Interpenetrating polymer networks using blocked polyurethane/polyurea prepolymers for golf ball layers

• US 7,157,527 B2
• Filed: 07/28/2004
• Issued: 01/02/2007
• Est. Priority Date: 04/13/2001
• Status: Expired due to Term

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Wu, Shenshen, Kuntimaddi, Manjari, Rajagopalan, Murali
• Primary Examiner(s): Buttner; David J.
• Application Number:
  US10/900,459
• Publication Number:
  US 20050009636A1
• Time in Patent Office: 888 Days
• Field of Search: None
• US Class Current: 525/454
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/00221 characterised by the material
• CPC Class Codes: A63B 37/0024 Materials other than ionomers or polyurethane
• CPC Class Codes: A63B 37/003 Coefficient of restitution
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0034 Deflection or compression
• CPC Class Codes: A63B 37/0037 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0051 Materials other than polybutadienes; Constructional details
• 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: 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 18/3206 aliphatic
• CPC Class Codes: C08G 2270/00 Compositions for creating interpenetrating networks
• 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 2666/22 Macromolecular compounds not provided for in C08L2666/16 - C08L2666/20
• CPC Class Codes: C08L 75/04 Polyurethanes

Abstract

The present invention is directed to a method of forming a golf ball that contains an interpenetrating polymer network, or IPN, which includes at least two polymeric systems, in one or more of the layers. The first polymeric system may include a polyurethane-based or polyurea-based system having blocked isocyanate groups and the second polymeric system may include an epoxy-based or acrylic-based system, wherein the two systems are polymerized or cured simultaneously or sequentially to form an IPN.

Claims

1. A golf ball comprising at least one layer formed from an interpenetrating polymer network comprising:

a first polymeric system comprising a polyurea prepolymer cured with a first curing agent, wherein the prepolymer comprises an isocyanate having terminal isocyanate groups, a blocking agent, and a polyamine; and

a second polymeric system comprising an epoxy resin and a second curing agent.

2. The golf ball of claim 1, wherein the blocking agent is selected from the group consisting of linear and branched alcohols;

phenols and phenol derivatives;

oximes;

lactams;

lactones;

β

-dicarbonyl compounds;

hydroxamic acid esters;

bisulfite addition compounds;

hydroxylamines;

esters of p-hydroxybenzoic acid;

N-hydroxyphthalimide;

N-hydroxysuccinimide;

triazoles;

substituted imidazolines;

tetrahydropyrimidines;

caprolactones; and

mixtures thereof.

3. The golf ball of claim 2, wherein the blocking agent is selected from the group consisting of phenols, branched alcohols, methyl ethyl ketoxime, ε

-caprolactam, ε

-caprolactone, and mixtures thereof.

4. The golf ball of claim 1, wherein the second curing agent is selected from the group consisting of anhydrides, Lewis bases, amines, amides, Lewis acids, and mixtures thereof.

5. The golf ball of claim 1, wherein at least about 80 percent of the terminal isocyanate radicals groups are blocked.

6. The golf ball of claim 5, wherein at least about 95 percent or more of the terminal isocyanate groups are blocked.

7. The golf ball of claim 1, wherein the at least one layer comprises a cover layer.

8. The golf ball of claim 7, wherein the cover layer comprises an inner cover layer and an outer cover layer.

9. The golf ball of claim 8, wherein the inner cover layer is formed from the interpenetrating polymer network.

10. The golf ball of claim 8, wherein the outer cover layer is formed from the interpenetrating polymer network.

11. A golf ball comprising a core and a cover, wherein a portion of the golf ball is formed from an interpenetrating polymer network comprising:

a first polymeric system comprising an isocyanate having terminal isocyanate groups, an amine-terminated component, and a blocked, delayed action curative; and

a second polymeric system comprising an epoxy resin and a curing agent.

12. The golf ball of claim 11, wherein the curing agent is selected from the group consisting of anhydrides, Lewis bases, amines, amides, Lewis acids, and mixtures thereof.

13. The golf ball of claim 11, wherein the blocked delayed action amine curative comprises methylene dianiline and sodium chloride.

14. The golf ball of claim 13, wherein the blocked delayed action amine curative has a deblocking temperature of about 175°

F. to about 350°

F.

15. The golf ball of claim 11, wherein at least about 95 percent or more of the terminal isocyanate groups are blocked.

16. The golf ball of claim 11, wherein at least about 97 percent or more of the terminal isocyanate groups are blocked.

17. The golf ball of claim 11, wherein the portion comprises the cover.