TW201321046A - 高爾夫球模壓成型的方法 - Google Patents

高爾夫球模壓成型的方法 Download PDF

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Publication number
TW201321046A
TW201321046A TW101134125A TW101134125A TW201321046A TW 201321046 A TW201321046 A TW 201321046A TW 101134125 A TW101134125 A TW 101134125A TW 101134125 A TW101134125 A TW 101134125A TW 201321046 A TW201321046 A TW 201321046A
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TW
Taiwan
Prior art keywords
core layer
inner core
golf ball
outer core
approximately
Prior art date
Application number
TW101134125A
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English (en)
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TWI546104B (zh
Inventor
Che-Ching Lin
Original Assignee
Nike International Ltd
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Publication date
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Publication of TW201321046A publication Critical patent/TW201321046A/zh
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Publication of TWI546104B publication Critical patent/TWI546104B/zh

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    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B45/00—Apparatus or methods for manufacturing balls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0042—Producing plain balls
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B37/00—Solid balls; Rigid hollow balls; Marbles
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B37/00—Solid balls; Rigid hollow balls; Marbles
    • A63B37/0003—Golf balls
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B37/00—Solid balls; Rigid hollow balls; Marbles
    • A63B37/0003—Golf balls
    • A63B37/0023—Covers
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B37/00—Solid balls; Rigid hollow balls; Marbles
    • A63B37/0003—Golf balls
    • A63B37/0023—Covers
    • A63B37/0024—Materials other than ionomers or polyurethane
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B37/00—Solid balls; Rigid hollow balls; Marbles
    • A63B37/0003—Golf balls
    • A63B37/0023—Covers
    • A63B37/0029—Physical properties
    • A63B37/0036—Melt flow rate [MFR]
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B37/00—Solid balls; Rigid hollow balls; Marbles
    • A63B37/0003—Golf balls
    • A63B37/005—Cores
    • A—HUMAN NECESSITIES
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    • A63B37/0003—Golf balls
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    • A63B37/0051—Materials other than polybutadienes; Constructional details
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    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
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    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73753—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized
    • B29C66/73754—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized the to-be-joined areas of both parts to be joined being partially cured
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/90—Measuring or controlling the joining process
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Abstract

一種製造高爾夫球的方法，包括：製成球形內球芯層；在壓模中製成兩個半球形殼；以及將這兩個半球形殼圍繞內球芯層組裝成外球芯層。此外，該方法可以包括在引起內球芯層熔融的溫度下固化兩個半球形殼以通過使殼圍繞內球芯層模壓成型從而製成整體的外球芯層。

