Single Layer Golf Ball Core Hardness Gradient
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Solution Overview
Problem
Existing golf balls with multiple core layers are costly and complex to manufacture, and none provide a single layer core with specific regions of increasing hardness from the center to the outer surface, which is desirable for improved performance and control on the green.
Innovation Solution
A golf ball with a single layer core having a geometric center, an outer surface, and an intermediate region, where the inner core region has a first hardness, the outer core region has a second hardness, and the intermediate region has third and fourth hardnesses that are less than and greater than the first and second hardnesses respectively, creating a positive hardness gradient, and a cover layer disposed about the single layer core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple core layers are used to create hardness gradient, then performance and control on the green are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The core is divided into distinct hardness regions (inner core region with first hardness, intermediate core region with third and fourth hardnesses, and outer core region with second hardness) within a single layer structure, creating a hardness gradient without requiring multiple separate layers to be joined together
Solution Approach 2:
Different regions of the core are given different hardness properties through varying crosslink density, with the inner core region being softer and the outer core region being harder, optimizing performance for different functional requirements within the same component
2Manufacturing precision
If multiple core layers are joined together, then hardness gradient is achieved, but manufacturing cost increases due to lamination and joining processes
Solution Approach 1:
Multiple hardness regions are combined into a single integrated core layer formed from substantially homogenous formulation, eliminating the need for separate lamination and joining operations while maintaining the desired hardness gradient
Solution Approach 2:
The hardness profile is controlled by varying crosslinking parameters (such as crosslink density and crosslinking agent distribution) within a single layer during the curing process, rather than assembling pre-formed layers with different hardnesses
3Strength
If hard core and hard cover are used, then resiliency for distance is maximized, but feel becomes hard and control is difficult
Solution Approach 1:
The core provides locally optimized properties with softer inner regions for improved feel and control, and harder outer regions for maintaining resiliency and distance, avoiding the need for uniformly hard construction
Data Source
AI summary
A golf ball comprising a single layer core formed from a substantially homogenous formulation and comprising a geometric center and an outer surface; a hardness of the outer surface is greater than a hardness of the geometric center. An inner core region is disposed about the geometric center and has a first hardness that is less than those of the geometric center and the outer surface; an outer core region is adjacent the outer surface and has a second hardness that is greater than those of the geometric center and the outer surface; and an intermediate core region is disposed between the inner and outer core regions and extends radially from about 5 mm to about 15.75 mm from the geometric center and has at least a third hardness and a fourth hardness, each of which are related to the first hardness and the second hardness in various ways.