Thermoplastic Golf Ball Core with Plasticizer Gradient
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for golf ball compositions that provide high performance properties, particularly for non-conforming balls designed to increase carry distance and suit golfers with low-swing speed, while maintaining toughness and resiliency without sacrificing feel, softness, and spin control.
Innovation Solution
The use of thermoplastic ethylene acid copolymer/plasticizer compositions in golf ball cores and layers, which include a combination of acid copolymers, plasticizers, and cation sources to create a positive hardness gradient across the core assembly, and can be used in various layers to achieve optimal Coefficient of Restitution (COR) and compression values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic ethylene acid copolymer/plasticizer compositions are used in golf ball cores, then resiliency and carry distance are improved, but maintaining toughness and spin control becomes challenging
Solution Approach 1:
The patent applies local quality by creating distinct layers with different material compositions and properties. The core uses thermoplastic ethylene acid copolymer/plasticizer composition for high resiliency, while the cover layer uses different materials to maintain spin control and toughness. This layering allows each region to optimize its local properties without compromising overall ball performance.
Solution Approach 2:
The patent employs composite materials by combining thermoplastic ethylene acid copolymer with plasticizers to create a new material composition that achieves both high resiliency and maintained toughness. The composite formulation allows the core material to provide enhanced carry distance while the cover materials ensure proper spin control, resolving the contradiction between these properties.
2Manufacturing precision
If a positive hardness gradient is created across the core assembly, then Coefficient of Restitution and compression values are optimized, but manufacturing complexity increases
Solution Approach 1:
The positive hardness gradient is achieved through local quality variation within the core assembly. Different regions of the core have progressively different hardness values, creating the desired gradient effect. This is accomplished by varying the plasticizer content or crosslinking degree in different core layers, allowing precise control of COR and compression while using established manufacturing techniques.
Solution Approach 2:
The patent applies parameter changes by systematically varying the composition parameters (plasticizer content, crosslinking degree) across the core assembly to create the hardness gradient. By controlling these parameters during manufacturing, the desired COR and compression values are achieved without requiring overly complex manufacturing processes.
3Productivity
If golf balls are designed for increased carry distance, then performance for low-swing speed golfers is improved, but conformity to USGA rules may be compromised
Solution Approach 1:
The patent uses parameter changes to push the boundaries of carry distance performance while staying within or near USGA conformance limits. By optimizing the thermoplastic composition ratios, plasticizer content, and core layer thicknesses, the ball achieves maximum carry distance for low-swing speed golfers while maintaining compliance with official specifications.
Data Source
AI summary
Golf balls having a single or dual-layered solid core are provided. In one embodiment, the golf ball has dimensions and properties that do not conform to the rules of the United States Golf Association (USGA). For example, the ball weight; ball size; ball spherical symmetry; ball initial velocity; and/or ball overall distance may fall outside of the USGA standards. The dual-layered core can have an inner core comprising a thermoplastic composition and surrounding outer core comprising a thermoset composition. In another embodiment, the dual-layered core has an inner core comprising a thermoplastic composition and outer core comprising a thermoset composition. The thermoplastic composition preferably comprises an ethylene acid copolymer ionomer and plasticizer. The thermoset composition preferably comprises polybutadiene rubber. The ball further includes a cover of at least one layer.