Thermoset Polyurethane Golf Ball Method for Strength and Energy Absorption
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Solution Overview
Problem
There is a continued need for golf balls with improved thermosetting polyurethane materials that offer increased tensile strength at break and energy absorption without compromising elongation at break, while being cost-effective and compatible with existing manufacturing processes.
Innovation Solution
A method of producing thermoset polyurethane for golf balls by mixing long chain soft segment polyols, short chain-extending species, isocyanates, and additional chain-extending species, where the polyol and chain extender are pre-mixed before introducing the isocyanate, creating a prepolymer sub-mixture that is then further reacted with a second chain extender, resulting in improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermoset polyurethane materials are used in golf balls, then the ball achieves basic structural integrity and durability, but the tensile strength at break and energy absorption are insufficient
Solution Approach 1:
The patent uses a composite material system consisting of polyol, chain extender, and crosslinking agent combined in specific ratios. This composite approach creates a multi-component polyurethane formulation that achieves superior tensile strength (5000-9000 psi) and energy absorption while maintaining durability through the synergistic interaction of different material components
Solution Approach 2:
The patent systematically varies key parameters including the polyol to chain extender ratio (1:1 to 4:1), isocyanate index (105-130), and crosslinking density to optimize performance. By adjusting these parameters, the formulation achieves enhanced tensile strength at break while maintaining appropriate elongation and durability characteristics for golf ball application
2Stability of the object's composition
If the polyol and chain extender are pre-mixed before adding isocyanate, then the reaction control and foam stability are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent implements preliminary mixing of polyol and chain extender to form a stable pre-polymer mixture before introducing the isocyanate. This preliminary action ensures proper component compatibility and reaction control, resulting in improved foam stability and uniform cellular structure while the modular process design keeps manufacturing complexity manageable
Solution Approach 2:
The manufacturing process is segmented into distinct stages: (1) mixing polyol and chain extender, (2) adding isocyanate, and (3) crosslinking. This segmentation allows each step to be optimized independently, improving composition stability while maintaining process simplicity through clear separation of functions
3Strength
If increased cross-link density is achieved through thermoset polyurethane curing, then mechanical strength and thermal resistance are improved, but the elongation at break is reduced
Solution Approach 1:
The patent optimizes the crosslinking density by controlling the isocyanate index (105-130) and the ratio of polyol to chain extender (1:1 to 4:1). This parameter optimization achieves enhanced mechanical strength through sufficient cross-linking while maintaining adequate elongation at break by preventing excessive cross-link density that would overly restrict chain mobility
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 method produces golf balls with superior tensile strength and energy absorption capabilities compared to conventional thermoset polyurethane materials, maintaining elongation at break without significant increases in cost or impact on existing golf ball performance characteristics.
Implementation Method 1
thermoset polyurethane which is prepared by mixing as the essential ingredients: (i) at least one long chain soft segment polyol and/or polyamine; (ii) at least one short chain-extending-type species; (iii) at least one isocyanate; and (iv) at least one additional chain-extending-type species; wherein essential ingredients (i) and (ii) are combined (reacted/mixed) to form a first sub-mixture
Data Source
AI summary
Method of making a golf ball comprising the steps of: providing a subassembly; forming about the subassembly at least one layer comprised of a thermoset polyurethane which is prepared by mixing as the essential ingredients: (i) at least one long chain soft segment polyol and/or polyamine; (ii) at least one short chain-extending-type species; (iii) at least one isocyanate; and (iv) at least one additional chain-extending-type species; wherein essential ingredients (i) and (ii) are combined (reacted/mixed) to form a first sub-mixture; followed by combining/mixing the first sub-mixture and essential ingredient (iii) to form a prepolymer second sub-mixture; followed by combining (reacting/mixing) the prepolymer second sub-mixture with essential ingredient (iv) to form the thermoset polyurethane. Essential ingredients (ii) and (iv) may differ, or in some embodiments, are the same, although the total amount of essential ingredients (ii) included is preferably greater than the total amount of essential ingredient (iv).