Moisture-Resistant Polyurethane Golf Ball Cover
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Solution Overview
Problem
Conventional golf balls with polyurethane components lack improved mechanical and playing properties, specifically requiring higher resiliency, impact durability, and a pleasant feel, which are not adequately met by existing multi-piece solid golf balls.
Innovation Solution
A multi-layered golf ball composition using a thermoset polyurethane or polyurea based on a moisture-resistant polyol, formed from an isocyanate compound, a moisture-resistant polyol with a specific molecular weight range, and a curing agent, providing a cross-link density of 10 to 300 mol/m3 and a Vicat softening temperature of 60° to 180° C, suitable for forming any layer in the golf ball structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polyurethane components are used in golf balls, then manufacturing is simpler and costs are lower, but resiliency, impact durability, and playing performance are insufficient
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the polyurethane system. Specifically, it uses polyols with specific molecular weights (500-10,000 g/mol), controlled cross-link densities (10-300 mol/m³), and specific Vicat softening temperatures (60-180°C) to achieve optimal resiliency and playing performance while maintaining manufacturability through standardized polymer synthesis processes.
Solution Approach 2:
The patent employs composite materials by creating thermoset polyurethane compositions that combine multiple functional components: polyisocyanate, moisture-resistant polyol, and curing agent. This composite approach allows the material to simultaneously provide high resiliency, impact durability, and moisture resistance, resolving the contradiction between performance and manufacturing simplicity.
2Strength
If polyurethane compositions with higher cross-link density are used to improve impact durability, then strength increases, but processing becomes more difficult and manufacturing complexity increases
Solution Approach 1:
The patent resolves this contradiction by optimizing the cross-link density parameter to a specific range (10-300 mol/m³) and controlling the Vicat softening temperature (60-180°C). These parameter optimizations enable the material to achieve high impact durability while maintaining processability, as the cross-linking occurs during standard curing processes without requiring overly complex manufacturing procedures.
Solution Approach 2:
The patent applies preliminary action by pre-forming the polyurethane composition with controlled cross-linking potential before final curing. The composition is prepared with polyol and polyisocyanate in specific ratios, allowing the cross-linking reaction to proceed in a controlled manner during manufacturing, thereby achieving high strength without excessive process complexity.
3Reliability
If thermoset polyurethane is used to improve resiliency and durability, then playing performance improves, but the material becomes more sensitive to moisture and processing becomes more challenging
Solution Approach 1:
The patent addresses moisture sensitivity by selecting polyols with specific molecular weights (500-10,000 g/mol) and controlling the cross-link density (10-300 mol/m³) and Vicat softening temperature (60-180°C). These parameter optimizations create a thermoset polyurethane that achieves high durability and resiliency while maintaining resistance to moisture degradation, as the cross-linked network structure prevents moisture penetration.
4Strength
If conventional ionomer resins are used for intermediate layers, then manufacturing is easier, but scuff resistance and abrasion resistance are insufficient
Solution Approach 1:
The patent applies composite materials by using thermoset polyurethane compositions that combine polyisocyanate, moisture-resistant polyol, and curing agent in specific proportions. This composite formulation provides superior scuff and abrasion resistance compared to conventional ionomer resins, while the standardized composition allows for straightforward manufacturing processes, thereby resolving the contradiction between strength and ease of manufacture.
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 resulting golf balls exhibit high resiliency, impact durability, and a soft feel, with optimal playing performance properties, including enhanced moisture resistance and improved scuff/abrasion resistance.
Implementation Method 1
the composition is produced from a reaction of polyisocyanate with a moisture-resistant polyol and curing agent
Implementation Method 2
The resulting thermoset composition has a cross-link density in the range of about 10 to about 300 mol/m3
Data Source
AI summary
The present invention provides golf balls having a rubber core, and a cover layer made from a thermoset polyurethane of polyurethane-urea that is the reaction product of a polyisocyanate with moisture-resistant polyol and curing agent. An intermediate layer, formed from an olefin-based acid copolymer ionomer composition and preferably an ethylene acid copolymer, is disposed between the rubber core and cover. The moisture-resistant polyol is preferably a reaction product of dimer acid or dimer ester and a polyolefin diol, or a polybutadiene polyol, or a polyisoprene. Preferably, the cover layer has a moisture vapor transmission rate (MVTR) between 3 grams·mm/m2·day to 4 grams·mm/m2·day.