Method of making a golf ball product from fast-curling reaction injection molded polyurethane

• US 7,067,081 B2
• Filed: 01/12/2001
• Issued: 06/27/2006
• Est. Priority Date: 10/21/1998
• Status: Expired due to Fees

• Current Assignee: Wilson Sporting Goods Company (Anta International Group Holdings Ltd.)
• Original Assignee: Wilson Sporting Goods Company (Anta International Group Holdings Ltd.)
• Inventors: Simonutti, Frank M., Peterson, Ralph E., Matheny, Richard D.
• Primary Examiner(s): Lee, Edmund H.
• Application Number:
  US09/760,431
• Publication Number:
  US 20020016435A1
• Time in Patent Office: 1,992 Days
• Field of Search: 264/279.1, 264/328.18, 264/328.6
• US Class Current: 264/279.1
• CPC Class Codes: A63B 37/0004 Surface depressions or protrusions
• CPC Class Codes: A63B 37/0023 Covers
• CPC Class Codes: A63B 37/0024 Materials other than ionomers or polyurethane
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0053 Thread wound
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0065 Deflection or compression
• 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 37/06 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: B29B 7/7471 Mixers in which the mixing takes place at the inlet of a mould, e.g. mixing chambers situated in the mould opening
• CPC Class Codes: B29B 7/7495 for mixing rubber
• CPC Class Codes: B29B 7/7615 characterised by arrangements for controlling, measuring or regulating, e.g. for feeding or proportioning the components
• CPC Class Codes: B29B 7/826 Apparatus therefor
• CPC Class Codes: B29C 67/246 Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM] casting monomers B29C39/006, mixing construction B29B7/74
• CPC Class Codes: C08G 18/10 Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
• CPC Class Codes: C08G 18/6685 with compounds of group C08G18/3225 or polyamines of C08G18/38
• CPC Class Codes: C08G 2120/00 : Compositions for reaction injection moulding processes

Abstract

Golf ball products are made by reaction injection molding (RIM) fast curing thermoset polyurethane compounds. A polyurethane prepolymer and a curing agent are mixed and injected at low temperature and pressure into a closed mold where the reaction mixture gels. The mold is opened and the golf ball product is removed within 10–60 seconds after the injection step.

Claims

1. A method of forming a cover on a golf ball product comprising:

positioning a spherical uncovered golf ball product in the center of a mold, the mold having a spherical mold surface,

closing the mold around the golf ball product,

mixing a polyurethane prepolymer and a curing agent to form a thermoset reaction mixture,

reaction injection molding the reaction mixture in the mold to form a golf ball cover layer over the golf ball product therein,

allowing the reaction mixture to gel and form a golf ball, and

opening the mold and removing the golf ball within about 10 to 60 seconds after the injecting step.

2. The method of claim 1 in which the spherical mold surface includes projections for forming dimples in the golf ball cover layer.

3. The method of claim 1 in which said step of injecting the reaction mixture into the closed mold is performed within 0.5 to 10 seconds.

4. The method of claim 1 in which the polyurethane prepolymer has a viscosity of less than 1000 cps at 25°

C.

5. The method of claim 4 in which the curing agent has a viscosity of less than 2000 cps at 25°

C.

6. The method of claim 1 in which the curing agent has a viscosity of less than 2000 cps at 25°

C.

7. The method of claim 1 in which the uncovered golf ball product is a wound golf ball core.

8. The method of claim 1 in which the uncovered golf ball product is a solid core.

9. The method of claim 1 in which the uncovered golf ball product comprises a solid core and a mantle layer surrounding the core.

11. The method of claim 1 in which the polyurethane prepolymer is selected from the class consisting of meta-toluene diisocyanate, 4,4′

-diphenylmethane diisocyante, pmdi, 3,3′

-dimethyl-4,4-biphenyl diisocyanate, naphthalene diisocyanate, and para-phenylene diisocyanate.

12. The method of claim 1 in which the mold is opened and the golf ball is removed about 45 seconds after the injecting step.

10. The method of clam 1 in which the uncovered golf ball product comprises a solid core and a lattice structure over the core.

13. A method of producing a golf ball having a golf ball cover layer including a polyurethane, said method comprising:

providing a first reactant which is an isocyanate;

providing a second reactant selected from the group consisting of a polyol, a polyamine, and combinations thereof;

heating said first reactant to a temperature of from about 80°

to about 130°

F.;

heating said second reactant to a temperature of from about 80°

to about 150°

F.;

mixing said first reactant and said second reactant together to form a thermoset reaction mixture;

providing a molding assembly defining a molded cavity and having a golf ball component positioned within said molding cavity;

closing the molding assembly around the golf ball component;

reaction injection molding said thermoset reaction mixture in said molding cavity; and

molding a golf ball cover layer about said golf ball component from said thermoset reaction mixture, thereby producing said golf ball.

14. The method of claim 13 wherein said second reactant is a polyol.

16. The method of claim 13 further comprising:

adding a density-increasing filler to at least one of said first reactant and said second reactant.

15. The method of clam 13 further comprising:

heating said molding assembly to a temperature of about 140°

to 170°

F.