Graphene Masterbatch Dispersion in Golf Ball Polybutadiene Cores

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Solution Overview

Problem

Existing methods for dispersing graphene in polymer matrices often require chemical functionalization, ultrasonication, or solvents, which can be inefficient and environmentally unfriendly, and do not ensure uniform dispersion, affecting the mechanical and electrical properties of composites.

Innovation Solution

Using a graphene masterbatch form with carrier polymers like polybutadiene and polyisoprene to achieve well-dispersed graphene in golf ball rubber cores, eliminating the need for solvents and oxidizing/reducing agents, and ensuring improved mechanical and electrical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If chemical functionalization methods are used to disperse graphene in polymer matrix, then dispersion quality improves, but process complexity and environmental harm increase

Engineering Contradiction:

Improvegraphene dispersion uniformityVSAvoidprocess complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the harmful chemical functionalization step from the graphene dispersion process. By using mechanical mixing and masterbatch technology instead of chemical treatments, the process achieves adequate dispersion without the complexity and environmental harm of chemical functionalization methods.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces masterbatch as an intermediary carrier to disperse graphene in the polymer matrix. The masterbatch contains pre-dispersed graphene particles that act as an intermediate form, making it easier to achieve uniform distribution in the final polymer product without requiring complex in-situ dispersion processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If ultrasonication is used to disperse graphene, then dispersion quality improves, but energy consumption and equipment complexity increase

Engineering Contradiction:

Improvegraphene dispersion uniformityVSAvoidenergy consumption

Core Design Contradiction:

Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

The patent replaces expensive and energy-intensive ultrasonication equipment with simpler, more economical mixing equipment. By using masterbatch technology, the dispersion is achieved through conventional mixing processes that consume significantly less energy while still achieving adequate uniformity for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If solvents are used to disperse graphene, then dispersion quality improves, but environmental harm and safety risks increase

Engineering Contradiction:

Improvegraphene dispersion uniformityVSAvoidenvironmental harm

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potential harm of using solvents into a benefit by completely eliminating solvent usage. Instead of relying on solvents to achieve dispersion, the process uses masterbatch technology where graphene is pre-dispersed in a polymer matrix, allowing solvent-free processing that is environmentally friendly while maintaining dispersion quality.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Ease of operation

If graphene is used in powdered form, then ease of handling improves, but dispersion uniformity deteriorates

Engineering Contradiction:

Improveease of handlingVSAvoiddispersion uniformity

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by pre-dispersing graphene particles in a polymer matrix to create masterbatch before the final processing step. This preliminary dispersion action ensures that when the masterbatch is added to the polymer blend, the graphene is already in a dispersed state, preventing aggregation and ensuring uniform distribution in the final product.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The masterbatch acts as an intermediary form between powdered graphene and the final polymer composite. It provides the handling ease of a consolidated material while maintaining the dispersion benefits of pre-mixed particles, serving as a bridge that resolves the contradiction between ease of handling and dispersion uniformity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11717727B1Process for incorporating graphene into a core of a golf ball

Publication Date: 2023.08.08 TOPGOLF CALLAWAY BRANDS CORP

AI summary

A method for forming a golf ball with a graphene core disclosed herein. The method includes mixing a graphene masterbatch material with a polybutadiene material to form a core mixture, wherein the graphene masterbatch material comprises graphene in an amount from 0.1 to 80.0 weight percent of the graphene masterbatch material mixed with a carrier polymer in an amount from 99.9 to 20 weight percent of the graphene masterbatch material.