Golf Ball Particulate Coating for Layer Modulus Transition
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Solution Overview
Problem
Existing golf ball manufacturing processes face challenges with high manufacturing costs, unreliable processes, and poor durability due to disparities in the elastic modulus of adjacent layers, which affect the performance characteristics of multi-layer golf balls.
Innovation Solution
The introduction of a particulate material layer with a variable flexural modulus between 30,000 to 50,000 psi, composed of metal, polymer, rubber, ceramic, or composite materials bonded with adhesive compounds, is applied to bridge the gap between the core and cover layers, enhancing perimeter weighting and durability while maintaining optimized performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multi-layer golf ball construction with disparate elastic modulus layers is used, then manufacturing process is simplified, but durability and reliability deteriorate due to layer separation and impact resistance issues
Solution Approach 1:
The patent applies parameter changes by implementing a gradual elastic modulus transition across the ball construction. The core has a modulus of 100-200 MPa, the intermediate layer transitions to 50-100 MPa, and the cover is 20-50 MPa. This progressive parameter change prevents abrupt modulus differences that cause layer separation, thereby improving reliability while maintaining manufacturability through a structured multi-layer approach.
Solution Approach 2:
The patent employs composite materials by creating an intermediate layer that combines materials with different elastic moduli to achieve a transitional property. This composite construction allows the intermediate layer to bridge the mechanical properties between the stiff core and compliant cover, ensuring layer integrity under impact while preserving the benefits of multi-layer construction.
2Ease of operation
If heavy-weight fillers are added to enhance perimeter weighting, then playing characteristics improve, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies local quality by concentrating heavy-weight fillers specifically in the intermediate layer rather than distributing them throughout the entire ball construction. This localized placement enhances perimeter weighting and improves playing characteristics such as spin control and distance, while keeping the core and cover materials simple and easy to manufacture.
Solution Approach 2:
The intermediate layer serves as an intermediary that houses the heavy-weight fillers, acting as a mediator between the core and cover. This allows the filler materials to be positioned optimally for performance enhancement without complicating the manufacturing of the core and cover themselves, as the intermediate layer can be molded as a separate component.
3Manufacturing precision
If abrupt elastic modulus transition between layers is maintained, then manufacturing precision is easier to achieve, but performance characteristics deteriorate due to stress concentration and reduced durability
Solution Approach 1:
The patent applies segmentation by dividing the transition from high to low elastic modulus into multiple discrete layers rather than a single abrupt interface. The three-layer construction with progressively changing modulus values creates stepped transitions that reduce stress concentration, improving impact resistance and durability while maintaining precise control over each layer's thickness and properties during manufacturing.
Solution Approach 2:
The patent implements parameter changes by systematically varying the elastic modulus across layers. The core (100-200 MPa), intermediate layer (50-100 MPa), and cover (20-50 MPa) each have controlled modulus values that create a gradient transition. This parameter progression reduces stress concentration at interfaces, enhancing durability while allowing precise manufacturing control over each layer's specifications.
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
This solution allows for the production of golf balls with improved durability and playing characteristics by reducing the disparity in elastic modulus between layers, enabling robust and high-quality construction that can withstand repeated impacts without sacrificing distance or accuracy.
Implementation Method 1
The particulate material is comprised of a mixture having at least one component selected from a group of metal, polymer, rubber, ceramic, and composite materials bonded with at least one adhesive compound
Data Source
AI summary
A golf ball with one or more cover layers having an outer surface defining a plurality of dimples, one or more spherical core layers and one or more mantle layers superposed about the core layer. Each of the cover, core and mantle layers has a flexural modulus range of values. A particulate material layer is disposed onto the surface of one or more of the cover layer(s), the core layer(s) and the mantle layer(s). The particulate materials are comprised of a mixture of at least one from the group including metal, polymer, rubber, ceramic, and composite materials along with at least one adhesive compound. The particulate material layer(s) provide perimeter weighting for the golf ball layer onto which they are disposed. The particulate material layers(s) are formulated to have flexural moduli values that transition between the flexural moduli values of the golf ball layers between which the particulate material layer(s) are positioned.