High Molecular Weight Polysiloxane Golf Ball Cover Mold Release
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Solution Overview
Problem
Current mold releases for TPU cover materials in golf ball injection molding migrate to the golf ball surface, affecting paint adhesion and UV properties, with existing solutions failing to adequately address this issue.
Innovation Solution
High molecular weight polysiloxane is used as a mold release due to its limited mobility, preventing migration and maintaining thermal properties, with preferred formulations including Flexil and Everglide from Polymer Dynamix, blended with thermoplastic resins and silica.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional mold releases are used for TPU cover material, then mold release function is achieved, but the mold release migrates to the golf ball surface during injection molding and post curing process, negatively impacting paint adhesion and UV property
Solution Approach 1:
The patent changes the molecular weight parameter of the polysiloxane from conventional low molecular weight to high molecular weight (10,000-1,000,000). This parameter change fundamentally alters the mobility and migration behavior of the polysiloxane, preventing it from migrating to the golf ball surface while maintaining its mold release functionality. The high molecular weight creates long chains with limited mobility that remain within the bulk material.
Solution Approach 2:
The patent creates a composite material system by blending thermoplastic resin (20-99 wt%) with high molecular weight polysiloxane (1-80 wt%). This composite approach combines the structural properties of the thermoplastic resin with the mold release properties of the polysiloxane, achieving both mold release function and surface stability simultaneously. The composite blend prevents the segregation and migration issues seen in conventional single-component systems.
2Reliability
If high molecular weight polysiloxane is used as mold release, then migration to surface is prevented and paint adhesion is improved, but the material must maintain appropriate processability during injection molding
Solution Approach 1:
The patent optimizes the molecular weight range of the polysiloxane (10,000-1,000,000) to balance two opposing requirements: high enough to prevent migration and improve paint adhesion, but not so high as to compromise processability. This parameter optimization ensures the polysiloxane remains sufficiently mobile during injection molding while preventing surface migration in the final product.
Solution Approach 2:
The patent creates different functional zones within the golf ball cover material. The high molecular weight polysiloxane localizes its mold release function at the mold-interface region during processing, while the thermoplastic resin matrix maintains structural integrity and processability. This local quality differentiation allows the system to exhibit different properties in different regions and processing stages.
3Stability of the object's composition
If high molecular weight polysiloxane is used as plasticizer or impact modifier, then it does not alter thermal transition temperature and melt flowability, but adequate plasticizing effect must be achieved
Solution Approach 1:
The patent changes the molecular weight parameter of the polysiloxane to a high range (10,000-1,000,000), which fundamentally alters its interaction with the thermoplastic resin. The high molecular weight creates long chains that provide plasticizing effect through entanglement and free volume changes rather than through small-molecule diffusion, thereby maintaining thermal transition temperature and melt flowability while still achieving adequate plasticizing effect.
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 use of high molecular weight polysiloxane as a mold release prevents surface migration, ensuring consistent paint adhesion and UV properties, while functioning as a plasticizer or impact modifier without altering thermal transition temperatures or melt flowability.
Implementation Method 1
The mobility of high molecular weight polysiloxane is limited due to its long chains, thus it does not migrate to the surface and affect the paintability and UV property
Implementation Method 2
It can be used as a plasticizer or impact modifier, especially for polyamide and polyurethane. Unlike other plasticizers and impact modifiers, it does not alter the thermal transition temperature and melt flowability
Data Source
AI summary
A golf ball with a cover layer composed of a blend of (a) 20 to 99 wt % of a thermoplastic resin, and (b) 1 to 80 wt % of a high molecular weight polysiloxane having a molecular weight (Mn) of at least 10,000 and not more than about 1,000,000 (Mn,), is disclosed herein. The high molecular weight polydimethylsiloxane has blended with it 3 to 35 weight percent of a silica. The high molecular weight polydimethylsiloxane has pendant groups, terminal groups or mixtures of pendant groups and terminal groups selected from the group consisting of hydrogen, trimethyl, dimethyl, methyl, phenyl, fluoro, amino, vinyl, hydroxyl, and methacrylate.