Description

高爾夫球模壓成型的方法 發明領域
本發明總體上涉及製造高爾夫球的方法，尤其涉及用於製造高爾夫球的模壓成型技術。
發明背景
高爾夫球手通常根據自己的偏好和/或技能選擇具有特徵的組合的高爾夫球。在一些情況下，可能期望高爾夫球的內球芯由熱塑性材料製成。儘管熱塑性內球芯層可以通過模壓成型製成，但在一些情況下可能期望通過注塑成型製成熱塑性內球芯層。在一些製造工藝中，例如注塑成型，高爾夫球材料內的氣體或材料之間的氣體會導致在製造高爾夫球時在高爾夫球的層中和/或層之間形成氣孔(氣泡)。
高爾夫球中的氣泡會影響一些高爾夫球特徵。因為氣泡中的氣體與用於製成高爾夫球的任何材料相比更加可壓縮，高爾夫球中的氣孔會不利地影響高爾夫球的若干性能。例如，氣孔會以不期望的方式吸收一些球桿的撞擊，從而減小當擊打這樣的高爾夫球時可獲得的距離。
氣泡的一個可能的起因可能是熱塑性材料的高水分。氣泡的另一個可能的起因可能與注塑成型工藝的參數有關。例如，如果注塑速度太快可能會導致氣泡。
已經提出在製造過程中阻止在高爾夫球中形成氣孔的 方法。例如，一個這樣的方法包括在球芯的外表面上形成槽。當將外層模制到球芯上時，層之間的氣體趨於通過槽漏出從而阻止氣體困在層之間並形成空隙。儘管該工藝試圖避免層間氣孔的形成，但該工藝沒有解決層內可能形成氣孔的問題。
本發明的目的在於改進高爾夫球模塑工藝。
發明概要
一方面，本發明旨在提供一種製造高爾夫球的方法。該方法可以包括製成球形內球芯層、在壓模中製成兩個半球形殼以及將這兩個半球形殼圍繞內球芯層組裝為外球芯層。此外，該方法可以包括在引起內球芯層熔融的溫度下固化兩個半球形殼以通過使殼圍繞內球芯層模壓成型從而製成整體的外球芯層。
另一方面，本發明旨在提供一種製造高爾夫球的方法。該方法可以包括製成球形內球芯層、在壓模中製成兩個半球形殼以及將這兩個半球形殼圍繞內球芯層組裝成外球芯層。此外，該方法可以包括在高於內球芯層材料的熔點至少30℃的溫度下固化這兩個半球形殼以通過使殼圍繞內球芯層模壓成型從而製成整體的外球芯層。
另一方面，本發明旨在提供一種高爾夫球。該高爾夫球可以包括表層、在表層的徑向向內設置的外球芯層以及在外球芯層的徑向向內設置的內球芯層。外球芯層可以由具有高於內球芯層的熔點至少30℃的固化溫度的材料製 成。
通過下面附圖及詳細的說明，對於本領域技術人員來說，本發明另外的系統、方法、特徵和優點會是或者會變得顯而易見。該說明書試圖在本發明範圍內包括所有那些另外的系統、方法、特徵和優點，並且使其受所述申請專利範圍的保護。
100‧‧‧高爾夫球
105‧‧‧表層
110‧‧‧外球芯層
115‧‧‧內球芯層
120‧‧‧直徑
200‧‧‧高爾夫球
205‧‧‧外表層
210‧‧‧內表層
215‧‧‧外球芯層
220‧‧‧內球芯層
225‧‧‧直徑
230‧‧‧凹坑
300‧‧‧壓模
305‧‧‧底部模
310‧‧‧腔
315‧‧‧中間板
320‧‧‧突出
325‧‧‧頂面
327‧‧‧縱軸
330‧‧‧底面
335‧‧‧頂部模
340‧‧‧腔
345‧‧‧半球形頂部空隙
350‧‧‧半球形底部空隙
355‧‧‧第一半球形外球芯殼
360‧‧‧第二半球形外球芯殼
365‧‧‧箭頭
參考下列附圖和說明，可以更好地理解本發明。附圖中的構成要素不一定按比例繪製，而是重點用於說明本發明的原理。而且，在不同視圖中，類似的附圖標記標示相應的部分。
圖1表示根據本發明的示例性高爾夫球的剖切的局部橫截面圖，其中高爾夫球為三件式結構；圖2表示根據本發明的示例性高爾夫球的剖切的局部橫截面圖，其中高爾夫球是四件式結構；圖3是用於製成外球芯層殼和圍繞內球芯層固化外球芯層殼的示例性壓模的分解圖；圖4是圖3的壓模的橫截面、組裝圖；圖5是在圖3的壓模中製成的外球芯層殼以及內球芯層的橫截面圖；圖6是組裝的用於在內球芯層周圍固化外球芯層的壓模的橫截面圖；以及圖7是利用圖6所示的模壓成型工藝製成的高爾夫球的橫截面圖。
具體實施方式 發明概述
本發明總體上涉及一種製造高爾夫球的工藝。本發明尤其涉及一種減少高爾夫球的內球芯層中的氣泡的工藝。
高爾夫球的性能特徵至少部分由層的結構構造和/或層的材料組分決定。高爾夫球的總體性能特徵以某種方式受各個層的組成的影響，並且還反映了製成高爾夫球的層和材料的結合和佈置。本發明所討論的思想可以適用於具有任何結構、包括任何適合數量的層的高爾夫球。在一些實施例中，可以實施這裡公開的方法以製造具有三層結構的高爾夫球。在其它實施例中，該方法可以用於製成具有四層結構的球。此外，該方法可以用於製成具有包括五層或更多層的其它結構的高爾夫球。
此外，儘管本發明描述了製造高爾夫球的各種方法，但本領域技術人員將能夠將本發明公開的思想用於製造(除了高爾夫球以外)其它類型的球的方法中並且用於製造其它類型的層狀物件。例如，本發明公開的思想可以適用於製造任何層狀物件，如拋射體(projectile)、娛樂設備或這些物件的各個元件。
