Golf ball which includes fast-chemical-reaction-produced component and method of making same

• US 6,905,424 B2
• Filed: 06/08/2001
• Issued: 06/14/2005
• Est. Priority Date: 03/18/1998
• Status: Expired due to Term

• Current Assignee: Callaway Golf Company
• Original Assignee: Callaway Golf Company
• Inventors: Kennedy, Thomas J. III, Risen, William, Keller, Viktor, Tzivanis, Michael John
• Primary Examiner(s): Gorden, Raeann
• Application Number:
  US09/877,600
• Publication Number:
  US 20010039220A1
• Time in Patent Office: 1,467 Days
• Field of Search: 473/377, 473/378, 473/373, 473/374, 473/368, 473/367, 473/371
• US Class Current: 473/378
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• 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 37/0037 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0045 Thickness
• 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 37/0053 Thread wound
• CPC Class Codes: A63B 37/0054 Substantially rigid, e.g. metal
• CPC Class Codes: A63B 37/0058 Polyurethane
• CPC Class Codes: A63B 37/0069 Flexural modulus; Bending stiffness
• 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 37/06 Elastic cores
• CPC Class Codes: A63B 37/12 Special coverings , i.e. outer layer material balls with finger holes A63B37/0001, golf ball covers A63B37/0023
• CPC Class Codes: A63B 45/00 Apparatus or methods for manufacturing balls working of plastics or substances in a plastic state B29
• CPC Class Codes: C08G 2120/00 Compositions for reaction injection moulding processes
• CPC Class Codes: C08L 75/04 Polyurethanes
• CPC Class Codes: Y02P 20/582 : Recycling of unreacted starting or intermediate materials

Abstract

Disclosed herein is a golf ball comprising one or more fast-chemical-reaction-produced components, such as a component which comprises a reaction injection molded polyurethane material. A process of making a golf ball by forming at least one core and/or cover component of the ball by mixing two or more reactants that react and form a reaction product with a flex modulus of 1 to 310 kpsi, with a setting time of about 30 seconds or less, the component having a thickness of at least 0.01 inches and a mold release time of 2 minutes or less is also disclosed. In one preferred form of the invention, excess polyurethane from forming golf ball covers is recycled by using it to form golf ball cores.

Claims

1. A process for making a golf ball, said process comprising:

forming at least one of a cover and a core component of said golf bail by mixing two or more reactants together to produce a reaction product having (i) a flex modulus of from about 1 to about 310 Kpsi, and (ii) a reaction time of less than 2 minutes, wherein said at least one of said cover and said core component formed from said mixing operation has a thickness of at least about 0.01 inches.

2. The process according to claim 1, wherein said reaction product comprises at least one member selected from the group consisting of polyurethanes, polyureas, epoxies and unsaturated polyesters.

3. The process according to claim 1, wherein said reaction product comprises at least one member selected from the group consisting of polyurethane and polyurea.

4. The process according to claim 1, wherein said reaction product exhibits a reaction time of about 1 minute or less.

5. The process according to claim 4, wherein said reaction product exhibits a reaction time of 30 seconds or less.

6. The process according to claim 1, wherein said reaction product exhibits a demold time of 2 minutes or less.

7. The process according to claim 6, wherein said reaction product exhibits a demold of 1 minute or less.

8. The process according to claim 1, wherein said cover is formed from said process.

9. The process according to claim 8, wherein said cover is a dimpled cover layer and said cover has a thickness of at least 0.02 inches.

10. The process according to claim 8, wherein said cover has a hardness of 10 to 95 Shore D.

11. The process according to claim 8, wherein said cover has a hardness of 30 to 75 Shore D.

12. The process according to claim 1, wherein said core component is formed form said process.

13. The process according to claim 2, further including a step of recycling at least a portion of said reaction product.

14. The process according to claim 13, wherein said reaction product is recycled by glycolysis.

15. A multi-piece golf ball comprising a reaction injection molded material comprising polyurethane/polyurea, wherein said polyurethane/polyurea material includes meta-tetramethylxylylene diisocyanate.