Three-Layer Golf Ball Cover with Plasticized Polyester Intermediate
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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 existing multi-layer balls often require complex and costly manufacturing processes to achieve optimal playing characteristics.
Innovation Solution
A golf ball design featuring a core surrounded by a three-layer cover, including a thermoplastic non-ionomeric inner cover layer, a stiff thermoplastic polyurethane or polyurea intermediate layer, and a thermoset polyurethane or polyurea outer cover layer, with specific hardness and composition profiles to enhance spin and feel without increasing manufacturing complexity.
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 construction types (wound center, solid center, intermediate layers) within a single ball, allowing different sections to provide different functions. The wound center provides spin characteristics while solid layers provide durability, combining benefits of both constructions.
Solution Approach 2:
The patent uses composite material structures combining different polymers (polybutadiene, polyurethane, polyester) with distinct properties in each layer. This allows optimization of spin, feel, and durability through material composition rather than relying on a single construction type.
2Reliability
If a wound construction golf ball is used, then spin and feel characteristics are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The wound construction is segmented and applied only to the center region, while outer layers use simpler solid constructions. This reduces overall manufacturing complexity while preserving spin characteristics where most needed.
Solution Approach 2:
Different construction methods are applied to different regions: wound construction at the center for spin, solid construction at outer layers for durability. Each region has optimized properties for its specific function.
3Reliability
If multiple cover layers are added to improve playing characteristics, then spin and feel are improved, but manufacturing complexity increases
Solution Approach 1:
The cover is segmented into three functional layers (inner, intermediate, outer), each with specific thicknesses and material properties optimized for particular functions, allowing complex performance characteristics to be achieved through systematic layering rather than monolithic construction.
Solution Approach 2:
Each cover layer has locally optimized properties: inner layer for durability and layer adhesion, intermediate layer for spin control, outer layer for feel and aesthetics. This localized optimization achieves superior playing characteristics without requiring excessive manufacturing complexity.
Data Source
AI summary
A golf ball includes a core and a three-layer cover disposed adjacent the core. The three-layer cover includes an inner cover, an intermediate cover, and an outer cover. The inner cover includes a non-ionomeric E/Y copolymer where E is an olefin and Y is a carboxylic acid. The inner cover has a hardness of about 45 to 68 Shore D. The outer cover includes a castable thermoset polyurethane and has a hardness of about 40 to 62 Shore D. The intermediate cover layer, disposed between the inner and outer cover layers, is formed from a polyester composition including about 40 wt % to about 99 wt % of a polyester thermoplastic elastomer and about 1 wt % to about 60 wt % of a plasticizer.