Golf ball comprising saturated polyurethanes and methods of making the same

• US 6,476,176 B1
• Filed: 12/17/1999
• Issued: 11/05/2002
• Est. Priority Date: 12/17/1999
• Status: Expired due to Term

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Wu, Shenshen
• Primary Examiner(s): Buttner, David J.
• Application Number:
  US09/466,434
• Time in Patent Office: 1,054 Days
• Field of Search: 528/76, 528/61, 528/65, 473/378, 473/354, 473/365, 473/374, 473/376
• US Class Current: 528/76
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0033 Thickness
• CPC Class Codes: A63B 37/0034 Deflection or compression
• CPC Class Codes: A63B 37/0035 Density; Specific gravity
• CPC Class Codes: A63B 37/0037 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0043 Hardness
• CPC Class Codes: A63B 37/0045 Thickness
• CPC Class Codes: A63B 37/0046 Deflection or compression
• CPC Class Codes: A63B 37/0049 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0051 Materials other than polybutadienes; Constructional details
• CPC Class Codes: A63B 37/0052 Liquid cores
• CPC Class Codes: A63B 37/0054 Substantially rigid, e.g. metal
• CPC Class Codes: A63B 37/0056 Hollow; Gas-filled
• 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: A63B 37/0076 Multi-piece balls, i.e. having two or more intermediate layers
• CPC Class Codes: A63B 37/12 Special coverings , i.e. outer layer material balls with finger holes A63B37/0001, golf ball covers A63B37/0023

Abstract

The invention provides a golf ball having a cover and intermediate layers comprising in whole or in part of a saturated polyurethane. The saturated polyurethane may be blended with conventional materials employed to form golf balls, cores and intermediate layers.

Claims

1. A golf ball comprising at least one cast cover layer, wherein said cover layer is cast from a saturated polyurethane composition comprising at least one prepolymer and at least one curing agent, said cover layer having a thickness of from about 0.02 inch to about 0.3 inch, a hardness of at least about 40 Shore D, a specific gravity of at least about 0.7, a flexural modulus of at least about 500 psi and at least about 60 percent dimple coverage, said golf ball having a PGA compression of from about 55 to about 120.

2. The golf ball of claim 1, wherein the cover layer has a thickness of from about 0.02 inch to about 0.125 inch and a hardness of between about 40 and about 80 Shore D.

3. The golf ball of claim 1, wherein the golf ball further comprises a core optionally comprised of a plurality of layers and at least one intermediate layer interposed between an innermost cover layer and an outermost core layer, wherein said intermediate layer is formed from a composition which comprises at least one saturated polyurethane, said intermediate layer having a thickness of at least about 0.02 inch, a hardness of at least about 40 Shore A, a specific gravity of at least about 0.7 and a flexural modulus of at least about 500 psi.

4. The golf ball of claim 1, wherein said saturated polyurethane is a reaction product of at least one saturated diisocyanate, at least one saturated polyol and at least one saturated curing agent.

5. The golf ball of claim 4 wherein said saturated diisocyanate is selected from the group consisting of ethylene diisocyanate;

propylene-1,2-diisocyanate;

tetramethylene-1,4-diisocyanate;

1,6-hexamethylene-diisocyanate (HDI);

2,2,4-trimethylhexamethylene diisocyanate;

2,4,4-trimethylhexamethylene diisocyanate;

dodecane-1,12-diisocyanate;

dicyclohexylmethane diisocyanate;

cyclobutane-1,3-diisocyanate;

cyclohexane-1,3-diisocyanate;

cyclohexane-1,4-diisocyanate;

1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane;

isophorone diisocyanate (IPDI);

methyl cyclohexylene diisocyanate;

triisocyanate of HDI;

triisocyanate of 2,2,4-trimethyl-1,6-hexane diisocyanate (TMDI);

4,4′

-dicyclohexylmethane diisocyanate (HMDI) and mixtures thereof.

6. The golf ball of claim 4 wherein said saturated polyol is selected from the group consisting of polytetramethylene ether glycol (PTMEG);

poly(oxypropylene) glycol;

polyethylene adipate glycol;

polyethylene propylene adipate glycol;

polybutylene adipate glycol;

polycarbonate glycol;

ethylene oxide-capped polyoxypropylene diol;

diethylene glycol initiated polycaprolactone;

1,4-butanediol initiated polycaprolactone;

1,6-hexanediol initiated polycaprolactone;

trimethylol propane initiated polycaprolactone;

neopentyl glycol initiated polycaprolactone;

polytetramethylene ether glycol (PTMEG) initiated polycaprolactone and mixtures thereof.

