Highly-resilient thermoplastic elastomer compositions

• US 6,815,480 B2
• Filed: 09/22/2001
• Issued: 11/09/2004
• Est. Priority Date: 10/21/1998
• Status: Expired due to Fees

• Current Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Hagman, John Francis, Chen, John C., Statz, Robert Joseph
• Primary Examiner(s): Buttner, David J.
• Application Number:
  US09/960,208
• Publication Number:
  US 20020091188A1
• Time in Patent Office: 1,144 Days
• Field of Search: 524/322, 524/394, 524/399, 524/400, 525/92.A, 473/371, 473/372, 473/373, 473/377, 473/357
• US Class Current: 524/322
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0039 characterised by the material
• CPC Class Codes: A63B 37/0043 Hardness
• CPC Class Codes: A63B 37/0045 Thickness
• CPC Class Codes: A63B 37/0047 Density; Specific gravity
• CPC Class Codes: A63B 37/0051 Materials other than polybutadienes; Constructional details
• CPC Class Codes: A63B 37/0062 Hardness
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0066 Density; Specific gravity
• CPC Class Codes: A63B 37/0073 Solid, i.e. formed of a single piece
• 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 37/0078 Coefficient of restitution
• CPC Class Codes: A63B 37/008 Diameter
• CPC Class Codes: A63B 37/0083 Weight; Mass
• CPC Class Codes: A63B 37/0084 Initial velocity
• CPC Class Codes: A63B 37/0087 Deflection or compression
• CPC Class Codes: C08K 5/098 Metal salts of carboxylic acids
• CPC Class Codes: C08L 2205/02 : containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 23/00 : Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 23/08 : Copolymers of ethene C08L23/16 takes precedence
• CPC Class Codes: C08L 23/0876 : Neutralised polymers, i.e. ionomers
• CPC Class Codes: C08L 2666/04 : Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 67/025 : containing polyether sequences
• CPC Class Codes: C08L 77/00 : Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain of polyhydrazides C08L79/06; of polyamideimides or polyamide acids C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 77/12 : Polyester-amides

Abstract

A thermoplastic composition of (a) an acid copolymer, (b) a salt of a high molecular weight, monomeric organic acid; (c) a thermoplastic polymer selected from copolyetheresters, elastomeric polyolefins, styrene diene block copolymers, elastomeric polyolefins thermoplastic polyurethanes and copolyetheramides; (d) cation source; and (d) optionally a filler. Also included is use of such compositions in components of one-, two- and three-piece golf balls or multi-layered golf balls made therefrom.

Claims

1. A composition comprising

a) an acid copolymer of the composition E/X/Y wherein E is ethylene, X is an α

,β

ethylenically unsaturated carboxylic acid, and Y is a C_1-8 alkyl acrylate or alkyl methacrylate, X is present in 6-35 wt. % of the acid copolymer, and Y is present in 5-25 wt. % of the acid copolymer;

b) about 10 to about 45 wt. % of a high molecular weight, monomeric organic acid or salt thereof based on total weight of components a), b), and c) provided that component (b) does not exceed 50 wt. % of (a) plus (b);

c) about 1 to about 30 wt. % thermoplastic elastomer selected from copolyetheramides, copolyetheresters, elastomeric polyolefins, block polystyrene polydiene copolymers, and thermoplastic polyurethanes;

d) a cation source present at a level sufficient to neutralize 80 to 110% of the combined acid content of components a) and b); and

e) zero to about 60 wt. % filler based on weight of components a) plus b) plus c) plus e).

2. The composition of claim 1 wherein component a) is an E/X/Y copolymer wherein X is present in 8-20 wt. % of the acid copolymer, and Y is present in 11-23 wt. % of the acid copolymer.

3. A one-piece golf ball comprising the composition of

a) an ethylene/(meth)acrylic acid/n-butyl acrylate terpolymer of the composition E/X/Y wherein E is ethylene, X is acrylic acid or methacrylic acid, and Y is n-butyl acrylate, X is present in 4-35 wt. % of the terpolymer, and Y is present in an amount up to 50 wt. % of the terpolymer;

b) about 10 to about 45 wt. % of a high molecular weight, monomeric fatty acid based on total weight of components a), b), and c) provided that component (b) does not exceed 50 wt. % of (a) plus (b);

c) about I to about 35 wt. % of a polyetherester having a shore D hardness of about 30-40;

d) a magnesium cation source present at a level sufficient to neutralize 95 to 110% of the combined acid content of components a) and b); and

e) ZnO present in a sufficient amount to adjust the density of the composition to a level that results in a golf ball that weighs about 45.93 grams.

4. A two-piece golf ball comprising a core and a cover, wherein the core comprises the composition of

a) an acid terpolymer of the composition E/X/Y wherein E is ethylene, X is acrylic acid or methacrylic acid, and Y is a C_1-8 alkyl acrylate or alkyl methacrylate, X is present in 4-35 wt. % of the acid terpolymer, and Y is present in an amount up to 50 wt. % of the acid terpolymer;

b) about 10 to about 45 wt. % of a high molecular weight, monomeric stearic acid or oleic acid or salt thereof based on total weight of components a), b), and c) provided that component (b) does not exceed 50 wt. % of (a) plus (b);

c) about 1 to about 35 wt. % polyetherester having a shore D hardness of about 30-40;

d) a cation source present at a level sufficient to neutralize 50 to 110% of the combined acid content of components a) and b); and

e) sufficient filler selected from ZnO and BaSO₄ to adjust the density of the core to about 1.18 gm/cc.

5. The two-piece golf ball of claim 4 wherein the salt of stearic acid is a magnesium salt, the ionomer is an ethylene/(meth)acrylic acid/n-butyl acrylate highly neutralized with Mg cations to form the ionomer, and the filler is ZnO.

6. The two-piece golf ball of claim 4 wherein the core has a dimple pattern such that when positioned in the ball and covered by the cover having a dimple pattern, the cover thickness in the dimple areas is the about the same as the dimple thickness in the non-dimpled areas.

7. A three-piece golf ball comprised of a center, an elastomeric winding and a cover, wherein the center comprises the composition of

a) an acid copolymer of the composition E/X/Y wherein E is ethylene, X is an α

,β

ethylenically unsaturated carboxylic acid, and Y is a C_1-8 alkyl acrylate or alkyl methacrylate, X is present in 4-35 wt. % of the acid copolymer, and Y is present in 0-50 wt. % of the acid copolymer;

b) about 10 to about 45 wt. % of a high molecular weight, monomeric organic acid or salt thereof based on total weight of components a), b), and c) provided that component (b) does not exceed 50 wt. % of (a) plus (b);

c) about 1 to about 35 wt. % thermoplastic elastomer selected from copolyetheramides, copolyetheresters, elastomeric polyolefmns, block polystyrene polydiene copolymers, and thermoplastic polyurethanes;

d) a cation source present at a level sufficient to neutralize 50 to 110% of the combined acid content of components a) and b); and

e) filler, present in a type and amount sufficient to achieve a density between the density of the composition without filler and 1.8 grams per cubic centimeter.

8. The three-piece golf ball of claim 7 wherein (a) acid copolymer of the center is an ethylene/acrylate ester/acrylic acid terpolymer highly neutralized with Mg cation, (b) metal salt of the organic acid of the center is a magnesium salt of stearic acid, (c) thermoplastic elastomer of the center is a copolyetherester having a shore D hardness of 30-40, and (e) filler in the center is ZnO.