Golf Ball Core Using Plasticized Thermoplastic for Feel and Durability
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Solution Overview
Problem
There is a need for improved core constructions in golf balls that provide a combination of toughness, resiliency, and optimal feel and spin control, without being excessively hard or stiff, as existing ethylene acid copolymer ionomer compositions do not fully meet these performance requirements.
Innovation Solution
The use of a thermoplastic ethylene acid copolymer/plasticizer composition in golf ball cores, with specific layering configurations such as a three-layered core assembly featuring an inner core, intermediate core layer, and outer core layer, and a cover layer, where the thermoplastic composition includes an acid copolymer, plasticizer, and cation source, and the layers have varying hardness gradients to achieve desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ethylene acid copolymer ionomer compositions are used in golf ball cores, then durability and cut-resistance are improved, but the ball becomes excessively hard and stiff, reducing feel and spin control
Solution Approach 1:
The patent applies local quality by creating distinct core layers with different material compositions and hardness levels. The inner core uses a softer thermoplastic elastomer for feel and spin control, while the outer core layer uses the harder ionomer for durability. This spatial differentiation of material properties resolves the contradiction between durability and playability.
Solution Approach 2:
The patent employs composite materials by combining thermoplastic elastomers with ionomer resins in a multi-layer core structure. This composite approach allows the ball to simultaneously exhibit the toughness and resiliency of elastomers and the durability and cut-resistance of ionomers, resolving the contradiction between softness and durability.
2Power
If multi-layered core constructions are implemented, then resiliency and COR are improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the core into multiple functional layers, each with specific material compositions and hardness levels. The inner core layer provides resiliency and COR, while the outer core layer provides durability. This segmentation allows optimization of each layer's function while managing overall complexity through a systematic multi-layer architecture.
Data Source
AI summary
Multi-layered golf balls containing a two or three-layered core assembly are provided. In one embodiment, the core assembly includes an inner core (center) comprising a thermoset composition, an intermediate core layer; and surrounding outer core layer. Preferably, the thermoplastic composition comprises: a) ethylene acid copolymer, b) plasticizer, and c) cation source. A fatty acid ester such as ethyl oleate is preferably used as the plasticizer. A second thermoset composition such as polybutadiene rubber may be used to form the outer core layer. The core layers have different hardness levels. In another embodiment, a two-layered core structure is provided. For example, the inner core and/or outer core layer may be made of the plasticized thermoplastic composition. The core structure and resulting ball have relatively good resiliency at given compressions.