Golf ball forming compositions comprising polyamide

• US 6,294,617 B1
• Filed: 05/14/1999
• Issued: 09/25/2001
• Est. Priority Date: 05/23/1997
• Status: Expired due to Fees

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Rajagopalan, Murali
• Primary Examiner(s): Buttner, David J.
• Application Number:
  US09/311,288
• Time in Patent Office: 865 Days
• Field of Search: 525/66, 525/425, 525/432, 473/354, 473/374, 473/375, 473/361
• US Class Current: 525/425
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0024 Materials other than ionomers or polyurethane
• CPC Class Codes: A63B 37/0037 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0039 characterised by the material
• CPC Class Codes: A63B 37/0069 Flexural modulus; Bending stiffness

Abstract

The present invention relates to a golf ball comprising a core layer, at least one intermediate layer, and a cover layer, wherein the core layer or the at least one intermediate layer are formed from compositions comprising a polyamide, in the form of a homopolymer, a copolymer, or mixtures thereof. The compositions comprise about 1 to about 99 weight percent of at least one nonionomer polymer and about 99 to about 1 weight percent of at least one polyamide polymer. The polyamides of the present invention comprise polyamides and polyamide copolymers, such as nylons, nylon copolymers, and nylon block copolymers. The nonionomer polymer comprises a nonionomer thermoplastic elastomer or a nonionomer thermoplastic. The present invention also relates to a method of making a golf ball comprising forming a golf ball core, preparing a composition comprising about 1 to about 99 weight percent of at least one nonionomer polymer and about 99 to about 1 weight percent of at least one polyamide polymer, and molding the blend around the golf ball core to form the golf ball.

Claims

1. A golf ball comprising at least one core layer, a cover layer, and at least one intermediate layer disposed between at least one said core layer and the cover layer, wherein at least one said core layer or at least one said intermediate layer comprises a polymer composition comprising about 1 to about 99 weight percent of at least one nonionomer thermoplastic polymer selected from the group consisting of poly(ethylene terephthalate), poly(butylene terephthalate), poly(trimethylene terephthalate), polycarbonate, poly(imide), poly(vinyl alcohol), poly(vinyl acetate), poly(silane), poly(vinylidene fluoride), acrylonitrile-butadiene-styrene copolymer, olefinic homopolymers, block copoly(ester-ester), block copoly(ester-ether), block copoly(amide-ester), block copoly(amide-ether), block copoly(urethane-ester), block copoly(urethane-ether), a thermoplastic and elastomer blend comprising polypropylene and ethylene-propylene-diene terpolymer, or ethylene-propylene copolymer rubber, wherein the rubber is dynamically vulcanized, metallocene-catalyzed polymers, a thermoplastic and elastomer blend comprising polypropylene and ethylene-propylene-diene monomer, polyethylene, polypropylene, a copolymer of ethylene or propylene with acrylic acid or methacrylic acid, a polymer formed with the use of metallocene catalysts and consisting essentially of a copolymer of ethylene and butene, a copolymer of ethylene and hexene or a copolymer of ethylene and octene, a terpolymer formed with the use of metallocene catalysts and consisting essentially of a polymer of ethylene, propylene and a diene monomer, poly(methyl acrylate), poly(methyl methacrylate), acrylonitrile-styrene-butadiene terpolymer, a terpolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms, an alkyl acrylate or an alkyl alkylacrylate monomer, and a glycidyl acrylate or a glycidyl alkylacrylate monomer, wherein each alkyl group ranges, independently, from methyl to decyl inclusive and may be linear or branched, a copolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms and a vinyloxazoline or 1-alkyl vinyloxazoline monomer, wherein the alkyl group ranges from methyl to decyl inclusive and may be linear or branched, a terpolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms, an alkyl acrylate or an alkyl alkylacrylate monomer, and a vinyloxazoline or 1-alkyl vinyloxazoline monomer, wherein each alkyl group ranges, independently, from methyl to decyl inclusive and may be linear or branched, a copolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms and carbon monoxide, a terpolymer consisting essentially of a first α

-olefin monomer containing from 2 to 10 carbon atoms, a second α

-olefin monomer containing from 2 to 10 carbon atoms, and carbon monoxide, a copolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms and sulfur dioxide, a terpolymer consisting essentially of a first α

