Sugar Ester HLB Modifiers for Highly Neutralized Ionomer Processability
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Solution Overview
Problem
Highly neutralized ionomers used in golf ball core and cover layers face processability issues due to decreased melt flow at neutralization levels above 60%, leading to unprocessable polymers without flow additives, and existing flow additives often result in compromises such as discoloration and surface blooming.
Innovation Solution
Incorporating a sugar ester HLB modifier in the polymer composition at 15 wt % to 40 wt % to improve the processability and properties of highly neutralized acid polymers, specifically a copolymer of C3 to C8 α,β-ethylenically unsaturated carboxylic acid and a C2 to C6 α-olefin, with the sugar ester being an ester of a fatty acid and a C5 or C6 sugar, enhancing melt flow index and maintaining desired neutralization levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the neutralization level of ionomer is increased to improve toughness and durability, then the strength and durability of golf ball layers are improved, but the melt flow decreases causing processability to deteriorate
Solution Approach 1:
A sugar ester HLB modifier is introduced as an intermediary substance to mediate between the highly neutralized ionomer and the processing system. The sugar ester modifies the melt flow characteristics without compromising the high neutralization level, thereby enabling processability while maintaining toughness and durability.
Solution Approach 2:
The invention changes the chemical composition parameters by incorporating sugar ester HLB modifiers at specific concentrations (0.1-10 wt%) into the ionomer system. This parameter change adjusts the melt flow index to suitable ranges (5-500 g/10min) while preserving the high neutralization level (60-100%) required for strength and durability.
2Ease of manufacture
If traditional flow additives are used to improve processability, then the melt flow and processability are improved, but discoloration and surface blooming occur
Solution Approach 1:
The sugar ester HLB modifier acts as a temporary processing aid that fulfills its function during manufacturing and then degrades or becomes part of the final product structure without causing harmful effects. Unlike traditional flow additives that leave residual discoloration and surface defects, the sugar ester provides the needed processability improvement without generating persistent harmful factors.
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 sugar ester HLB modifier improves the melt flow index and processability of highly neutralized acid polymers, allowing for the production of golf balls with enhanced properties while avoiding the limitations of traditional flow additives, such as discoloration and surface issues.
Implementation Method 1
the melt flow of the ionomer is decreased to an extent such that processability decreases or disappears altogether
Data Source
AI summary
A golf ball comprising a core and a cover layer surrounding the core, where at least one of the core and the cover layer includes a polymer composition of a highly neutralized acid polymer and a sugar ester HLB modifier such that the sugar ester HLB modifier is present from about 15 wt % to about 40 wt % of the polymer composition.