Thermoplastic Golf Ball Core Negative Hardness Gradient
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Solution Overview
Problem
Conventional golf ball cores made from thermoset materials have limited ability to achieve varying properties across the core, as they cannot be reprocessed, restricting the creation of desired hardness gradients essential for customized golf ball characteristics such as compression, feel, and spin.
Innovation Solution
A thermoplastic golf ball core with a negative hardness gradient is achieved by exposing the core to a gradient-initiating solution containing a plasticizer and solvent, allowing for a softer outer surface and harder center, enabling customizable properties through the use of thermoplastic materials like ionomers and polyurethanes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermoset materials are used for golf ball cores, then the core can achieve certain hardness and compression properties through curing cycles, but the ability to create varying properties across the core is limited because the materials cannot be reprocessed
Solution Approach 1:
The patent applies parameter changes by transitioning from thermoset to thermoplastic materials, which fundamentally alters the material's response to heat and processing. Thermoplastic materials allow repeated heating and re-forming without degradation, enabling manufacturers to create cores with varying properties through controlled cooling rates and processing parameters after molding, thus achieving adaptability while maintaining ease of manufacture.
Solution Approach 2:
The patent implements dynamics by enabling the core material to be dynamically adjusted through reprocessing. Thermoplastic cores can be remolded and reformed multiple times, allowing for optimization of hardness gradients and property distribution across the core. This dynamic capability resolves the contradiction by providing both manufacturing flexibility and property variation without the limitations of thermoset curing cycles.
2Manufacturing precision
If thermoset rubber is heated and crosslinked during molding, then desirable characteristics such as compression and hardness can be achieved, but the physical properties become fixed and cannot be changed without degradation
Solution Approach 1:
The patent uses parameter changes by selecting thermoplastic materials whose physical properties can be adjusted through processing parameters rather than being fixed by chemical crosslinking. The degree of crystallinity, cooling rate, and heating temperature can be varied to precisely control compression and hardness while maintaining the ability to make further adjustments, thus achieving both manufacturing precision and adaptability.
Solution Approach 2:
The patent applies preliminary action by establishing the basic core structure and property gradient through initial molding, then allowing for subsequent property adjustments through controlled heating and reprocessing. This preliminary formation followed by adjustable refinement enables precise control over compression and hardness while maintaining versatility for customization.
3Productivity
If conventional thermoset cores are used, then production can be efficient with standardized curing cycles, but customization of gradient properties for different golfer abilities is restricted
Solution Approach 1:
The patent resolves this contradiction by using thermoplastic materials that allow property customization through parameter adjustments during and after molding. Different cooling rates, heating temperatures, and processing times can create various hardness gradients and compression characteristics while maintaining efficient production workflows. This enables customization for different golfer abilities without sacrificing productivity.
Solution Approach 2:
The patent implements dynamics by enabling post-production adjustments to core properties. Thermoplastic cores can be reheated and reformed to create different property gradients, allowing the same basic core design to be customized for various golfer needs. This dynamic capability maintains production efficiency through standardized base manufacturing while enabling versatile customization when needed.
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 approach allows for the creation of golf balls with unique gradient properties, enhancing customization options for compression, feel, and spin, while being cost-effective and efficient in production.
Implementation Method 1
exposing the core to a gradient-initiating solution comprising sufficient amount of plasticizer such that the hardness of the outer surface is less than the hardness of the geometric center
Data Source
AI summary
A golf ball comprising a thermoplastic core, the core having an outer diameter of 1.51 inches to 1.59 inches and having an outer surface and a geometric center, each having a hardness; an outer cover layer; and an inner cover layer disposed between the core and the outer cover layer; wherein the hardness of the outer surface is less than the hardness of the geometric center to define a “negative” hardness gradient of 5 Shore C or greater.