Method for making multilayer golf ball

• US 7,041,007 B2
• Filed: 09/26/2003
• Issued: 05/09/2006
• Est. Priority Date: 03/11/1996
• Status: Expired due to Fees

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Morgan, William E., Dalton, Jeffrey L., Sullivan, Michael J., Cavallaro, Christopher, Boehm, Herbert C., Harris, Kevin M., Pasqua, Samuel A. Jr., Reid, Walter L. Jr.
• Primary Examiner(s): Gorden, Raeann
• Application Number:
  US10/670,514
• Publication Number:
  US 20040092335A1
• Time in Patent Office: 956 Days
• Field of Search: 473/354, 473/351, 473/373, 473/374, 473/368, 473/376
• US Class Current: 473/354
• CPC Class Codes: A63B 2037/085 liquid, jellylike
• CPC Class Codes: A63B 37/0003 Golf balls
• 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 37/0052 Liquid cores
• CPC Class Codes: A63B 37/0056 Hollow; Gas-filled
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0069 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0076 Multi-piece balls, i.e. having two or more intermediate layers
• CPC Class Codes: A63B 37/008 Diameter
• CPC Class Codes: A63B 37/04 Rigid cores
• CPC Class Codes: A63B 37/08 Liquid cores; Plastic cores
• CPC Class Codes: A63B 39/08 made of two halves
• 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: B29C 2043/023 having a plurality of grooves
• CPC Class Codes: B29C 33/0022 Multi-cavity moulds B29C33/301 takes precedence
• CPC Class Codes: B29C 43/027 having an axis of symmetry B29C43/102 takes precedence
• CPC Class Codes: B29C 43/146 for making multilayered articles
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 66/1142 : Single butt to butt joints
• CPC Class Codes: B29C 66/12461 : being rounded, i.e. U-shaped or C-shaped
• CPC Class Codes: B29C 66/54 : Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/73756 : the to-be-joined areas of both parts to be joined being fully cured
• CPC Class Codes: B29C 66/73775 : the to-be-joined area of at least one of the parts to be joined being crystalline
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/73941 : characterised by the materials of both parts being thermosets
• CPC Class Codes: B29C 66/8322 : Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/83221 : cooperating reciprocating tools, each tool reciprocating along one axis
• CPC Class Codes: B29K 2009/00 : Use of rubber derived from conjugated dienes, as moulding material
• CPC Class Codes: B29K 2009/06 : SB polymers, i.e. butadiene-styrene polymers
• CPC Class Codes: B29K 2021/00 : Use of unspecified rubbers as moulding material
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/02 : Polyureas
• CPC Class Codes: B29L 2031/54 : Balls
• CPC Class Codes: B29L 2031/545 : Football balls

Abstract

The present invention encompasses a golf ball having a diameter and being comprised of a core and a cover, wherein the core is further comprised of a fluid mass at the center of the ball, a first mantle layer surrounding the fluid mass and a second, solid, non-wound mantle layer surrounding and abutting the first mantle layer, wherein the first mantle layer comprises a polymer material selected from the group consisting of a thermoset rubber, plastic and thermoplastic elastomeric material and the second mantle layer comprises a polymer material selected from the group consisting of a thermoset rubber material and thermoplastic elastomeric material, and wherein the cover comprises polyurethane, polyurea, or a polyurea/polyurethane hybrid.

Claims

1. A golf ball having a diameter and being comprised of a core and a cover, wherein the core is further comprised of a fluid mass at the center of the ball, a first mantle layer surrounding the fluid mass and a second, solid, non-wound mantle layer surrounding and abutting the first mantle layer, wherein the first mantle layer comprises a polymer material selected from the group consisting of a thermoset rubber, plastic and thermoplastic elastomeric material and the second mantle layer comprises a polymer material selected from the group consisting of a thermoset rubber material and thermoplastic elastomeric material, wherein the first mantle layer or second mantle layer further comprises a halogenated thiophenol, and wherein the cover comprises polyurethane, polyurea, or a polyurea/polyurethane hybrid.

