Recyclable Golf Ball Dissolvable Tie Layer
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Solution Overview
Problem
Golf balls with excellent adhesive strength during play are difficult to recycle effectively, as existing methods like centerless grinding and chemical processes are costly or hazardous, and grinding into a regrind stream does not allow for material isolation.
Innovation Solution
A golf ball design featuring a dissolvable tie layer with a thickness of less than 0.010 inches, formed from a 1-50 percent aqueous mono-valent high acid ionomer dispersion, which is dispersible in water at 80° C.-90° C., allowing for easy separation of layers during recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If layers are bonded with excellent adhesive strength for durability during play, then impact durability and shear resistance are improved, but layer separation during recycling becomes complex and difficult
Solution Approach 1:
The golf ball is divided into distinct layers with different properties: durable outer layers (cover, intermediate layers) and a dissolvable inner tie layer. This segmentation allows the ball to maintain structural integrity during play while enabling easy separation during recycling by targeting the dissolvable layer for breakdown.
Solution Approach 2:
The tie layer is designed with specific parameters that make it dissolvable under controlled conditions (water-soluble polymers, specific molecular weight ranges, glass transition temperatures). These parameter changes allow the layer to be strong during play but easily separated during recycling through chemical or thermal treatment.
2Ease of operation
If centerless grinding is used to remove covers and core layers, then layer separation is achieved, but the process becomes costly
Solution Approach 1:
The dissolvable tie layer replaces the need for mechanical grinding to separate layers. Instead of using centerless grinding machinery to mechanically remove layers, the invention uses chemical dissolution (water or mild solvents) to automatically separate the layers, significantly reducing equipment costs and operational complexity.
Solution Approach 2:
The dissolvable tie layer acts as an intermediary substance between the durable outer layers and the core. This intermediary layer is designed to be selectively removed through dissolution, facilitating layer separation without requiring direct mechanical contact or complex separation equipment.
3Ease of operation
If chemical processes are used to remove paint and cover layers, then layer separation is achieved, but the processes become dangerous and impractical
Solution Approach 1:
The tie layer is designed with specific chemical parameters (water-soluble polymers, ionomers with specific acid levels, controlled molecular weight) that enable dissolution in water or very mild solvents at controlled temperatures. This eliminates the need for dangerous strong chemicals while achieving the same layer separation function.
Solution Approach 2:
The invention converts the potential harm of chemical processes into a benefit by using the controlled dissolvability of the tie layer. Instead of using hazardous chemicals to force separation, the design inherently includes a layer that willingly dissolves under safe, controlled conditions, turning a potential safety issue into a recycling advantage.
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
Enables the golf ball to maintain durability during play while being cost-effectively recyclable, with the dissolvable tie layer facilitating the separation of layers without the need for costly or hazardous processes.
Implementation Method 1
The dissolvable tie layer is dispersible in water when the water is heated to a heating temperature of about 80° C.-90° C. or greater
Data Source
AI summary
Golf ball comprising a non-dissolvable layer having a spherical outer surface; and a dissolvable tie layer or dissolvable layer, dispersible in water heated to a heating temperature of about 80° C.-90° C. or greater, disposed concentrically about the spherical outer surface and being bonded with the first non-dissolvable layer at an interface there between. The dissolvable tie layer/dissolvable layer may be formed from a composition consisting of a 1-50 percent aqueous mono-valent high acid ionomer dispersion, or, from an ionomer resin composition. The ionomer of either composition has an acid level greater than 18%; has more than 45% of acid groups that are neutralized with a monovalent cation; and is formed from an acid copolymer having a starting melt index of greater than 180 g/10 min. @ 190° C. with a 2160 g load. The dissolvable tie layer/dissolvable layer may have a thickness of less than about 0.010 inches, and up to about 0.090 inches in some embodiments.