Multi-Piece Golf Ball Layer Hardness Gradient
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Solution Overview
Problem
Multi-piece solid golf balls for professionals and skilled golfers face challenges in achieving a balance between distance and controllability, with existing designs often resulting in high spin rates when hit with drivers, leading to inadequate distance and durability issues under repeated impact.
Innovation Solution
A golf ball design featuring a core made of rubber with a specific hardness gradient, an envelope layer composed of a resin mixture, and a polyurethane cover, with optimized thickness and hardness relationships between the layers to reduce spin rates and enhance durability and scuff resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a multi-piece solid golf ball with optimized hardness relationship between intermediate layer and cover layer is used, then superior distance in high head speed range and good controllability on iron shots are achieved, but spin rate on driver shots remains too high
Solution Approach 1:
The golf ball is divided into multiple functional layers: core, envelope layer, intermediate layer, and cover layer. Each layer is optimized independently to address different performance requirements - the core provides rebound, the envelope layer controls spin rate, the intermediate layer provides durability, and the cover layer provides controllability.
Solution Approach 2:
Different layers of the golf ball have different material properties and hardness values tailored to specific functions. The envelope layer has specific hardness (50-70 durometer) to reduce spin rate, while the cover layer has different hardness (40-60 durometer) for controllability. This local differentiation allows simultaneous optimization of multiple performance characteristics.
2Reliability
If the envelope layer is made of specific resin mixture, then lower spin rate on driver shots and good durability on repeated impact are obtained, but manufacturing complexity increases
Solution Approach 1:
The envelope layer uses a composite resin mixture combining ionomer resin (30-70 parts), thermoplastic elastomer (10-40 parts), and thermoplastic resin (10-40 parts). This composite formulation provides both durability through repeated impact resistance and spin rate control, while the standardized composition facilitates consistent manufacturing.
3Object-affected harmful factors
If the cover is made of polyurethane with optimized thickness, then high scuff resistance and good spin performance on approach shots are achieved, but distance performance may be compromised
Solution Approach 1:
The cover layer thickness is precisely controlled within 0.5-1.5mm, and its hardness is optimized to 40-60 durometer. These parameter optimizations ensure the cover provides sufficient scuff resistance and spin control on approach shots while maintaining adequate distance performance through proper thickness management that balances protection with energy transfer.
4Strength
If core hardness gradient is optimized, then rebound and feel are improved, but manufacturing precision requirements increase
Solution Approach 1:
The core is pre-formed with a specific hardness gradient (surface hardness 50-70 durometer, center hardness 60-80 durometer) before the envelope layer is applied. This preliminary preparation ensures the core provides the necessary rebound and feel characteristics, while the subsequent envelope layer application does not require precise control of the core's internal hardness distribution.
Data Source
AI summary
A multi-piece solid golf ball comprising a core, an envelope layer encasing the core, an intermediate layer encasing the envelope layer, and a cover which encases the intermediate layer and has formed on a surface thereof a plurality of dimples, wherein the core is made primarily of a rubber material and has a diameter of at least 31 mm, the envelope layer and intermediate layer are each made primarily of the same or different resin materials and the cover is made primarily of polyurethane; intermediate layer and cover have an optimized thickness relationship; the core, envelope layer, intermediate layer and cover have optimized hardness relationships; and the core surface and core center have a large hardness difference therebetween. The golf ball has excellent flight performance and controllability acceptable to professionals and other skilled golfers, while also having excellent durability to cracking upon repeated impact and excellent scuff resistance.