Multi-layer Golf Ball Core and Cover Design
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Solution Overview
Problem
There is a need in the golf ball industry for improved core and cover constructions that enhance resiliency and allow for higher initial ball speed and reduced initial ball spin when driving, resulting in longer overall distance.
Innovation Solution
A multi-piece golf ball design featuring a multi-layered solid core and cover, comprising an inner core layer made from thermoset rubber, an intermediate core layer from thermoplastic material, an outer core layer from highly neutralized polymer, an inner cover layer from thermoplastic composition, and an outer cover layer from polyurethanes or polyureas, with specific hardness ranges to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-layered core and cover construction is used, then resiliency and initial ball speed are improved, but device complexity increases
Solution Approach 1:
The golf ball is divided into multiple discrete layers including an inner core layer, intermediate core layer, outer core layer, inner cover layer, and outer cover layer. Each layer is formed from specific materials with controlled hardness ranges to independently contribute to overall resiliency while maintaining manageable manufacturing complexity through modular construction
Solution Approach 2:
The patent employs composite material construction by combining different polymers and elastomers in specific layers. The inner core uses thermoset rubber, intermediate core uses thermoplastic, outer core uses highly neutralized polymer, and covers use polyurethane/polyurea compositions, creating a composite structure that optimizes resiliency and ball speed while distributing functional requirements across material types
2Speed
If multi-layered core and cover construction is implemented, then initial ball speed increases, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into discrete molding operations for each layer. The inner core layer, intermediate core layer, outer core layer, inner cover layer, and outer cover layer are formed sequentially or simultaneously using mold assemblies that allow independent control of each layer's properties while streamlining production through standardized multi-cavity or stacked mold configurations
Solution Approach 2:
The patent controls initial ball speed by precisely adjusting material hardness parameters across layers. The inner core layer hardness is controlled at 50-70 Shore C, intermediate core at 70-90 Shore C, outer core at 40-60 Shore D, inner cover at 50-70 Shore D, and outer cover at 40-60 Shore D. These parameter specifications enable consistent performance while facilitating manufacturing through targeted material selection and processing conditions
3Object-generated harmful factors
If multi-layered core and cover construction is used, then spin reduction is achieved, but device complexity increases
Solution Approach 1:
The patent applies local quality by assigning specific hardness characteristics to different regions and layers of the golf ball. The softer inner core layer (50-70 Shore C) and outer core layer (40-60 Shore D) work together with the harder intermediate core (70-90 Shore C) to create localized deformation zones that reduce spin generation during impact, while each layer's specific properties are optimized for its position in the overall structure
Data Source
AI summary
Multi-piece golf balls having a multi-layered solid core and multi-layered cover are provided.