7. The golf ball of claim 4 wherein said saturated curing agent is selected from the group consisting of 1,4-butanediol;

isomers and mixtures of cyclohexyldimethylol;

ethylene glycol;

diethylene glycol;

polytetramethylene ether glycol;

propylene glycol;

trimethanolpropane;

tetra-(2-hydroxypropyl)-ethylenediamine;

isomers and mixtures of cyclohexanebis(methylamine);

triisopropanolamine;

4,4′

-dicyclohexylmethane diamine;

isomers and mixtures of diaminocyclohexane;

2,2,4-trimethyl-1,6-hexanediamine;

2,4,4-trimethyl-1,6-hexanediamine;

diethyleneglycol di-(aminopropyl)ether;

4,4′

-bis-(sec-butylamino)-dicyclohexylmethane;

1,2-bis-(sec-butylamino)cyclohexane;

1,4-bis-(sec-butylamino)cyclohexane;

isophorone diamine;

hexamethylene diamine;

propylene diamine;

1-methyl-2,4-cyclohexyl diamine;

1-methyl-2,6-cyclohexyl diamine;

ethylene diamine;

diethylene triamine;

triethylene tetramine;

tetraethylene pentamine;

1,3-diaminopropane;

dimethylamino propylamine;

diethylamino propylamine;

imido-bis-propylamine;

monoethanolamine;

diethanolamine;

triethanolamine;

monoisopropanolamine;

diisopropanolamine and mixtures thereof.

8. The golf ball of claim 1 wherein the composition further comprises at least one additional thermoplastic or thermoset component.

9. The golf ball of claim 8, wherein the additional component is a material selected from the group consisting of polyurethanes, epoxy resins, polyethylenes, polyamides, polyesters, acid copolymers or their ionomer derivatives and blends thereof.

10. The golf ball of claim 8 wherein the composition comprises about 10 to about 90 weight percent of the saturated polyurethane.

11. The golf ball of claim 1 wherein the golf ball further comprises a core optionally comprised of a plurality of layers and at least one intermediate layer interposed between an innermost core layer and an outermost core layer, wherein said intermediate layer is formed from a composition which comprises at least one saturated polyurethane.

12. The golf ball of claim 1 wherein the saturated polyurethane is foamed.

13. The golf ball of claim 1, wherein the golf ball is a solid or wound ball having a fluid filled solid or hollow center.

14. A golf ball comprising a solid core and a cover, wherein the cover is cast from a saturated polyurethane composition comprising at least one prepolymer and at least one curing agent, wherein the cover has a specific gravity of at least about 0.7 and a flexural modulus of at least about 500 psi, and wherein the golf ball has a PGA compression of from about 55 to about 120.

15. The golf ball of claim 14, wherein the saturated polyurethane is a reaction product of at least one saturated diisocyanate, at least one saturated polyol, and at least one curing agent.

16. The golf ball of claim 15, wherein the saturated diisocyanate is selected from the group consisting of ethylene diisocyanate;

propylene-1,2-diisocyanate;

tetramethylene-1,4-diisocyanate;

1,6-hexamethylene-diisocyanate (HDI);

2,2,4-trimethylhexamethylene diisocyanate;

2,4,4-trimethylhexamethylene diisocyanate;

dodecane-1,12-diisocyanate;

dicyclohexylmethane diisocyanate;

cyclobutane-1,3-diisocyanate;

cyclohexane-1,3-diisocyanate;

cyclohexane-1,4-diisocyanate;

1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane;

isophorone diisocyanate (IPDI);

methyl cyclohexylene diisocyanate;

triisocyanate of HDI;

triisocyanate of 2,2,4-trimethyl-1,6-hexane diisocyanate (TMDI);

4,4′

-dicyclohexylmethane diisocyanate (HMDI) and mixtures thereof.

17. The golf ball of claim 15, wherein the saturated polyol is selected from the group consisting of polytetramethylene ether glycol (PTMEG);

poly(oxypropylene) glycol;

polyethylene adipate glycol;

polyethylene propylene adipate glycol;

polybutylene adipate glycol;

polycarbonate glycol;

ethylene oxide-capped polyoxypropylene diol;

diethylene glycol initiated polycaprolactone;

1,4-butanediol initiated polycaprolactone;

1,6-hexanediol initiated polycaprolactone;

trimethylol propane initiated polycaprolactone;

neopentyl glycol initiated polycaprolactone;

polytetramethylene ether glycol (PTMEG) initiated polycaprolactone and mixtures thereof.