2. The golf ball of claim 1, wherein the fluid mass is a gas, liquid, gel, paste or a combination thereof.

3. The golf ball of claim 1, wherein the fluid mass is a liquid having a low coefficient of thermal expansion or high boiling point.

4. The golf ball of claim 3, wherein the liquid having a low coefficient of thermal expansion or high boiling point is selected from the group consisting of an oil, a polyol and mixtures thereof.

5. The golf ball of claim 2, wherein the fluid mass is a gas, wherein the gas is selected from the group consisting of air, nitrogen, helium, argon, neon, carbon dioxide, nitrous oxide and mixtures thereof.

6. The golf ball of claim 1, wherein the first mantle layer comprises dynamically vulcanized thermoplastic elastomer, functionalized styrene-butadiene elastomer, thermoplastic polyurethane, thermoplastic polyetherester or polyetheramide, thermoplastic ionomer resin, thermoplastic polyester, metallocene polymer or blends thereof.

7. The golf ball of claim 1, wherein the cover comprises an inner cover layer and a thin outer cover layer, wherein the outer cover layer comprises a thermoset material formed from a castable, reactive liquid and the inner cover layer comprises a high flexural modulus material.

8. The golf ball of claim 1, wherein at least one of the first mantle layer, second mantle layer, or cover comprises a polymer containing an acid group that is neutralized by an organic acid or a salt thereof, the organic acid or salt thereof being present in an amount sufficient to neutralize the polymer by at least about 70%.

9. The golf ball of claim 8, wherein the polymer comprises ionomeric copolymers and terpolymers, ionomer precursors, thermoplastics, thermoplastic elastomers, polybutadiene rubber, balata, grafted metallocene-catalyzed polymers, non-grafted metallocene-catalyzed polymers, single-site polymers, high-crystalline acid polymers, cationic ionomers, and mixtures thereof.

10. The golf ball of claim 8, wherein the organic acid is selected from the group consisting of aliphatic organic acids, aromatic organic acids, saturated mono-functional organic acids, unsaturated mono-functional organic acids, and multi-unsaturated mono-functional organic acids.

11. The golf ball of claim 8, wherein the salt of organic acids comprise barium, lithium, sodium, zinc, bismuth, chromium, cobalt, copper, potassium, strontium, titanium, tungsten, magnesium, cesium, iron, nickel, silver, aluminum, tin, and calcium salts of stearic acid, behenic acid, erucic acid, oleic acid, linoelic acid, dimerized derivatives, and mixtures thereof.

12. The golf ball of claim 1, wherein the golf ball diameter is at least 1.68 inches.

13. The golf ball of claim 12, wherein the first mantle layer has an inner diameter of about 0.75 to 1.1 inches.

14. The golf ball of claim 1, wherein the core diameter is about 1.590 inches or greater.

15. The golf ball of claim 1, wherein the cover has a thickness of from about 0.015 to 0.12 inches.

16. The golf ball of claim 1, wherein the halogenated thiophenol is zinc pentachlorothiophenol.

17. The golf ball of claim 1, wherein the cover comprises polyether thermoplastic urethane, polyester thermoplastic urethane, thermoset polyurethane, polyurea, or polyurethane/polyurea hybrid that is formed from an isocyanate prepolymer.

18. The golf ball of claim 17, wherein the isocyanate prepolymer is paraphenylene diisocyanate.

19. The golf ball of claim 1 having a moment of inertia of greater than 0.460 oz-in².

20. The golf ball of claim 1 having a moment of inertia of less than 0.450 oz-in².

21. A golf ball having a diameter and being comprised of a core and a cover, wherein the core is further comprised of a fluid mass at the center of the ball, a first mantle layer surrounding the fluid mass and a second, solid, non-wound mantle layer surrounding and abutting the first mantle layer, wherein the first mantle layer comprises a polymer material selected from the group consisting of a thermoset rubber, plastic and thermoplastic elastomeric material and the second mantle layer comprises a polymer material selected from the group consisting of a thermoset rubber material and thermoplastic elastomeric material, and wherein the cover comprises material selected from the group consisting of polyether thermoplastic urethane, polyester thermoplastic urethane, thermoset polyurethane, ionomer resins, low modulus ionomers, high modulus ionomers and blends thereof, and wherein the first mantle layer or second mantle layer further comprises a halogenated thiophenol.

