Thermoset Non-Diene Rubber Intermediate Core Layer for Golf Ball Molding
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Solution Overview
Problem
Existing golf ball designs with multi-layer cores face challenges in molding hard rubber outer core layers due to the melting or flowing of intermediate thermoplastic core compositions during the manufacturing process.
Innovation Solution
A golf ball construction featuring a diene rubber inner core, a thermoset non-diene rubber intermediate core layer, and a diene rubber outer core layer, with specific hardness and thickness ranges, to improve the molding process by preventing the melting and flowing of the intermediate core layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic intermediate core compositions are used, then the molding process is simplified, but the intermediate layer melts or flows during manufacturing causing defects
Solution Approach 1:
The patent changes the material parameter of the intermediate core layer from thermoplastic to thermoset composition. This parameter change prevents melting and flowing during the molding process while maintaining manufacturability, as thermoset materials cure to a rigid state that maintains dimensional stability under molding conditions.
Solution Approach 2:
The patent employs a composite multi-layer core structure combining different material types: thermoset intermediate layer with thermoplastic inner and outer core layers. This composite approach allows each layer to contribute its advantageous properties - the thermoset intermediate layer provides dimensional stability and prevents flowing, while the thermoplastic layers provide ease of molding and desired ball performance characteristics.
2Manufacturing precision
If thermoset non-diene rubber intermediate core layer is used, then the intermediate layer maintains integrity during molding, but the manufacturing process becomes more complex
Solution Approach 1:
The thermoset intermediate core layer undergoes preliminary curing to achieve a rigid, dimensionally stable state before the final molding process. This preliminary action of curing the intermediate layer first allows subsequent molding operations to proceed without the intermediate layer deforming, thereby simplifying the overall manufacturing sequence despite the added curing step.
3Reliability
If multi-layer core structure is implemented, then golf ball performance is improved, but the device complexity increases
Solution Approach 1:
The patent segments the core into multiple functional layers with distinct material compositions and properties. The thermoset intermediate layer is segmented as a separate functional component between the inner and outer core layers, allowing each segment to perform its specific function - the intermediate layer provides structural stability while the outer layers provide performance characteristics, thereby achieving improved performance through functional segmentation.
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 configuration enhances the manufacturing process by maintaining the integrity of the intermediate core layer, allowing for the successful molding of hard rubber outer core layers and resulting in improved golf ball performance.
Implementation Method 1
a thermoset non-diene rubber intermediate core layer
Data Source
AI summary
Golf balls consisting of a multi-layer core and a cover are disclosed. The multi-layer core comprises at least one intermediate core layer formed from a thermoset composition other than diene rubber.