GOLD BALL HAVING A FOAMED LAYER CREATED BY INFRARED RADIATION

• US 20070155542A1
• Filed: 03/14/2007
• Published: 07/05/2007
• Est. Priority Date: 05/08/2002
• Status: Abandoned Application

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Sullivan, Michael, Ladd, Derek, Hogge, Matthew
• Application Number:
  US11/685,932
• Publication Number:
  US 20070155542A1
• Time in Patent Office: Days
• US Class Current: 473/371
• CPC Class Codes: A63B 37/0063 Hardness gradient
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0074 Two piece balls, i.e. cover and core
• CPC Class Codes: A63B 37/0075 Three piece balls, i.e. cover, intermediate layer and core
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 35/0266 Local curing for repairing B29C73/34
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29K 2105/243 Partially cured
• CPC Class Codes: B29L 2031/54 Balls

Abstract

This invention is directed to a golf ball having a foamed layer and the method for creating the foamed layer by the heating of blowing agents with infrared radiation. Either physical blowing agents can be de-volatized, or chemical blowing agents (both organic and inorganic) may be decomposed wherein the blowing agents are generated within the layer. The resultant layer is less dense than the core layer beneath it.

Claims

1. A multilayer golf ball comprising a core, an intermediate layer, and a cover, wherein the intermediate layer comprises an expandable polymeric composition containing a blowing agent therein,

wherein the expandable polymeric composition expands from 5% to 200% of its pre-expand thickness when the expandable polymeric composition is heated with infrared radiation at a specific temperature and predetermined time.

2. The golf ball of claim 1, wherein the blowing agent is a thermally decomposable inorganic chemical blowing agent selected from the group consisting of ammonium carbonate and carbonates of alkali metals.

3. The golf ball of claim 1, wherein the blowing agent is a thermally decomposable organic blowing agent selected from the group consisting of azo and diazo compounds, nitroso compounds, sulfonylhydrazides, azides of organic acids and their analogs, triazines, tri-and tetrazole derivatives, sulfonyl semicarbazides, urea derivatives, guanidine derivatives, or esters such as alkoxyboroxines.

4. The golf ball of claim 1, wherein the blowing agent is a de-volatizable physical blowing agent selected from a volatile liquid group consisting of freons, halogenated hydrocarbons, water, aliphatic hydrocarbons, gases, or solid adsorbents that liberate gas as a result of desorption of gas.

5. The golf ball of claim 4, wherein the solid adsorbents are selected from a group consisting of activated carbon, calcium carbonate, diatomaceous earth, and silicates saturated with carbon dioxide.

6. The golf ball of claim 1, wherein the expandable polymeric composition comprises a plurality of thermally expandable polyspheres encapsulating an expandable blowing agent in the form of a solvent, wherein when heated by infrared radiation the solvent expands into a gas that is released into the layer.

7. The golf ball of claim 1, wherein the intermediate layer has a density that is lower than the density of the core.

9. The golf ball of claim 1, wherein the intermediate layer is a water vapor barrier layer.

10. A method of forming a foamed intermediate layer in a multi-layer golf ball, the method comprising:

providing a core;

encapsulating the core with a intermediate layer comprising an expandable polymeric composition containing a blowing agent;

heating the intermediate layer with infrared radiation at a specific temperature for a pre-determined time, wherein the expandable polymeric composition expands from 5% to 200% to create a foamed layer; and

enclosing the intermediate layer with a cover.

8. The golf ball of claim 11, wherein the intermediate layer includes a blowing agent that liberates a gas as a result of a chemical interaction between components selected from a group consisting of mixtures of acids and metals, mixtures of organic acids and inorganic carbonates, mixtures of nitrites and ammonium salts and the hydrolytic decomposition of urea.

11. The method of claim 10, wherein the blowing agent is a thermally decomposable inorganic chemical blowing agent selected from the group consisting of ammonium carbonate and carbonates of alkali metals.

12. The method of claim 10, wherein the blowing agent is a thermally decomposable organic blowing agent selected from the group consisting of azo and diazo compounds, nitroso compounds, sulfonylhydrazides, azides of organic acids and their analogs, triazines, tri-and tetrazole derivatives, sulfonyl semicarbazides, urea derivatives, guanidine derivatives, or esters such as alkoxyboroxines.

13. The method of claim 10, wherein the blowing agent is a devolatizable physical blowing agent selected from a volatile liquid group consisting of freons, halogenated hydrocarbons, water, aliphatic hydrocarbons, gases, or solid adsorbents that liberate gas as a result of desorption of gas.

14. The method of claim 13, wherein the solid adsorbents are selected from a group consisting of activated carbon, calcium carbonate, diatomaceous earth, and silicates saturated with carbon dioxide.

15. The method of claim 10, wherein the expandable polymeric composition comprises a plurality of thermally expandable polyspheres encapsulating an expandable blowing agent in the form of a solvent which expands into a gas that is released into the layer.

16. The method of claim 10, wherein the intermediate layer has a density that is lower than the density of the core.

17. The method of claim 10, wherein the cover layer has a density lower than the density of the intermediate layer.

18. The method of claim 10, wherein the intermediate layer includes a blowing agent that liberates a gas as a result of a chemical interaction between components selected from a group consisting of mixtures of acids and metals, mixtures of organic acids and inorganic carbonates, mixtures of nitrites and ammonium salts and the hydrolytic decomposition of urea.