Golf ball covers made from plasticized thermoplastic materials

• US 9,901,782 B2
• Filed: 01/27/2017
• Issued: 02/27/2018
• Est. Priority Date: 01/10/2008
• Status: Active Grant

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Sullivan, Michael J., Binette, Mark L., Blink, Robert, Bulpett, David A., Comeau, Brian, Goguen, Douglas S.
• Primary Examiner(s): Gorden, Raeann
• Application Number:
  US15/417,398
• Publication Number:
  US 20170136310A1
• Time in Patent Office: 396 Days
• Field of Search: 473376
• CPC Class Codes: A63B 37/0024 Materials other than ionomers or polyurethane
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0039 characterised by the material
• CPC Class Codes: A63B 37/0043 Hardness
• CPC Class Codes: A63B 37/0044 Hardness gradient
• CPC Class Codes: A63B 37/006 Physical properties
• CPC Class Codes: A63B 37/0063 Hardness gradient
• 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 37/00922 whereby hardness of the cover is lower than hardness of the intermediate layers
• CPC Class Codes: C08K 5/101 of monocarboxylic acids
• CPC Class Codes: C08L 21/00 Compositions of unspecified rubbers
• CPC Class Codes: C08L 9/00 Compositions of homopolymers or copolymers of conjugated diene hydrocarbons

Abstract

Multi-layered golf balls containing a two or three-layered cover assembly are provided. In one embodiment, the cover assembly includes a relatively hard inner cover and relatively soft outer cover. Alternatively, the cover assembly may include a relatively soft inner cover with a relatively hard outer cover. Three-layered covers comprising an inner cover, intermediate cover, and outer cover layer also may be prepared. Preferably, at least one of the layers is formed from a thermoplastic composition that preferably comprises: a) ethylene acid copolymer, b) plasticizer, and c) cation source. A fatty acid ester such as ethyl oleate is preferably used as the plasticizer. The cover assembly has good impact durability and helps provide the ball with relatively high resiliency at given compressions.

Claims

1. A golf ball, comprising:

i) a core having at least one layer;

ii) an inner cover layer being disposed about the core;

iii) an intermediate cover layer comprising a thermoplastic material, the intermediate layer being disposed about the inner cover layer, the thermoplastic material comprising;

a) an acid copolymer of ethylene and an α

,β

-unsaturated carboxylic add, optionally including a softening monomer selected from the group consisting of alkyl acrylates and methacrylates;

b) a plasticizer in an amount of about 3 to about 50%, the plasticizer being an alkyl oleate selected from the group consisting of methyl oleate, ethyl oleate, propyl oleate, butyl oleate, and octyl oleate, and mixtures thereof; and

c) a cation source present in an amount sufficient to neutralize from about 0 to about 100% of all acid groups present in the material; and

iv) an outer cover layer disposed about the intermediate cover layer, the outer cover layer comprising a polymer selected from the group consisting of polyurethanes, polyureas, polyurethane-polyurea hybrids, and blends thereof.

2. The golf ball of claim 1, wherein the core is single-layered and comprises a polybutadiene rubber composition.

3. The golf ball of claim 1, wherein the inner cover comprises an ethylene acid copolymer ionomer composition.

4. The golf ball of claim 1, wherein the inner and intermediate cover layers have midpoint hardness levels and the outer cover layer has an outer surface hardness;

and the midpoint hardness of the inner cover layer (H_{inner cov}) is greater than the midpoint hardness of the intermediate cover layer (H_{intermed cov}) and the midpoint hardness of the H_{intermed cov} is greater than the surface hardness of the outer cover layer (H_{outer cov}).

5. The golf ball of claim 1, wherein the inner cover layer has a hardness in the range of 55 to 75 Shore D;

the intermediate cover layer has a hardness in the range of 25 to 65 Shore D; and

the outer cover layer has a hardness in the range of 15 to 60 Shore D.

6. The golf ball of claim 1, wherein the inner and intermediate cover layers have midpoint hardness levels and the outer cover layer has an outer surface hardness;

and the midpoint hardness of the inner cover layer (H_{inner cov}) is less than the midpoint hardness of the intermediate cover layer (H_{intermed cov}) and the midpoint hardness of the H_{intermed cov} is greater than the surface hardness of the outer cover layer (H_{outer cov}).

7. The golf ball of claim 6, wherein the inner cover layer has a hardness in the range of 10 to 55 Shore D;

the intermediate cover layer has a hardness in the range of 55 to 75 Shore D; and

the outer cover layer has a hardness in the range of 25 to 65 Shore D.

8. The golf ball of claim 1, wherein the inner and intermediate cover layers have midpoint hardness levels and the outer cover layer has an outer surface hardness;

and the midpoint hardness of the inner cover layer (H_{inner cov}) is less than the midpoint hardness of the intermediate cover layer (H_{intermed cov}), and the midpoint hardness of the intermediate cover layer (H_{intermed cov}) is less than the surface hardness of the outer cover layer (H_{outer cov}).

9. The golf ball of claim 8, wherein the inner cover layer has a hardness in the range of 10 to 55 Shore D;

the intermediate cover layer has a hardness in the range of 25 to 65 Shore D; and

the outer cover layer has a hardness in the range of 55 to 75 Shore D.

10. A golf ball, comprising:

i) a core having at least one layer;

ii) an inner cover layer comprising a thermoplastic material, the inner cover being disposed about the core, the thermoplastic composition comprising;

a) an acid copolymer of ethylene and an α

,β

-unsaturated carboxylic acid, optionally including a softening monomer selected from the group consisting of alkyl acrylates and methacrylates;

b) a plasticizer in an amount of about 3 to about 50%, the plasticizer being an alkyl oleate selected from the group consisting of methyl oleate, ethyl oleate, propyl oleate, butyl oleate, and octyl oleate, and mixtures thereof; and

c) a cation source present in an amount sufficient to neutralize from about 0 to about 100% of all acid groups present in the material;

iii) an intermediate cover layer comprising a thermoplastic material, the intermediate layer being disposed about the inner cover layer; and

iv) an outer cover layer disposed about the intermediate cover layer.

11. The golf ball of claim 10, wherein the core is single-layered and comprises a polybutadiene rubber composition.

12. The golf ball of claim 10, wherein the intermediate cover comprises an ethylene acid copolymer ionomer composition.

13. The golf ball of claim 10, wherein the outer cover comprises a polyrner selected from the group consisting of polyurethanes, polyureas, polyurethane-polyurea hybrids, and blends thereof.