Propylene Elastomer Golf Ball Cover for Distance and Spin
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Solution Overview
Problem
Conventional golf balls, particularly two-piece balls, offer high distance but low spin control due to their rigid materials, making them difficult to control, especially on short approach shots, and require longer manufacturing times and higher production costs compared to multi-layer balls which often compromise on Coefficient of Restitution (COR) and speed.
Innovation Solution
Incorporating specialty propylene elastomers into the core, outer cover layer, or intermediate layers of golf balls to enhance mechanical properties such as toughness and processability, allowing for improved hardness without detrimental effects on COR, and combining these with ionomers to create blends that optimize ball performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional two-piece golf balls with rigid materials are used, then distance is improved, but spin control deteriorates
Solution Approach 1:
The golf ball is divided into multiple layers with different material properties. The core uses rigid materials for distance, while the cover and intermediate layers use softer materials for spin control. This segmentation allows each layer to independently optimize for its specific function without compromising the other.
Solution Approach 2:
The patent employs composite material construction combining different polymers and elastomers in various layers. The core may use high-rebound materials like polybutadiene, while intermediate layers use propylene elastomers, and covers use ionomers or thermoplastic polyurethanes. This composite approach enables simultaneous optimization of distance and spin characteristics.
2Ease of operation
If multi-layer golf balls are used to improve spin control, then manufacturing complexity increases
Solution Approach 1:
The golf ball construction is segmented into discrete layers that can be manufactured separately and then assembled. This modular approach simplifies the overall manufacturing process compared to trying to create a single complex structure, as each layer can be optimized and produced using standard molding techniques.
Solution Approach 2:
Intermediate layers and covers are prepared with predetermined material compositions and thicknesses before final assembly. The propylene elastomer layers are pre-formulated with specific properties to achieve desired spin rates, allowing for consistent performance without requiring complex real-time manufacturing adjustments.
3Ease of operation
If softer cover materials are used to improve spin control, then Coefficient of Restitution deteriorates
Solution Approach 1:
The golf ball is segmented into a hard core and softer cover layers. The core maintains high Coefficient of Restitution for distance, while the softer intermediate and cover layers provide spin control. This segmentation allows the ball to exhibit both high rebound efficiency and desirable spin characteristics.
Solution Approach 2:
Composite material construction combines high-rebound core materials with softer cover materials. The propylene elastomer intermediate layer acts as a transition zone, allowing efficient energy transfer from the core while enabling the softer cover to deform and generate spin without significantly compromising overall COR.
4Strength
If propylene elastomer blends are used to improve mechanical properties, then material cost increases
Solution Approach 1:
Propylene elastomer blends are applied locally in specific layers where enhanced mechanical properties are most beneficial, such as the intermediate layer between core and cover. This targeted approach provides improved toughness and durability where needed while minimizing the overall amount of expensive specialty materials required in the ball construction.
Solution Approach 2:
The patent uses composite material formulations combining propylene elastomers with more cost-effective base materials. The blends are designed to provide enhanced mechanical properties and processability at optimal concentrations, balancing performance benefits with material costs through carefully controlled composition ratios.
Data Source
AI summary
A golf ball including a core comprising a center; an outer cover layer; and one or more intermediate layers, wherein at least one of the core, the outer cover layer, or the intermediate layer comprises a composition that includes at least one specialty propylene elastomer. The specialty propylene elastomer is preferably present in the outer cover layer and/or the intermediate layer. Also disclosed is a composition that includes at least one ionomer and at least one specialty propylene elastomer, wherein the ionomer is present in an amount of about 95 to about 5 weight percent and the specialty propylene elastomer is present in an amount of about 5 to about 95 weight percent, based on the total weight of all polymers in the composition. The specialty propylene elastomer/ionomer composition can be used to make the outer cover layer and/or the intermediate layer of a golf ball.