Sprayed Polyurea Golf Ball Cover Layer

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Solution Overview

Problem

Conventional methods for producing thin polyurethane cover layers for golf balls, such as injection molding and casting, require significant investment in tooling and operators, and struggle to achieve layers thinner than 0.030″ with high quality and durability.

Innovation Solution

A sprayed polyurea cover layer is formed using a rapid reaction between a low viscous diisocyanate component and a solvent-free diamine, eliminating the need for costly tooling and allowing for thin layers of 0.010 to 0.040″ thickness with excellent shear cut durability and adhesion to the mantle layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If injection molding or casting methods are used to produce thin polyurethane cover layers, then the cover layer can achieve a thickness of 0.030 inches or less, but the manufacturing cost increases significantly due to huge investment in tooling and operators

Engineering Contradiction:

Improvecover layer thicknessVSAvoidmanufacturing cost

Core Design Contradiction:

Length of moving objectVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical injection molding or casting processes with a chemical spray application method. The polyurea cover layer is formed by spraying a mixture of isocyanate and amine components that react chemically to form the solid cover layer, eliminating the need for expensive injection molding tools and complex casting operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the material system from polyurethane (requiring injection molding/casting) to polyurea (formed by spray application of reacting components). This parameter change in material chemistry enables a different manufacturing approach that reduces tooling requirements and manufacturing complexity while achieving thin cover layers.

Inventive Principle:

Principle #35Parameter changes

2Length of moving object

If injection molding or casting methods are used to produce thin polyurethane cover layers, then the cover layer can achieve a thickness of 0.030 inches or less, but the manufacturing complexity increases due to huge investment in tooling and operators

Engineering Contradiction:

Improvecover layer thicknessVSAvoidmanufacturing process complexity

Core Design Contradiction:

Length of moving objectVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts the cover layer formation process from the complex injection molding or casting systems. By using spray application of reactive components, the process separates the cover formation into a simpler, standalone operation that doesn't require integration into complex molding equipment.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If conventional injection molding or casting methods are used, then production quality can be maintained, but the production time increases due to the complexity of the processes and need for multiple operators

Engineering Contradiction:

Improveproduct qualityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The sprayed polyurea system is self-curing through the chemical reaction between isocyanate and amine components. The cover layer forms and cures automatically after application without requiring additional operators or complex post-processing steps, enabling faster production cycles while maintaining quality.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The spray application method allows for continuous formation and curing of the cover layer as the material is applied. The chemical reaction proceeds continuously during and after spraying, eliminating idle time between application and curing that would be required in batch injection molding or casting processes.

Inventive Principle:

Principle #20Continuity of useful action

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

This method reduces production costs, eliminates the need for seam buffing and vanmark processes, and enables the use of existing paint lines, while providing excellent durability and ease in forming thin layers, enhancing the golf ball's performance.

Implementation Method 1

a sprayed polyurea cover layer is formed using a rapid reaction between a low viscous diisocyanate component and a solvent-free diamine

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

a mixture of a low viscous diisocyanate component and a diamine free of organic solvent are sprayed onto a mantle insert to form a cover layer

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS10207154B1Sprayed polyurea covered golf ball

Publication Date: 2019.02.19 CALLAWAY GOLF COMPANY

AI summary

A golf ball with a cover formed by spraying is disclosed herein. In the present invention, a mixture of a low viscous diisocyanate component and a diamine free of organic solvent are sprayed onto a mantle insert to form a cover layer for a golf ball. A rapid reaction occurs and a solid layer forms within ten seconds. The polyurea material is extremely durable so that the cover layer performs with excellent shear cut durability.