Thermoplastic Golf Ball Core Hardness Gradient via Silane Treatment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thermoplastic golf ball cores lack the ability to achieve a hardness gradient from the surface to the center, unlike thermoset materials, which limits the customization of golf ball properties such as compression, feel, and spin.
Innovation Solution
A thermoplastic golf ball core is created with a 'positive' hardness gradient by exposing it to a gradient-initiating solution containing a silane with a specific formula, which alters the hardness from the outer surface to the geometric center, achieving a hardness difference of 10 Shore C or greater.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic material is used for the core, then reprocessability is maintained, but the ability to achieve a hardness gradient from surface to center is lost
Solution Approach 1:
The patent applies preliminary action by treating the thermoplastic core with a silane solution before final assembly. The silane penetrates the core surface and undergoes hydrolysis and condensation reactions that create crosslinked regions, establishing the hardness gradient in advance. This allows the core to be processed as thermoplastic (maintaining reprocessability) while simultaneously creating the desired hardness variation through pre-treatment.
Solution Approach 2:
The patent utilizes parameter changes by modifying the chemical composition and molecular structure of the thermoplastic material through silane treatment. The silane crosslinking alters the physical and chemical parameters of the polymer, creating regions with different molecular weights, crosslink densities, and crystallinity levels, which manifest as a hardness gradient from surface to center.
2Stability of the object's composition
If thermoset material is used for the core, then a hardness gradient can be achieved through curing cycles, but reprocessability is lost
Solution Approach 1:
The patent applies local quality by creating regions with different properties within the thermoplastic core. The silane treatment concentrates crosslinking reactions at the surface and gradually decreases toward the center, producing a spatially varying hardness profile. This local differentiation allows the core to exhibit gradient properties while remaining fundamentally thermoplastic and reprocessable.
3Adaptability or versatility
If a hardness gradient is created in thermoplastic core, then customization of compression, feel, and spin is enabled, but additional processing steps are required
Solution Approach 1:
The patent uses an intermediary substance (silane solution) to mediate between the thermoplastic core material and the desired hardness gradient property. The silane acts as a chemical intermediary that facilitates crosslinking reactions on the core surface, enabling gradient formation without requiring complex multi-step processing or specialized equipment beyond standard solution treatment capabilities.
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 allows for the creation of golf balls with unique gradient properties, enabling customization of compression, feel, and spin characteristics, while maintaining the reprocessability of thermoplastic materials.
Implementation Method 1
a gradient-initiating solution including a silane and a solvent
Implementation Method 2
a gradient-initiating solution including a silane and a solvent
Implementation Method 3
the hardness of the outer surface is greater than the hardness of the geometric center to define a 'positive' hardness gradient
Data Source
AI summary
A golf ball comprising a thermoplastic 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 thermoplastic core has been exposed to a gradient-initiating solution comprising a silane having the formula:wherein R′ is a non-hydrolysable organofunctional group, X is a hydrolysable group, and n is 0-24, such that the hardness of the outer surface is greater than the hardness of the geometric center to define a positive hardness gradient of 5 Shore C or greater.