22. The golf ball of claim 21, wherein the cover comprises a thermoset polyurethane.

23. The golf ball of claim 21, wherein the fluid mass is a liquid having a low coefficient of thermal expansion or high boiling point.

24. The golf ball of claim 23, wherein the liquid having a low coefficient of thermal expansion or high boiling point is selected from the group consisting of an oil, a polyol and mixtures thereof.

25. The golf ball of claim 21, wherein the fluid mass is a gas, wherein the gas is selected from the group consisting of air, nitrogen, helium, argon, neon, carbon dioxide, nitrous oxide and mixtures thereof.

26. The golf ball of claim 21, wherein the first mantle layer comprises dynamically vulcanized thermoplastic elastomer, functionalized styrene-butadiene elastomer, thermoplastic polyurethane, thermoplastic polyetherester or polyetheramide, thermoplastic ionomer resin, thermoplastic polyester, metallocene polymer or blends thereof.

27. The golf ball of claim 21, wherein the cover comprises an inner cover layer and a thin outer cover layer, wherein the outer cover layer comprises a thermoset material formed from a castable, reactive liquid and the inner cover layer comprises a high flexural modulus material.

28. The golf ball of claim 21, wherein at least one of the first mantle layer, second mantle layer, or cover comprises a polymer containing an acid group that is neutralized by an organic acid or a salt thereof, the organic acid or salt thereof being present in an amount sufficient to neutralize the polymer by at least about 70%.

29. The golf ball of claim 28, wherein the polymer comprises ionomeric copolymers and terpolymers, ionomer precursors, thermoplastics, thermoplastic elastomers, polybutadiene rubber, balata, grafted metallocene-catalyzed polymers, non-grafted metallocene-catalyzed polymers, single-site polymers, high-crystalline acid polymers, cationic ionomers, and mixtures thereof.

30. The golf ball of claim 28, wherein the organic acid is selected from the group consisting of aliphatic organic acids, aromatic organic acids, saturated mono-functional organic acids, unsaturated mono-functional organic acids, and multi-unsaturated mono-functional organic acids.

31. The golf ball of claim 28, wherein the salt of organic acids comprise barium, lithium, sodium, zinc, bismuth, chromium, cobalt, copper, potassium, strontium, titanium, tungsten, magnesium, cesium, iron, nickel, silver, aluminum, tin, and calcium salts of stearic acid, behenic acid, erucic acid, oleic acid, linoelic acid, dimerized derivatives, and mixtures thereof.

32. The golf ball of claim 21, wherein the golf ball diameter is at least 1.68 inches.

33. The golf ball of claim 21, wherein the first mantle layer has an inner diameter of about 0.75 to 1.1 inches.

34. The golf ball of claim 21, wherein the core diameter is about 1.590 inches or greater.

35. The golf ball of claim 21, wherein the cover has a thickness of from about 0.015 to 0.12 inches.

36. The golf ball of claim 21, wherein the halogenated thiophenol is zinc pentachlorothiophenol.

37. The golf ball of claim 21 having a moment of inertia of greater than 0.460 oz-in².

38. The golf ball of claim 21 having a moment of inertia of less than 0.450 oz-in².

39. A golf ball having a diameter and being comprised of a core and a cover, wherein the core is further comprised of a fluid mass at the center of the ball, a first mantle layer surrounding the fluid mass and a second, solid, non-wound mantle layer surrounding and abutting the first mantle layer, wherein the first mantle layer comprises a polymer material selected from the group consisting of a thermoset rubber, plastic and thermoplastic elastomeric material and the second mantle layer comprises two or more layers, each made from material that comprises a polymer material selected from the group consisting of a thermoset rubber material and thermoplastic elastomeric material, and wherein the first mantle layer or smantle layer econd further comprises a halogenated thiophenol.

