Neutralized Acid Polymer Golf Ball Ionomer Layer
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Solution Overview
Problem
Conventional golf ball ionomer compositions require blending high and low molecular weight acid-containing polymers to achieve desirable physical properties and melt flow, which is inefficient and costly, and do not effectively contribute to desired resilience and feel.
Innovation Solution
A golf ball layer comprising a neutralized acid polymer composition made from a mixture of low molecular weight acid-containing wax, a non-acid polymer, and an organic acid or salt, which achieves excellent melt flow and heat stability without the need for blending high and low molecular weight polymers, using specific weight percentages and molecular weights to optimize properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high molecular weight acid-containing polymers are used in golf ball ionomer compositions, then heat stability is improved, but melt flow deteriorates
Solution Approach 1:
The patent changes the molecular weight parameter of the acid-containing polymer from high to low range, and adjusts the neutralization level parameter to very high (90-100%), thereby achieving both excellent melt flow and heat stability without requiring polymer blending
Solution Approach 2:
The patent applies very high neutralization specifically to the low molecular weight acid-containing polymer component, creating a localized property enhancement that simultaneously improves both melt flow and heat stability characteristics
2Ease of manufacture
If low molecular weight acid-containing polymers are used in golf ball ionomer compositions, then melt flow is improved, but heat stability deteriorates
Solution Approach 1:
The patent changes the neutralization level parameter to very high (90-100%) for low molecular weight acid-containing polymers, which transforms the material properties to achieve both excellent melt flow and heat stability simultaneously
Solution Approach 2:
The patent creates a composite ionomer system by combining low molecular weight acid-containing polymer with non-acid polymer components, achieving synergistic effects that provide both processability and thermal performance
3Reliability
If high and low molecular weight acid-containing polymers are blended to achieve desirable physical properties and melt flow, then physical properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the high molecular weight polymer component from the blend formulation, achieving the desired physical properties through very high neutralization of low molecular weight polymer alone, thereby simplifying the formulation
Solution Approach 2:
The patent makes low molecular weight acid-containing polymer perform multiple functions simultaneously - providing both the physical properties and melt flow characteristics that previously required a combination of high and low molecular weight polymers
4Ease of manufacture
If conventional ionomer compositions are used, then manufacturing process is simplified, but resilience and feel performance deteriorate
Solution Approach 1:
The patent changes the neutralization level parameter to very high (90-100%) and adjusts the molecular weight parameter to low range, which improves resilience and feel while maintaining manufacturing simplicity through a single-component formulation
Data Source
AI summary
A golf ball comprising at least one layer comprised of a neutralized acid polymer composition consisting of a mixture of: (a) at least one low molecular weight acid-containing wax; (b) at least one non-acid-polymer; and (c) at least one organic acid or salt thereof. Each low molecular weight acid-containing wax may have a molecular weight of from about 500 to about 7000, and in some embodiments, the molecular weight may be considered low up to 30,000. Interactions between components (a), (b) and (c) as disclosed herein advantageously produce a layer of ionomeric material having desirable physical properties, such as heat stability, and processability (excellent melt flow) without the need for blending high and low molecular weight acid-containing polymer(s).