highly neutralized acid polymers and additives, which are difficult to blend due to differences in Vicat softening temperatures and specific gravities, leading to processing issues such as gas formation and stratification, resulting in defects like voids and heterogeneity in the final product.
Innovation Solution
A method involving the use of an ionomer-based masterbatch that controls the Vicat softening temperatures and specific gravities of highly neutralized acid polymers, allowing for the easy introduction of additives and simplifying the blending process by minimizing differences in these parameters, thereby facilitating the formation of a homogeneous blend.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If highly neutralized acid polymers and additives are blended directly, then the golf ball can incorporate desired functional additives, but the differences in Vicat softening temperatures and specific gravities cause processing issues such as gas formation and stratification
Solution Approach 1:
The patent uses an ionomer-based masterbatch as an intermediary carrier to introduce additives into the highly neutralized acid polymer blend. The masterbatch acts as a mediator that facilitates additive incorporation while its controlled Vicat softening temperature and specific gravity match the polymer blend, preventing stratification and gas formation during processing
Solution Approach 2:
The patent controls the Vicat softening temperature of the ionomer-based masterbatch to be within 15°C of the highly neutralized acid polymer, and matches their specific gravities within 0.015. This parameter matching eliminates processing defects caused by temperature and density differences between components
2Adaptability or versatility
If additives with different Vicat softening temperatures are used, then functional properties can be adjusted, but gas formation and voids occur during manufacturing
Solution Approach 1:
The patent controls the Vicat softening temperature of the ionomer-based masterbatch to be within 15°C of the highly neutralized acid polymer. This parameter control ensures that all components soften and process at similar temperatures, preventing gas formation and voids while still allowing functional property adjustment through additive selection
3Adaptability or versatility
If components with different specific gravities are blended, then material properties can be optimized, but stratification and heterogeneity occur in the final product
Solution Approach 1:
The patent controls the specific gravity of the ionomer-based masterbatch to match the highly neutralized acid polymer within 0.015. This specific gravity matching prevents stratification and ensures homogeneous distribution of additives throughout the golf ball layers during the molding process
Data Source
AI summary
Method of making a golf ball. A blend of a first highly neutralized acid polymer, a second highly neutralized acid polymer, and an ionomer-based masterbatch comprising an ionomer resin and an additive is used to form a layer of a golf ball. A second layer that essentially encloses the blend-containing layer then is formed.