Bi-modal ionomers

• US 7,037,967 B2
• Filed: 05/26/2004
• Issued: 05/02/2006
• Est. Priority Date: 08/11/2000
• Status: Expired due to Fees

• Current Assignee: Performance Materials NA, Inc. (Dow, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Chen, John C.
• Primary Examiner(s): Nutter, Nathan M.
• Application Number:
  US10/854,725
• Publication Number:
  US 20040220343A1
• Time in Patent Office: 706 Days
• Field of Search: 524/430, 524/432, 524/500, 524/515, 473/351, 473/371, 473/377, 473/378
• US Class Current: 524/430
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0024 Materials other than ionomers or polyurethane
• CPC Class Codes: A63B 37/0034 Deflection or compression
• CPC Class Codes: A63B 37/0039 characterised by the material
• CPC Class Codes: A63B 37/0046 Deflection or compression
• CPC Class Codes: A63B 37/0051 Materials other than polybutadienes; Constructional details
• CPC Class Codes: A63B 37/0065 Deflection or compression
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 2205/025 containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 2205/035 containing four or more polymers in a blend
• CPC Class Codes: C08L 23/025 Copolymer of an unspecified olefin with a monomer other than an olefin
• CPC Class Codes: C08L 23/08 Copolymers of ethene C08L23/16 takes precedence
• CPC Class Codes: C08L 23/0869 Acids or derivatives thereof
• 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 2666/06 Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof
• CPC Class Codes: C08L 2666/14 Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C08L 53/02 of vinyl-aromatic monomers and conjugated dienes
• CPC Class Codes: C08L 67/025 containing polyether sequences
• CPC Class Codes: C08L 75/04 Polyurethanes

Abstract

The present invention relates to compositions and preparative process of partially or fully neutralized mixtures of carboxylate functionalized ethylene high copolymers or terpolymers (Mw between 80,000 and 500,000) with carboxylate functionalized ethylene low copolymers (Mw between 2,000 and 30,000) and organic acid salts and injection or compression molded applications such as golf ball components thereof.

Claims

1. A cover of a golf ball comprising a bi-modal composition comprising a thermoplastic composition that is melt processible consisting essentially of

(a) E/X/Y copolymers where E is ethylene, X is derived from a C3 to C8 α

,β

ethylenically unsaturated carboxylic acid, and Y is a softening comonomer selected from the group consisting of alkyl acrylates and alkyl methacrylates, wherein the alkyl groups have from 1-8 carbon atoms, or ionomers of the E/X/Y copolymers wherein X is about 2-30 wt. % of the E/X/Y copolymer, and Y is 0 to about 35 wt. % of the E/X/Y copolymer;

(b) 5-50 wt. % based on (a)+(b) of one or more E/(M)AA copolymers having 3-25 wt. % (M)AA or salts thereof, wherein the E/X/Y copolymers have an Mw in the range of 80,000 to 500,000, and the E/(M)AA copolymers have an Mw between 2,000 and 30,000; and

(c) 5-50 wt. % based on (a)+(b) of one or more aliphatic, mono-functional organic acids having fewer than 30 carbon atoms or salt thereof, wherein greater than 80% of all the acid of (a) and of (b) and of (c) is neutralized;

wherein sufficient filler is added (to one or more components of the golf ball) to adjust the weight of the golf ball to a level meeting the limits set by the golfer'"'"'s governing authority.

2. An intermediate layer in a multi-layer golf ball comprising a bi-modal composition comprising a thermoplastic composition that is melt processible consisting essentially of

(a) E/X/Y copolymers where E is ethylene, X is derived from a C3 to C8 α

,β

ethylenically unsaturated carboxylic acid, and Y is a softening comonomer selected from the group consisting of alkyl acrylates and alkyl methacrylates, wherein the alkyl groups have from 1-8 carbon atoms, or ionomers of the E/X/Y copolymers wherein X is about 2-30 wt. % of the E/X/Y copolymer, and Y is 0 to about 35 wt. % of the E/X/Y copolymer;

(b) 5-50 wt. % based on (a)+(b) of one or more E/(M)AA copolymers having 3-25 wt. % (M)AA or salts thereof, wherein the E/X/Y copolymers have an Mw in the range of 80,000 to 500,000, and the E/(M)AA copolymers have an Mw between 2,000 and 30,000;

(c) 5-50 wt. % based on (a)+(b) of one or more aliphatic, mono-functional organic acids having fewer than 30 carbon atoms or salt thereof, wherein greater than 80% of all the acid of (a) and of (b) and of (c) is neutralized; and

, optionally,

(d) 1-30 wt. % based on the total weight of the bimodal composition of thermoplastic elastomeric resin selected from copolyetheramides, copolyetheresters, elastomeric polymerolefins, block polystyrene polydiene copolymers, and thermoplastic urethanes;

wherein sufficient filler is added (to one or more components of the golf ball) to adjust the weight of the golf ball to a level meeting the limits set by the golfer'"'"'s governing authority.

