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

• US 7,888,448 B2
• Filed: 02/27/2008
• Issued: 02/15/2011
• 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: Kuntimaddi, Manjari, Wu, Shenshen, Rajagopalan, Murali
• Primary Examiner(s): BUTTNER, DAVID J
• Application Number:
  US12/071,902
• Publication Number:
  US 20080214735A1
• Time in Patent Office: 1,084 Days
• Field of Search: None
• US Class Current: 528/45
• 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 formed from the reaction product of a half-blocked intermediate and an amine-terminated component, wherein the half-blocked intermediate is the reaction product of an isocyanate having terminal isocyanate groups and a first curing agent comprising a blocked, delayed action curative;

providing a second polymeric precursor comprising an acrylate resin;

adding a second curing agent to the second polymeric precursor to form a second polymeric system;

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 first curing agent 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.

2. The method of claim 1, wherein the step of adding occurs prior to the steps of combining and elevating.

3. The method of claim 1, wherein the first curing agent comprises a diamine.

4. The method of claim 1, wherein the blocked, delayed action curative comprises a salt complex.

5. The method of claim 1, wherein the blocked, delayed action curative comprises a complex of methylene dianiline and sodium chloride.

6. The method of claim 1, wherein the step of elevating comprises elevating the temperature in the vessel to about 185°

F. to about 325°

F.

7. The method of claim 6, wherein the step of elevating comprises elevating the temperature in the vessel to about 195°

F. to about 315°

F.

8. The method of claim 7, wherein the step of elevating comprises elevating the temperature in the vessel to about 205°

F. to about 305°

F.

9. The method of claim 1, wherein the second curing agent is selected from the group consisting of benzoyl peroxide, t-amyl peroxide, and mixtures thereof.

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

providing a first polymeric precursor comprising the reaction product of a half-blocked intermediate and an amine-terminated component, wherein the half-blocked intermediate is the reaction product of an isocyanate and a first curing agent comprising a blocked, delayed action curative comprising a salt complex;

providing a second polymeric precursor comprising an acrylate resin;

adding a second curing agent to the second polymeric precursor to form a second polymeric system;

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

elevating the temperature in the vessel to about 175°

F. to about 350°

F. 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.

11. The method of claim 10, wherein the step of adding occurs prior to the steps of combining and elevating.

12. The method of claim 10, wherein the step of providing a first polymeric precursor further comprises the step of forming a blocked, delayed action curative by:

dispersing sodium chloride in dioctyl phthalate; and

complexing the sodium chloride with methylene dianiline.

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

providing a half-blocked intermediate that is the reaction product of an isocyanate and a curative comprising a salt complex having a deblocking temperature ranging from 212°

F. to 302°

F.;

reacting the half-blocked intermediate with an amine-terminated component to form a first polymeric precursor;

providing a second polymeric precursor comprising an acrylate resin;

adding a second curing agent to the second polymeric precursor to form a second polymeric system;

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

elevating the temperature in the vessel to the deblocking temperature 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.

14. The method of claim 13, wherein the curative comprises a complex of methylene dianiline and sodium chloride dispersed in dioctyl phthalate.

15. The method of claim 13, wherein the step of adding a second curing agent comprises adding an initiator selected from the group consisting of benzoyl peroxide, t-amyl peroxide, and mixtures thereof.