Urethane Golf Ball Cover Casting via Dual Mixer Conveyor
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Solution Overview
Problem
Current methods for manufacturing urethane-covered golf balls are inefficient and lack automation, leading to increased working area and manpower requirements, which hinder the production of high-volume premium golf balls with precise cover layer thickness and quality.
Innovation Solution
A continuous conveyor system with pre-heated mold halves and dual urethane mixers with shuttling nozzles ensures simultaneous dispensing of polyurethane into multiple molds, maintaining process integrity and achieving precise pressure control for efficient curing and thermodynamics, allowing for the formation of a thin, durable cover layer around a golf ball subassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual methods are used for casting urethane cover layers, then working area and manpower requirements increase, but manufacturing precision and productivity remain limited
Solution Approach 1:
The system divides the mold set into multiple stationary mold positions (at least two positions) along the conveyor path, allowing simultaneous operation of multiple molds. Each mold position operates independently while being transported through the curing chamber, enabling parallel production without increasing device complexity
Solution Approach 2:
The conveyor system dynamically transports molds through different zones (dispensing zone, curing zone, removal zone) at controlled speeds. The conveyor speed and positioning are dynamically adjusted to synchronize with the urethane dispensing rate and curing requirements, optimizing both productivity and precision
2Manufacturing precision
If multiple molds are cast simultaneously, then production volume increases, but maintaining consistent cover layer thickness becomes more difficult
Solution Approach 1:
The system incorporates sensors and control mechanisms that monitor the casting process in real-time for each mold position. Feedback from temperature sensors, position sensors, and dispensing rate monitors allows the controller to adjust parameters dynamically, ensuring consistent cover layer thickness across all simultaneously cast molds
Solution Approach 2:
The system controls and adjusts critical parameters including conveyor speed, urethane dispensing rate, curing chamber temperature, and mold positioning to maintain optimal conditions for consistent cover layer formation. These parameters are precisely controlled and can be modified based on real-time process conditions
3Use of energy by stationary object
If pre-heating and pre-sorting of mold halves is implemented, then thermodynamic efficiency improves, but process complexity increases
Solution Approach 1:
Mold halves are pre-heated to the required temperature before being assembled into complete molds. This preliminary heating action ensures that the molds are thermally prepared for the curing process, improving thermodynamic efficiency by reducing the energy required during actual curing and preventing defects from thermal shock
Solution Approach 2:
The conveyor system serves multiple functions: it transports molds through the curing chamber, positions molds for urethane dispensing, controls curing temperature and time, and facilitates mold removal. This multi-functionality reduces the need for separate dedicated equipment for each process step
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 significantly increases production efficiency, maintains precise control over cover layer thickness, and enhances the thermodynamic curing process, resulting in high-quality golf balls with improved in-flight characteristics and durability.
Implementation Method 1
pre-heated first (top) and second (bottom) mold halves are pre-heated and pre-sorted
Implementation Method 2
casting the cover thereon... thermoset or thermoplastic material... polyurethane material being deposited
Implementation Method 3
continuous conveyor system wherein pre-heated first (top) and second (bottom) mold halves are pre-heated and pre-sorted
Implementation Method 4
The molds are automatically mated at a pressure of about 6,800 lbs of force per mold, or about 1,700 lbs of force per cavity
Data Source
AI summary
The present invention is directed relates to a method of applying a thin thermoset or thermoplastic cover over a golf ball subassembly by simultaneously dispensing polyurethane into multiple molds while using multiple mixers from multiple polyurethane sources. The method employs a continuous conveyor system wherein pre-heated first (top) and second (bottom) mold halves are pre-heated and pre-sorted prior to a polyurethane material being deposited in each mold half, preferably, each mold half comprises four cavities. A rotary table maneuvers the mold halves into position to receive a shot of polyurethane in each cavity. The polyurethane is dispensed from two separate mixers, each mixer having a pair of dispensing nozzles capable of shuttling back and forth between the cavities. To maintain process integrity, it is imperative that polyurethane dispensed into a particular top mold half and the polyurethane dispensed into the corresponding mated bottom mold half be from the same polyurethane mixer. The method of the invention provides a mechanism to maintain that the shot of polyurethane in each mold half is dispensed from the same mixer.