Golf Ball Intermediate Layer Using Polyamide Blend for COR and Feel
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Solution Overview
Problem
Golf balls face challenges in achieving maximum Coefficient of Restitution (COR) without exceeding velocity limitations, while also requiring lower driver spin rates and a soft shot feel, which existing multi-layer constructions often compromise on due to material limitations.
Innovation Solution
A golf ball design featuring a core, outer cover layer, and intermediate layers comprising a blend of polyamides with functional polymer modifiers, such as copolymers or terpolymers with glycidyl, hydroxyl, maleic anhydride, or carboxylic groups, which provide improved impact durability and elasticity, enhancing COR without brittleness and maintaining toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high acid ionomer mantle layers are used to achieve high COR, then the ball can achieve comparable or better COR values, but the ball may become too hard and lose the soft shot feel that golfers desire
Solution Approach 1:
The patent uses a composite material system consisting of high acid ionomer (30-70 wt%), thermoplastic polyurethane (20-40 wt%), and thermoplastic polyurea (10-30 wt%) to create an intermediate layer that combines the high COR properties of ionomer with the soft feel characteristics of polyurethane and polyurea. This composite approach allows the ball to achieve both high COR and soft shot feel simultaneously.
Solution Approach 2:
The patent applies different material properties to different layers of the golf ball. The intermediate layer uses a specific composite formulation optimized for COR and feel, while the cover layer uses a different composition (ionomer, polyurethane, or polyurea) optimized for durability and spin control. This local differentiation of material properties allows each layer to optimize for its specific function.
2Speed
If multi-layer constructions are used to optimize COR and spin rates, then driver spin can be reduced and distance improved, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the golf ball into distinct functional segments: a core layer for energy storage and release, an intermediate layer (comprising one or more layers) for COR optimization and spin control, and a cover layer for durability and feel. This segmentation allows each layer to be optimized for its specific function while maintaining overall ball performance.
Solution Approach 2:
The patent optimizes performance by carefully controlling compositional parameters within specific ranges: high acid ionomer (30-70 wt%), thermoplastic polyurethane (20-40 wt%), and thermoplastic polyurea (10-30 wt%). By maintaining these parameter ranges, the patent achieves consistent COR values (0.82-0.85) and driver spin rates (200-400 rpm) while simplifying the manufacturing process through standardized formulations.
3Strength
If ionomer materials are used for cover and intermediate layers, then cut or shear resistance is improved, but the ball lacks the click and feel that golfers are accustomed to
Solution Approach 1:
The patent creates a composite material system combining high acid ionomer (providing cut/shear resistance) with thermoplastic polyurethane and thermoplastic polyurea (providing click and feel). This composite approach allows the intermediate layer to simultaneously deliver the durability of ionomer and the desirable sensory characteristics of polyurethane/polyurea materials.
Solution Approach 2:
The patent applies different material properties to different layers: the intermediate layer uses a composite formulation optimized for COR and feel, while the cover layer uses materials (ionomer, polyurethane, or polyurea) optimized for cut resistance and durability. This local differentiation allows each layer to optimize for its specific function without compromising overall performance.
Data Source
AI summary
The present disclosure relates to golf balls having components including intermediate layers and outer cover layers prepared from blends of polyamides mixed with one or more functional polymer modifiers. The functional polymer modifier incorporates a copolymer or a terpolymer having a glycidyl group, hydroxyl group, maleic anhydride group or carboxylic group, or a mixture of these. When used in golf ball covers or mantles, these materials exhibit improved impact durability when compared to analogous balls but having ionomeric- or polyurethane-based layers of similar hardness.