-olefin monomer containing from 2 to 10 carbon atoms, a second α

-olefin monomer containing from 2 to 10 carbon atoms, and sulfur dioxide, a copolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms and maleic anhydride, a terpolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms, maleic anhydride, and carbon monoxide;

a terpolymer consisting essentially of an α

-olefin monomer containing from 2 to 10 carbon atoms, maleic anhydride, and sulfur dioxide, and mixtures thereof, and about 99 to about 1 weight percent of at least one polyamide polymer selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, polyamide 4,6, polyamide 6,6, polyamide 6,9, polyamide 6,10, polyamide 6,12, polyamide 6/6,6, polyamide 6,6/6,10, polyamide 6/6,T, polyamide 6/6,6/6,10, and mixtures thereof.

2. The golf ball of claim 1, wherein the golf ball has a coefficient of restitution of at least 0.79.

3. The golf ball of claim 1, wherein the polyamide polymer is selected from the group consisting of polyamide homopolymers, polyamide copolymers and mixtures thereof.

4. The golf ball of claim 1, wherein the polyamide polymer has a flexural modulus of at least about 30,000 psi.

5. The golf ball of claim 4, wherein the polyamide polymer has a flexural modulus of about 30,000 psi to about 500,000 psi.

6. The golf ball of claim 1, wherein the polymer composition further comprises at least one additional material.

7. The golf ball of claim 6, wherein the at least one additional material comprises dyes, whitening agents, UV absorbers, processing aids, metal particles, metal powders, antioxidants, stabilizers, softening agents, plasticizers, impact modifiers, toughening agents, foaming agents, fillers, reinforcing materials, compatibilizers, and mixtures thereof.

8. The golf ball of claim 1, wherein at least one said intermediate layer comprises a tensioned elastomeric material formed of the polymer composition that is wound about an outermost one of the at least one said core layer.

9. The golf ball of claim 1, wherein the at least one said core layer, the cover layer, or the at least one said intermediate layer further comprises a thermoset polymer.

10. The golf ball of claim 9, wherein the thermoset polymer comprises poly(isoprene), poly(butadiene), poly(urethane), poly(urea), or mixtures thereof.

11. The golf ball of claim 1, wherein the at least one said core layer or the at least one said intermediate layer is comprised of said polymer composition and wherein the cover layer is formed of at least one material selected from the group consisting of ionic or nonionic olefinic polymers, styrene-(hydrogenated butadiene)-styrene ionomers, thermoset poly(isoprene), thermoset poly(butadiene), thermoset poly(urethanes), thermoset poly(ureas), and mixtures thereof.

12. The golf ball of claim 11, wherein the at least one said core layer or the at least one said intermediate layer comprises about 15 to about 75 weight percent of at least one nonionomer thermoplastic polymer and about 85 to about 25 weight percent of at least one polyamide polymer.

13. The golf ball of claim 1, wherein the polymer composition further comprises at least one density-adjusting filler.

14. A golf ball comprising at least one core layer, a cover layer, and at least one intermediate layer disposed between at least one said core layer and the cover layer, wherein the cover layer comprises a polymer composition comprising about 25 to about 55 weight percent of at least one nonionomer thermoplastic polymer selected from the group consisting of poly(ethylene terephthalate), poly(butylene terephthalate), poly(trimethylene terephthalate), polycarbonate, poly(imide), poly(vinyl alcohol), poly(vinyl acetate), poly(silane), poly(vinylidene fluoride), acrylonitrile-butadiene-styrene copolymer, olefinic homopolymers, block copoly(ester-ester), block copoly(ester-ether), block copoly(amide-ester), block copoly(amide-ether), block copoly(urethane-ester), block copoly(urethane-ether), a thermoplastic and elastomer blend comprising polypropylene and ethylene-propylene-diene terpolymer, or ethylene-propylene copolymer rubber, wherein the rubber is dynamically vulcanized, metallocene-catalyzed polymers, and mixtures thereof and about 75 to about 45 weight percent of at least one polyamide polymer selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, polyamide 4,6, polyamide 6,6, polyamide 6,9, polyamide 6,10, polyamide 6,12, polyamide 6/6,6, polyamide 6,6/6,10, polyamide 6/6,T, polyamide 6/6,6/6,10, and mixtures thereof.