18. The golf ball of claim 15, wherein the saturated curing agent is selected from the group consisting of 1,4-butanediol;

isomers and mixtures of cyclohexyldimethylol;

ethylene glycol;

diethylene glycol;

polytetramethylene ether glycol;

propylene glycol;

trimethanolpropane;

tetra-(2-hydroxypropyl)-ethylenediamine;

isomers and mixtures of cyclohexanebis(methylamine);

triisopropanolamine;

4,4′

-dicyclohexylmethane diamine;

isomers and mixtures of diaminocyclohexane;

2,2,4-trimethyl-1,6-hexanediamine;

2,4,4-trimethyl-1,6-hexanediamine;

diethyleneglycol di-(aminopropyl) ether);

4,4′

-bis-(sec-butylamino)-dicyclohexylmethane;

1,2-bis-(sec-butylamino)cyclohexane;

1,4-bis-(sec-butylamino)cyclohexane;

isophorone diamine;

hexamethylene diamine, propylene diamine;

1-methyl-2,4-cyclohexyl diamine;

1-methyl-2,6-cyclohexyl diamine;

ethylene diamine;

diethylene triamine;

triethylene tetramine;

tetraethylene pentamine;

1,3-diaminopropane;

dimethylamino propylamine;

diethylamino propylamine;

imido-bis-propylamine;

monoethanolamine;

diethanolamine;

triethanolamine;

monoisopropanolamine;

diisopropanolamine and mixtures thereof.

19. The golf ball of claim 14, wherein the composition further comprises at least one additional component selected from the group consisting of polyurethanes, epoxy resins, polyethylenes, polyamides, polyesters, acid copolymers or their ionomer derivatives and blends thereof.

20. The golf ball of claim 14, wherein the core is formed of a composition comprising polybutadiene.

21. A golf ball comprising a core, an inner cover layer, and an outer cover layer, wherein the outer cover layer cover layer is cast from a saturated thermoset polyurethane composition comprising at least one prepolymer and at least one curing agent, wherein the at least one cover layer has a thickness of from about 0.02 inch to about 0.3 inch, a hardness of at least about 40 Shore D. a specific gravity of at least about 0.7, and wherein the golf ball has a PGA compression of about 55 to about 120.

22. The golf ball of claim 21, wherein said saturated polyurethane is a reaction product of at least one saturated diisocyanate, at least one saturated polyol and at least one saturated cuing agent.

23. The golf ball of claim 22, wherein said saturated diisocyanate is selected from the group consisting of ethylene diisocyanate;

propylene-1,2-diisocyanate;

tetramethylene-1,4-diisocyanate;

1,6-hexamethylene-diisocyanate (HDI);

2,2,4-trimethylhexamethylene diisocyanate;

2,4,4-trimethylhexamethylene diisocyanate;

dodecane-1,12-diisocyanate;

dicyclohexylmethane diisocyanate;

cyclobutane-1,3-diisocyanate;

cyclohexane-1,3-diisocyanate;

cyclohexane-1,4-diisocyanate;

1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane;

isophorone diisocyanate (IPDI);

methyl cyclohexylene diisocyanate;

triisocyanate of HDI;

triisocyanate of 2,2,4-trimethyl-1,6-hexane diisocyanate (TMDI), 4,4′

-dicyclohexylmethane diisocyanate (HMDI) and mixtures thereof.

24. The golf ball of claim 22, wherein said saturated polyol is selected from the group consisting of polytetramethylene ether glycol (PTMEG);

poly(oxypropylene)glycol;

polyethylene adipate glycol;

polyethylene propylene adipate glycol;

polybutylene adipate glycol;

polycarbonate glycol;

ethylene oxide-capped polyoxypropylene diol;

diethylene glycol initiated polycaprolactone;

1,4-butanediol initiated polycaprolactone, 1,6-hexanediol initiated polycaprolactone;

trimethylol propane initiated polycaprolactone;

neopentyl glycol initiated polycaprolactone;

polytetramethylene ether glycol (PTMEG) initiated polycaprolactone and mixtures thereof.

25. The golf ball of claim 22, wherein said saturated curing agent is selected from the group consisting of 1,4-butanediol;

isomers and mixtures of cyclohexyldimethylol;

ethylene glycol;

diethylene glycol;

polytetramethylene ether glycol;

propylene glycol;

trimethanolpropane;

tetra-(2-hydroxypropyl)-ethylenediamine, isomers and mixtures of cyclohexanebis(methylamine);

triisopropanolamine;

4,4′

-dicyclohexylmethane diamine;

isomers and mixtures of diaminocyclohexane;

2,2,4-trimethyl-1,6-hexanediamine;

2,4,4-trimethyl-1,6-hexanediamine;

diethyleneglycol di-(aminopropyl)ether);

4,4′

-bis-(sec-butylamino)-dicyclohexylmethane;

1,2-bis-(sec-butylamino)cyclohexane;

1,4-bis-(sec-butylamino)cyclohexane;

isophorone diamine;

hexamethylene diamine;

propylene diamine;

1-methyl-2,4-cyclohexyl diamine;

1-methyl-2,6-cyclohexyl diamine;

ethylene diamine;

diethylene triamine;

triethylene tetramine;

tetraethylene pentamine 1,3-diaminopropane;

dimethylamino propylamine;

diethylamino propylamine;

imido-bis-propylamine;

monoethanolamine;

diethanolamine;

triethanolamine;

monoisopropanolamine;

diisopropanolamine and mixtures thereof.