Mechanically Hybridized Golf Ball Layers for Adhesion
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Solution Overview
Problem
Golf ball manufacturers face challenges with adhesion issues between layers, particularly when using incompatible materials like ionomer resin and polyurethane or polyurea, leading to durability and performance problems, and conventional surface treatments add cost and time to the manufacturing process.
Innovation Solution
A golf ball design featuring a mechanically hybridized component with a first layer of polyolefin polymer and porosity-generating agents, such as microballoons or nanotubes, creating a network of interconnecting pores that are filled by a second layer, eliminating the need for surface treatments and enhancing adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional surface treatments (corona discharge/silane dipping) are used to improve adhesion between layers, then adhesion between incompatible materials is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent removes the need for conventional surface treatments (corona discharge, silane dipping) by extracting the adhesion enhancement function and integrating it directly into the polymer composition through reactive functional groups. The composition includes polymers with complementary functional groups that chemically bond to each other, eliminating the separate surface treatment steps and their associated costs and time requirements.
Solution Approach 2:
The patent introduces reactive functional groups (carboxylic acid, hydroxyl, amine, isocyanate, epoxide) as chemical intermediaries between incompatible polymer layers. These functional groups act as mediators that form covalent bonds across the interface between layers, enabling direct chemical adhesion without requiring external surface treatments.
2Reliability
If highly neutralized polymers are used to overcome adhesion problems, then adhesion between layers is improved, but gas generation during molding occurs leading to molding defects
Solution Approach 1:
The patent modifies the chemical parameters of the polymer composition by incorporating specific functional groups with controlled reactivity. Instead of using highly neutralized polymers that generate excessive gas, the composition uses polymers with complementary functional groups (carboxylic acid, hydroxyl, amine, isocyanate, epoxide) that provide adequate adhesion while generating minimal gas during the molding process, thus maintaining molding quality.
3Reliability
If fatty acid-based highly neutralized polymers are used as inner cover layer, then adhesion between layers is improved, but the fatty acids vaporize during injection molding generating gas that prevents outer cover layer from adhering properly
Solution Approach 1:
The patent converts the potential harm of gas generation into a benefit by selecting functional groups that provide adhesion through chemical bonding rather than through vaporization. The complementary functional groups (carboxylic acid, hydroxyl, amine, isocyanate, epoxide) form stable covalent bonds during molding, transforming the adhesion mechanism from one that relies on material vaporization to one that relies on direct chemical bonding, thereby eliminating the harmful gas generation effect.
4Ease of manufacture
If materials with poor moisture resistance or low resiliency are used, then cost is reduced, but performance and durability are compromised
Solution Approach 1:
The patent creates a composite polymer composition where multiple polymers with complementary functional groups are combined in a single composition. This composite approach allows the use of materials that individually may have limitations, but when combined, they provide enhanced performance through synergistic chemical bonding. The composition includes polymers with functional groups that improve moisture resistance and resiliency through covalent bonding networks, achieving both cost-effectiveness and high performance.
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
The mechanically hybridized component improves layer adhesion and overall performance and durability of the golf ball, reducing or eliminating the need for surface treatments and allowing the use of previously incompatible materials, resulting in a more efficient and cost-effective manufacturing process.
Implementation Method 1
a first layer formed of a first composition comprising at least one polyolefin polymer and a plurality of porosity-generating agents, such as microballoons or nanotubes, creating a network of interconnecting pores
Implementation Method 2
a second layer disposed thereon comprising a second composition, wherein the second composition fills the interconnecting pores to form the mechanically hybridized component
Data Source
AI summary
Golf balls having at least one layer that is formed from a mechanically hybridizing two or more materials. In particular, the mechanically hybridized layers of the invention improve performance and increase durability of the finished golf ball, as well increase adhesion between layers.