15. The golf ball of claim 14, wherein wherein the polyamide polymer is selected from the group consisting of polyamide homopolymers, polyamide copolymers and mixtures thereof.

16. The golf ball of claim 14, wherein the polyamide homopolymer is selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, polyamide 4,6, polyamide 6,6, polyamide 6,9, polyamide 6,10, polyamide 6,12, and mixtures thereof.

17. The golf ball of claim 14, wherein the polyamide copolymer is selected from the group consisting of polyamide 6/6,6, polyamide 6,6/6,10, polyamide 6/6,T, polyamide 6/6,6/6,10, and mixtures thereof.

18. The golf ball of claim 14, wherein the nonionomer thermoplastic polymer is selected from the group consisting of poly(ethylene terephthalate), poly(butylene terephthalate), poly(trimethylene terephthalate), polycarbonate, poly(imide), poly(vinyl alcohol), poly(vinyl acetate), poly(silane), poly(vinylidene fluoride), acrylonitrile-butadiene-styrene copolymer, olefinic homopolymers, olefinic copolymers, block copoly(ester-ester), block copoly(ester-ether), block copoly(amide-ester), block copoly(amide-ether), block copoly(urethane-ester), block copoly(urethane-ether), a thermoplastic and elastomer blend comprising polypropylene and ethylene-propylene-diene terpolymer, or ethylene-propylene copolymer rubber, wherein the rubber is dynamically vulcanized, and mixtures thereof.

19. A method of making the golf ball of claim 14, comprising:

forming a core having at least one core layer;

forming at least one intermediate layer disposed about the core; and

forming a cover disposed about the at least one said intermediate layer.

20. The method of claim 19, wherein the at least one core layer has a center that is solid, fluid, or hollow.

21. The method of claim 19, wherein the center is solid and comprises vulcanized polybutadiene.

22. A golf ball comprising at least one core layer, a cover layer, and at least one intermediate layer disposed between at least one said core layer and the cover layer, wherein the at least one said intermediate layer comprises a polymer blend comprising about 1 to about 99 weight percent of at least one nonionomer thermoplastic polymer and about 99 to about 1 weight percent of at least one polyamide polymer selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, polyamide 4,6, polyamide 6,6, polyamide 6,9, polyamide 6,10, polyamide 6,12, polyamide 6/6,6, polyamide 6,6/6,10, polyamide 6/6,T, polyamide 6/6,6/6,10, and mixtures thereof, wherein said intermediate layer has a Shore D hardness of not greater than about 74, and wherein the nonionomer thermoplastic polymer is selected from the group consisting of poly(ethylene terephthalate), poly(butylene terephthalate), poly(trimethylene terephthalate), polycarbonate, poly(imide), poly(vinyl alcohol), poly(vinyl acetate), poly(silane), poly(vinylidene fluoride), acrylonitrile-butadiene-styrene copolymer, olefinic homopolymers, block copoly(ester-ester), block copoly(ester-ether), block copoly(amide-ester), block copoly(amide-ether), block copoly(urethane-ester), block copoly(urethane-ether), a thermoplastic and elastomer blend comprising polypropylene and ethylene-propylene-diene terpolymer, or ethylene-propylene copolymer rubber, wherein the rubber is dynamically vulcanized, metallocene-catalyzed polymers, and mixtures thereof.

23. The golf ball of claim 22, wherein the polyamide polymer is selected from the group consisting of polyamide homopolymers, polyamide copolymers and mixtures thereof.

24. The golf ball of claim 22, wherein the polyamide homopolymer is selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, polyamide 4,6, polyamide 6,6, polyamide 6,9, polyamide 6,10, polyamide 6,12, and mixtures thereof.

25. The golf ball of claim 22, wherein the polyamide copolymer is selected from the group consisting of polyamide 6/6,6, polyamide 6,6/6,10, polyamide 6/6,T, polyamide 6/6,6/6,10, and mixtures thereof.

26. A method of making the golf ball of claim 22, comprising:

forming a core having at least one core layer;

forming at least one intermediate layer disposed about the core; and

forming a cover disposed about the at least one said intermediate layer.

27. The method of claim 26, wherein the at least one core layer has a center that is solid, fluid, or hollow.

28. The method of claim 27, wherein the center is solid and comprises vulcanized polybutadiene.