3. A core or part of a core of a two- or multiple-piece golf ball or a center of a three-piece golf ball comprising a bi-modal composition comprising a thermoplastic composition that is melt processible consisting essentially of

(a) E/X/Y copolymers where E is ethylene, X is derived from a C3 to C8 α

,β

ethylenically unsaturated carboxylic acid, and Y is a softening comonomer selected from the group consisting of alkyl acrylates and alkyl methacrylates, wherein the alkyl groups have from 1-8 carbon atoms, or ionomers of the E/X/Y copolymers wherein X is about 2-30 wt. % of the E/X/Y copolymer, and Y is 0 to about 35 wt. % of the E/X/Y copolymer;

(b) 5-50 wt. % based on (a)+(b) of one or more E/(M)AA copolymers having 3-25 wt. % (M)AA or salts thereof, wherein the E/X/Y copolymers have an Mw in the range of 80,000 to 500,000, and the E/(M)AA copolymers have an Mw between 2,000 and 30,000;

(c) 5-50 wt. % based on (a)+(b) of one or more aliphatic, mono-functional organic acids having fewer than 30 carbon atoms or salt thereof, wherein greater than 80% of all the acid of (a) and of (b) and of (c) is neutralized; and

, optionally,

(d) 1-30 wt. % based on the total weight of the bimodal composition of thermoplastic elastomeric resin selected from copolyetheramides, copolyetheresters, elastomeric polymerolefins, block polystyrene polydiene copolymers, and thermoplastic urethanes;

wherein sufficient filler is added (to one or more components of the golf ball) to adjust the weight of the golf ball to a level meeting the limits set by the golfer'"'"'s governing authority.

4. A one-piece golf ball comprising the a bi-modal composition comprising a thermoplastic composition that is melt processible consisting essentially of

(a) E/X/Y copolymers where E is ethylene, X is derived from a C3 to C8 α

,β

ethylenically unsaturated carboxylic acid, and Y is a softening comonomer selected from the group consisting of alkyl acrylates and alkyl methacrylates, wherein the alkyl groups have from 1-8 carbon atoms, or ionomers of the E/X/Y copolymers wherein X is about 2-30 wt. % of the E/X/Y copolymer, and Y is 0 to about 35 wt. % of the E/X/Y copolymer;

(b) 5-50 wt. % based on (a+(b) of one or more E/(M)AA copolymers having 3-25 wt. % (M)AA or salts thereof, wherein the E/X/Y copolymers have an Mw in the range of 80,000 to 500,000, and the E/(M)AA copolymers have an Mw between 2,000 and 30,000;

(c) 5-50 wt. % based on (a)+(b) of one or more aliphatic, mono-functional organic acids having fewer than 30 carbon atoms or salt thereof, wherein greater than 80% of all the acid of (a) and of (b) and of (c) is neutralized; and

, optionally,

(d) 1-30 wt. % based on the total weight of the bimodal composition of thermoplastic elastomeric resin selected from copolyetheramides, copolyetheresters, elastomeric polymerolefins, block polystyrene polydiene copolymers, and thermoplastic urethanes;

wherein sufficient filler is added to adjust the weight of the golf ball to a level meeting the limits set by the golfer'"'"'s governing authority.

5. An intermediate layer in a multi-layer golf ball comprising the composition consisting essentially of (a) E/X/Y copolymers where E is ethylene, X is derived from a C3 to C8 α

,β

ethylenically unsaturated carboxylic acid, and Y is a softening comonomer selected from the group consisting of alkyl acrylates and alkyl methacrylates, wherein the alkyl groups have from 1-8 carbon atoms, or ionomers of the E/X/Y copolymers wherein X is about 2-30 wt. % of the E/X/Y copolymer, and Y is 0 to about 35 wt. % of the E/X/Y copolymer, and (b) 5-50 wt. % based on (a)+(b) of one or more E/(M)AA copolymers having 3-25 wt. % (M)AA or salts thereof, wherein greater than 80% of all the acid of (a) and of (b) is neutralized and wherein sufficient filler is added (to one or more components of the golf ball) to adjust the weight of the golf ball to a level meeting the limits set by the golfer'"'"'s governing authority.

6. A core or part of a core of a two- or multiple-piece golf ball or a center of a three-piece golf ball comprising the composition consisting essentially of (a) E/X/Y copolymers where E is ethylene, X is derived from a C3 to C8 α

,β

ethylenically unsaturated carboxylic acid, and Y is a softening comonomer selected from the group consisting of alkyl acrylates and alkyl methacrylates, wherein the alkyl groups have from 1-8 carbon atoms, or ionomers of the E/X/Y copolymers wherein X is about 2-30 wt. % of the E/X/Y copolymer, and Y is 0 to about 35 wt. % of the E/X/Y copolymer, and (b) 5-50 wt. % based on (a)+(b) of one or more E/(M)AA copolymers having 3-25 wt. % (M)AA or salts thereof, wherein greater than 80% of all the acid of (a) and of (b) is neutralized, wherein sufficient filler is added (to one or more components of the golf ball) to adjust the weight of the golf ball to a level meeting the limits set by the golfer'"'"'s governing authority.

7. A one-piece golf ball comprising the composition consisting essentially of (a) E/X/Y copolymers where E is ethylene, X is derived from a C3 to C8 α

,β

ethylenically unsaturated carboxylic acid, and Y is a softening comonomer selected from the group consisting of alkyl acrylates and alkyl methacrylates, wherein the alkyl groups have from 1-8 carbon atoms, or ionomers of the E/X/Y copolymers wherein X is about 2-30 wt. % of the E/X/Y copolymer, and Y is 0 to about 35 wt. % of the E/X/Y copolymer, and (b) 5-50 wt. % based on (a)+(b) of one or more E/(M)AA copolymers having 3-25 wt. % (M)AA or salts thereof, wherein greater than 80% of all the acid of (a) and of (b) is neutralized, and wherein sufficient filler is added to adjust the weight of the golf ball to a level meeting the limits set by the golfers governing authority.