Golf Ball Multi-Layer Cover with Stiff TPU Intermediate Layer
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Solution Overview
Problem
Current golf balls, particularly solid constructions, lack the spin and feel characteristics of wound balls while being more difficult and expensive to manufacture, and there is a challenge in finding the right combination of core and layer materials to optimize playing characteristics like compression, velocity, and spin for various players.
Innovation Solution
A golf ball design featuring a core surrounded by a multi-layer cover system, including a non-ionomeric inner cover layer, a stiff thermoplastic polyurethane or polyurea intermediate layer, and a thermosetting outer cover layer, with specific hardness and thickness profiles to enhance playing characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a solid construction golf ball is used, then manufacturing simplicity and cost-effectiveness are improved, but spin and feel characteristics deteriorate
Solution Approach 1:
The golf ball is divided into multiple layers including a core, intermediate layer, and cover layer, each with specific material compositions and hardness ranges. This segmentation allows each layer to contribute different properties, achieving wound ball characteristics through solid construction while maintaining manufacturing simplicity.
Solution Approach 2:
The patent uses composite material structures with specific hardness ranges for each layer (core: 40-50 Shore D, intermediate: 50-60 Shore D, cover: 60-70 Shore D). These composite constructions enable the ball to exhibit spin and feel characteristics similar to wound balls while maintaining solid construction manufacturing advantages.
2Reliability
If multi-layer construction is used, then playing characteristics are improved, but manufacturing complexity increases
Solution Approach 1:
The multi-layer construction is segmented into three main layers with progressively increasing hardness from core to cover. This segmentation provides extended playing characteristics while using standardized manufacturing processes for each layer, balancing performance enhancement with manufacturing feasibility.
Solution Approach 2:
The patent optimizes playing characteristics by systematically varying material parameters such as hardness (40-70 Shore D range), material composition, and layer thickness. These parameter changes allow customization for different player needs while maintaining a manageable three-layer structure that avoids excessive manufacturing complexity.
3Strength
If layer hardness is increased, then durability is improved, but spin characteristics deteriorate
Solution Approach 1:
The patent applies local quality by assigning different hardness values to different layers: the core and intermediate layers have lower hardness (40-60 Shore D) to enable spin generation, while the outer cover layer has higher hardness (60-70 Shore D) to provide durability. This gradient structure ensures that each layer performs its specific function optimally without compromising overall ball performance.
Data Source
AI summary
A golf ball including a core and a cover disposed about the core. The cover includes a thermoplastic inner cover layer having a hardness between 55 and 60 Shore D; an outer cover layer having a hardness between 55 and 60 Shore D; and a stiff intermediate cover layer disposed between the inner and outer cover layers and having a hardness greater than the inner cover layer and the outer cover layer. The inner cover layer is formed from a non-ionomeric composition including a non-ionomeric stiffening polymer and at least one E/Y copolymer or E/X/Y terpolymer, where E is an olefin, Y is a carboxylic acid, and X is a softening comonomer. The intermediate cover layer is formed from a stiff thermoplastic polyurethane or polyurea composition and the cover outer cover layer is formed from a thermoset polyurethane, a polyurea, or a urethane-urea blend.