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

• US 7,339,010 B2
• Filed: 07/28/2004
• Issued: 03/04/2008
• Est. Priority Date: 04/13/2001
• Status: Expired due to Fees

• 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:
  US10/900,456
• Publication Number:
  US 20050009635A1
• Time in Patent Office: 1,315 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 method of forming a portion of a golf ball comprising the steps of:

providing a first polymeric precursor comprising a polyurethane or polyurea prepolymer having blocked isocyanate groups and a first curing agent;

providing a second polymeric precursor comprising an epoxy resin;

adding a second curing agent to the second polymeric precursor to form a second polymeric system wherein the second curing agent is substantially unreactive with the first polymeric precursor;

combining the first polymeric precursor and second polymeric system in a vessel;

elevating the temperature in the vessel to an amount sufficient to unblock the isocyanate groups in the first polymeric component to provide a first polymeric system resulting in an interpenetrating polymer network (“

IPN”

) comprising the first and second polymeric systems; and

forming the IPN into the portion of the golf ball, wherein the step of adding occurs prior to the steps of combining and elevating.

2. The method of claim 1, wherein at least about 80 percent of the isocyanate groups are blocked.

3. The method of claim 1, wherein the step of providing the first polymeric precursor further comprises the steps of:

providing an isocyanate having terminal isocyanate groups;

providing a polyol or amine-terminated component;

reacting the isocyanate and polyol or amine-terminated component to form a prepolymer;

blocking the terminal isocyanate groups; and

adding the first curing agent.

4. The method of claim 3, wherein the step of blocking the terminal isocyanate groups further comprises the steps of:

providing a blocking agent; and

blocking the terminal isocyanate groups with the blocking agent to form a blocked prepolymer.

5. The method of claim 4, wherein the blocking agent comprises 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;

or mixtures thereof.

6. The method of claim 1, wherein the step of providing the first polymeric precursor further comprises the steps of:

providing an isocyanate having terminal isocyanate groups;

providing a blocking agent;

reacting the isocyanate and blocking agent to form a half-blocked intermediate;

providing a polyol or amine-terminated component;

reacting the half-blocked intermediate with a polyol or amine-terminated component to form a prepolymer; and

adding the first curing agent.

7. The method of claim 6, wherein the blocking agent comprises 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;

or mixtures thereof.

8. The method of claim 1, wherein the IPN is included in a cover layer disposed about a center.

9. The method of claim 1, wherein the second curing agent is substantially unreactive with the first polymeric precursor.

10. A method of forming a portion of a golf ball comprising the steps of:

providing a first polymeric component comprising an isocyanate, a polyol or amine-terminated component and a blocked, delayed action curative;

providing a second polymeric component comprising an epoxy resin or acrylate resin;

reacting the second polymeric component with a second curing agent to form a second polymeric system, wherein the second curing agent is substantially unreactive with first polymeric component;

combining the first polymeric component and second polymeric system;

exposing the first polymeric component to elevated temperature to form a first polymeric system resulting in an interpenetrating network (“

IPN”

) comprising the first and second polymeric systems; and

forming the IPN into the portion of the golf ball,

wherein the step of reacting occurs prior to the steps of combining and exposing.

11. The method of claim 10, wherein the step of providing the first polymeric component further comprises the steps of:

providing an isocyanate having terminal isocyanate groups; and

reacting the isocyanate and a polyol or amine-terminated component to form a prepolymer.

12. The method of claim 10, wherein the step of providing the first polymeric component further comprises the steps of:

providing an isocyanate having terminal isocyanate groups;

reacting the isocyanate and polyol or amine-terminated component to form a prepolymer; and

adding the blocked, delayed action curative to the prepolymer.

13. The method of claim 10, wherein the blocked, delayed action curative comprises a diamine.

14. The method of claim 10, wherein the step of providing the first polymeric component further comprises the steps of:

providing an isocyanate having terminal isocyanate groups;

reacting the isocyanate and the blocked, delayed action curative to form a half-blocked intermediate;

reacting the half-blocked intermediate with the polyol or amine-terminated component to form a prepolymer.

15. The method of claim 14, wherein the blocked, delayed action curative comprises methylene dianiline.

16. The method of claim 10, wherein the second curing agent comprises a catalyst complex comprising BF₃ and 4-chlorobenzenamine.