Thin Moisture Vapor Barrier Layer for Golf Ball Core Protection
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Solution Overview
Problem
Golf balls face challenges with water vapor penetration, which affects their properties such as resiliency and coefficient of restitution, and existing thin moisture barrier layers face issues like inter-layer adhesion problems and durability deficiencies, especially when using ionomeric materials.
Innovation Solution
A golf ball with a thin moisture vapor barrier layer formed from a 1-50% aqueous mono-valent high acid ionomer dispersion, where the ionomer has an acid level greater than 18% and more than 45% acid groups neutralized with a monovalent cation, and a starting melt index greater than 180 g/10 min, applied in a thickness of less than 0.010 inches to provide a low moisture vapor transmission rate without requiring high pressures or solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a thin moisture barrier layer is applied to prevent water vapor penetration, then moisture protection is improved, but the layer thickness is reduced which may compromise durability and resistance to cracking
Solution Approach 1:
The patent uses a composite ionomeric material that combines the moisture barrier properties of ionomers with enhanced durability and crack resistance. The specific ionomer composition (with controlled acid content, neutralization level, and molecular weight) creates a composite structure that maintains effectiveness at thin thicknesses while resisting the harmful effects of cracking and delamination.
Solution Approach 2:
The patent carefully controls multiple parameters of the ionomeric material including acid content (15-30%), neutralization level (40-70%), and molecular weight to optimize the balance between moisture barrier performance and mechanical durability. These parameter changes enable the material to function effectively at thicknesses below 0.010 inches while maintaining reliability.
2Object-affected harmful factors
If ionomeric materials are used for the moisture barrier layer, then moisture vapor transmission resistance is improved, but high pressures and temperatures are required for application which increases manufacturing complexity
Solution Approach 1:
The patent modifies the processing parameters by using ionomeric materials with specific molecular weights and acid contents that can be applied at lower pressures and temperatures than conventional ionomers. This enables the material to be applied using standard golf ball manufacturing processes without requiring specialized high-pressure equipment or extensive pre-heating.
Solution Approach 2:
The patent employs a thin-layer application approach where the ionomeric moisture barrier is applied as a thin coating rather than a thick layer, reducing the total material quantity and processing requirements. This thin-layer approach maintains effectiveness while simplifying the manufacturing process.
3Ease of manufacture
If the moisture barrier layer is made thinner to reduce material cost and processing complexity, then manufacturing cost is reduced, but the barrier effectiveness may be compromised
Solution Approach 1:
The patent uses a specialized ionomeric composite material that provides superior moisture barrier performance per unit thickness compared to conventional materials. The controlled composition (acid content, neutralization level, molecular weight) creates a denser, more effective barrier that maintains performance even at reduced thicknesses, thereby reducing material costs while preserving barrier effectiveness.
Solution Approach 2:
The patent optimizes the ionomeric material parameters to achieve maximum barrier effectiveness at minimum thickness. By controlling acid content (15-30%), neutralization level (40-70%), and molecular weight, the material achieves optimal packing density and crystallinity that enhance barrier performance, allowing thinner layers to maintain effectiveness.
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 effectively prevents moisture penetration, maintaining the golf ball's optimal properties like high coefficient of restitution even in humid conditions, without compromising durability or increasing production costs.
Implementation Method 1
ionomeric materials are often preferred in many constructions due to their superior durability and desirable performance characteristics such as scuff resistance and rebound. Also being known to be non-soluble in water, ionomers would therefore serve as excellent moisture vapor barrier materials
Implementation Method 2
an effective moisture barrier layer has a water vapor transmission rate that is low enough to create a barrier against moisture penetration into the enveloped material and thereby protect the material against the negative effects of water
Data Source
AI summary
Golf ball comprising a first layer having a first spherical outer surface; a thin moisture vapor barrier layer disposed concentrically about the first spherical outer surface and having a thickness of less than about 0.010 inches; and a second layer disposed concentrically about a second spherical outer surface of the thin moisture vapor barrier layer. The thin moisture vapor barrier layer is formed from an ionomer composition consisting of a 1-50 percent aqueous mono-valent high acid ionomer dispersion, with the ionomer: having an acid level greater than 18%; having more than 45% of acid groups that are neutralized with a monovalent cation; and being formed from an acid copolymer having a starting melt index of greater than 180 g/10 min.@190° C. with a 2160 g load. The moisture vapor barrier layer has a moisture vapor transmission rate that is lower than that of at least one of the first layer and/or the second layer.