Golf Ball Layer Composition With Reversible Crosslinks for Adhesion
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Solution Overview
Problem
Modern golf balls face issues with adhesion between layers leading to delamination, lack of recyclability due to thermoset materials, and high manufacturing costs from adhesion-promoting processes.
Innovation Solution
The use of compositions forming thermo-reversible covalent adaptable networks (CANs) with diene and dienophile functional groups, crosslinked via Diels-Alder reactions, to enhance adhesion and recyclability, using base polymers like polyurethanes and ionomers, and incorporating rubber regrind as a filler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermoset materials are used in golf ball layers, then structural integrity and durability are maintained, but adhesion between layers deteriorates leading to delamination
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional permanent thermoset crosslinks to dynamic covalent bonds that can reversibly break and reform. The Diels-Alder adducts formed between diene and dienophile functional groups create bonds that dynamically exchange at elevated temperatures, enabling improved adhesion through continuous bond renewal while maintaining structural integrity during normal use conditions.
Solution Approach 2:
The patent employs composite materials by combining polymer layers with embedded diene and dienophile functional groups that form Diels-Alder adducts at the interfaces. This creates a composite structure where the dynamic covalent bonds between different polymer layers provide enhanced adhesion and prevent delamination while maintaining the individual layer properties.
2Reliability
If thermoset materials are used in golf ball construction, then durability and performance are achieved, but recyclability is lost
Solution Approach 1:
The patent enables recyclability through parameter changes in the bond stability. The Diels-Alder adducts are stable at room temperature and moderate temperatures, providing durability during use, but become reversible at elevated temperatures. This allows the golf ball to be recycled by heating to break the dynamic covalent bonds, separate the layers, and potentially reuse the materials, combining durability with recyclability.
3Reliability
If adhesion-promoting processes are used to prevent delamination, then layer bonding is improved, but manufacturing costs increase
Solution Approach 1:
The patent applies self-service by incorporating diene and dienophile functional groups directly into the polymer layer compositions during manufacturing. The dynamic covalent bonds form automatically during the curing process without requiring separate adhesion-promoting treatments, primers, or additional manufacturing steps, thereby reducing manufacturing costs while ensuring reliable layer adhesion.
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
Improves shear durability and adhesion strength, allows for increased recyclability, and reduces manufacturing costs by integrating recycled materials without performance degradation.
Implementation Method 1
compositions having diene functional groups and dienophile functional groups, crosslinked
Implementation Method 2
thermo-reversible covalent adaptable network (CAN)
Data Source
AI summary
Compositions including a base polymer and diene functional groups and/or dienophile functional groups attached to and crosslinking the base polymer, and golf balls made from such compositions are disclosed. The type and concentration of the components in the compositions, including the base polymer, the diene functional groups, and the dienophile functional groups, affect the hardness and resiliency of golf ball components made from such compositions, and thus, can be used to produce a golf ball having desirable performance characteristics. The compositions of the present disclosure may also be used in adjacent golf ball components to create crosslinks between such components that affect the adhesion between such golf balls components and, thus, can be used to produce a golf ball having increased durability. Golf ball components made from the compositions of the present disclosure may also have increased recyclability.