40. The golf ball of claim 39, wherein the thermoset rubber material is selected from the group consisting of polyisoprene, styrene butadiene, polybutadiene and mixtures thereof.

41. The golf ball of claim 39, wherein the thermoplastic elastomeric material is selected from the group consisting of copolymers of methyl-methacrylate with butadiene and styrene, copolymers of methyl-acrylate with butadiene and styrene, acrylonitrile styrene copolymers, polyether-ester, polyether-amide, polyurethane, propylene/ethylene-propylene-diene rubber, styrene-butadiene elastomers, metallocene polymers, polyetheresters, polyetheramides, ionomer resins, polyesters, and blends thereof.

42. The golf ball of claim 39, wherein the fluid mass is a liquid having a low coefficient of thermal expansion or high boiling point.

43. The golf ball of claim 42, wherein the liquid having a low coefficient of thermal expansion or high boiling point is selected from the group consisting of an oil, a polyol and mixtures thereof.

44. The golf ball of claim 39, wherein the fluid mass is a gas, wherein the gas is selected from the group consisting of air, nitrogen, helium, argon, neon, carbon dioxide, nitrous oxide and mixtures thereof.

45. The golf ball of claim 39, wherein the first mantle layer comprises dynamically vulcanized thermoplastic elastomer, functionalized styrene-butadiene elastomer, thermoplastic polyurethane, thermoplastic polyetherester or polyetheramide, thermoplastic ionomer resin, thermoplastic polyester, metallocene polymer or blends thereof.

46. The golf ball of claim 39, wherein the cover comprises an inner cover layer and a thin outer cover layer, wherein the outer cover layer comprises a thermoset material formed from a castable, reactive liquid and the inner cover layer comprises a high flexural modulus material.

47. The golf ball of claim 39, wherein at least one of the first mantle layer, second mantle layer, or cover comprises a polymer containing an acid group that is neutralized by an organic acid or a salt thereof, the organic acid or salt thereof being present in an amount sufficient neutralize the polymer by at least about 70%.

48. The golf ball of claim 47, wherein the polymer comprises ionomeric copolymers and terpolymers, ionomer precursors, thermoplastics, thermoplastic elastomers, polybutadiene rubber, balata, grafted metallocene-catalyzed polymers, non-grafted metallocene-catalyzed polymers, single-site polymers, high-crystalline acid polymers, cationic ionomers, and mixtures thereof.

49. The golf ball of claim 47, wherein the organic acid is selected from the group consisting of aliphatic organic acids, aromatic organic acids, saturated mono-functional organic acids, unsaturated mono-functional organic acids, and multi-unsaturated mono-functional organic acids.

50. The golf ball of claim 47, wherein the salt of organic acids comprise barium, lithium, sodium, zinc, bismuth, chromium, cobalt, copper, potassium, strontium, titanium, tungsten, magnesium, cesium, iron, nickel, silver, aluminum, tin, and calcium salts of stearic acid, behenic acid, erucic acid, oleic acid, linoelic acid, dimerized derivatives, and mixtures thereof.

51. The golf ball of claim 39, wherein the golf ball diameter is at least 1.68 inches.

52. The golf ball of claim 51, wherein the first mantle layer has an inner diameter of about 0.75 to 1.1 inches.

53. The golf ball of claim 39, wherein the core diameter is about 1.590 inches or greater.

54. The golf ball of claim 39, wherein the cover has a thickness of from about 0.015 to 0.12 inches.

55. The golf ball of claim 39, wherein the halogenated thiophenol is zinc pentachlorothiophenol.

56. The golf ball of claim 39 having a moment of inertia of greater than 0.460 oz-in².

57. The golf ball of claim 39 having a moment of inertia of less than 0.450 oz-in².