Hemispherical Cup Geometry for Golf Ball Compression Molding
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Solution Overview
Problem
Conventional compression molding techniques often result in core blowout and cup shifting when forming thin outer layers over large, soft golf ball cores, leading to inconsistent golf ball characteristics such as compression, weight, size, and roundness.
Innovation Solution
The use of hemispherical cups with a specific configuration and geometry, featuring a melt flow index of 0.8-4 g/10 min and a cup thickness ratio of 1.10-1.70, which taper from top to bottom to ensure concentric compression molding and prevent core deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional compression molding techniques are used to form thin outer layers over large, soft golf ball cores, then the manufacturing process is simple, but core blowout and cup shifting occur leading to inconsistent golf ball characteristics
Solution Approach 1:
The hemispherical cup is designed with non-uniform wall thickness, being thicker at the top section and thinner at the bottom section. This local variation in thickness provides structural support where needed while maintaining conformability to the core surface, preventing both core blowout and cup shifting during compression molding.
Solution Approach 2:
The cup thickness ratio between the top section and bottom section is specifically controlled within 1.10-1.70, creating an asymmetric thickness distribution. This asymmetric design optimizes the balance between structural integrity to prevent shifting and flexibility to conform to the core, resolving the contradiction between precision and simplicity.
2Quantity of substance
If thin outer layers are compression molded over large, soft cores, then material usage is reduced, but core deformation and blowout occur
Solution Approach 1:
The cup's thicker top section provides enhanced structural support during molding to prevent core blowout, while the thinner bottom section reduces overall material usage. This local quality variation allows the outer layer to be thin yet still protect core integrity during the molding process.
Solution Approach 2:
The asymmetric thickness distribution acts as a preventive measure, with the thicker top section providing advance cushioning and support against core deformation during compression molding, before the actual molding pressure is applied.
3Manufacturing precision
If the cup thickness is uniform, then manufacturing is simpler, but concentric compression molding cannot be achieved and cup shifting occurs
Solution Approach 1:
The deliberate asymmetric thickness distribution (ratio 1.10-1.70) creates a self-centering effect during compression molding. The thicker top section provides a reference plane that helps maintain concentric alignment, achieving precise concentric molding despite the increased manufacturing complexity of the asymmetric cup.
Solution Approach 2:
By changing the thickness parameter from uniform to asymmetric distribution, the cup gains the ability to self-align during compression molding. This parameter change transforms the cup from a simple form requiring external alignment mechanisms to a self-centering design that achieves concentric molding inherently.
Data Source
AI summary
Golf ball having CoR of at least 0.700 and comprising: a substantially spherical subassembly having diameter of 1.3 inches or greater and compression of from about 15-60; and a thin outer layer having a compression molded thickness of about 0.015-0.055 inches and consisting of first and second hemispherical cups consisting of a polymer composition having a melt flow index at 190° C. under a 2.16-kg load of from about 0.8 g/10 min. to about 4 g/10 min. and having a cup thickness ratio of from about 1.10 to 1.70 as well as an inner surface that is sized, shaped and contoured to receive and conformally and adhesively mate onto and about the subassembly during compression molding such that the subassembly in the finished golf ball is substantially spherical and disposed concentrically within the thin outer layer. Also, the novel hemispherical cups and the method of making the golf ball.