3-層球結構
圖1表示示例性三層高爾夫球結構的剖切的局部橫截面圖。如圖1所示，高爾夫球100可以包括表層105、在表層105的徑向向內設置的外球芯層110以及在外球芯層110的 徑向向內設置的內球芯層115。可以選擇每一層的尺寸和材料以獲得期望的性能特徵。
表層105可以由相對軟但耐用的材料製成。例如，表層105可以由在被高爾夫球桿擊打時壓縮/彎曲的材料製成，從而為高爾夫球手提供球的旋轉和手感。儘管相對軟，但該材料也可以是耐用的，以便經受來自球桿和/或高爾夫球場的刮擦。示例性表層材料可以包括氨基甲酸酯(urethane)或離聚物混合物，和/或任何其它適合的材料。
此外，圖1將表層105的外表面表示為具有一般的凹坑樣式。儘管高爾夫球100上的凹坑樣式會影響高爾夫球100的飛行路徑，但任何適合的凹坑樣式可以與公開的實施例一起使用。在一些實施例中，高爾夫100可以具有包括凹坑總數量在近似300至400之間的凹坑樣式。
外球芯層110可以由相對堅硬並適度彈性的材料製成。可以將外球芯層110設置成在用長擊桿擊打球時提供相對大的發球角度和相對低的旋轉率，並且在用鐵桿擊打時提供相對較高的旋轉率和增加的控制。這樣可以在綠地附近為離開球座的距離提供旋轉和控制。內球芯層115可以由相對堅硬的材料製成從而提供距離。
為了獲得期望的性能特徵，可以改變高爾夫球層的厚度。在一些實施例中，內球芯層115的直徑可以在約19mm至30mm的範圍內。例如，在一些實施例中，內球芯層115可以是具有近似24mm至28mm的直徑120的球。
儘管本發明公開的思想可以適用於三件式高爾夫球， 例如高爾夫球100，但為了說明的目的，以下將針對四件式高爾夫球結構對公開的思想進行更加詳細的說明。然而，應當理解的是，以上和/或以下公開的思想適用於具有三件式結構、四件式結構、五件式結構或任何其它適合的結構的高爾夫球。
4-層球結構
圖2是具有四件式結構的高爾夫球200的剖切的局部橫截面圖。如圖2所示，高爾夫球200可以具有相互鄰接設置的四個層。例如，在一些實施例中，高爾夫球200可以包括外表層205和在外表層205的徑向向內設置的內表層210。高爾夫球200還可以包括在內表層210的徑向向內設置的外球芯層215以及在外球芯層215的徑向向內設置的內球芯層220。任一層可以包圍或實質上包圍在該層的徑向向內設置的任一層。例如，外球芯層215可以包圍或實質上包圍內球芯層220。
在本發明和附圖中，對高爾夫球200進行描述並將其示為具有四個層。在一些實施例中，可以增加至少一個附加層。例如，在一些實施例中，可以在外球芯層215和內表層210之間增加覆蓋層。在一些實施例中，可以在內表層210和外表層205之間插入中間表層。此外，在一些實施例中，可以在內球芯層220和外球芯層215之間插入中間球芯層。可以根據需要在任何公開的層的任一側增加其它層從而獲得某些性能特徵和/或屬性。
在一些實施例中，根據高爾夫球規則(Rules of Golf)， 高爾夫球200的直徑可以是至少42.67mm(1.680英寸)。例如，在一些實施例中，高爾夫球200的球直徑可以在約42.67mm和約42.9mm之間，並且，在一些實施例中，球直徑可以是約42.7mm。高爾夫球200的球重量可以在約45 g和約45.8 g之間，並且，在一些實施例中，球重量可以是約45.4 g。
為了獲得期望的性能特徵，可以改變高爾夫球200的層的厚度。在一些實施例中，外表層205的厚度可以是近似0.5mm至2mm。此外，在一些實施例中，內表層210的厚度可以是近似0.5mm至2mm。在一些實施例中，外表層205和/或內表層210的厚度可以是近似0.8mm至2mm。在一些實施例中，外表層205和/或內表層210的厚度可以是近似1mm至1.5mm。
在一些實施例中，外球芯層215的厚度可以是至少約5mm。在一些實施例中，內球芯層220可以是具有在近似21mm至30mm範圍內的直徑225的球。在一些實施例中，內球芯層220的直徑225可以在近似24mm至28mm的範圍內。例如，在一些實施例中，直徑225可以是24mm。在其它實施例中，直徑225可以是28mm。
內球芯層的形成
一種根據本發明的製造高爾夫球的方法可以包括製成球形內球芯層。在一些實施例中，內球芯層可以通過模塑製成，例如通過注塑成型製成。在一些實施例中，注塑成型的材料可以包括熱塑性材料。可以在模塑之前採取措施 以確保材料的水分維持在預定的限度以下。
在一些實施例中，公開的方法可以包括執行乾燥工藝，包括將將要用於製成內球芯層220的材料保存密封在能夠產生乾燥空氣的防潮乾燥器中。乾燥工藝可以包括維持材料在50℃環境下近似2至24小時。此外，如果水分已經超過預定閾值，為了去除水分，乾燥工藝可以包括利用真空和/或加熱。例如，在一些實施例中，該閾值可以是近似2,000 ppm。
內球芯層220可以利用模塑工藝製成，例如注塑成型。可以利用注塑機(未示出)進行注塑成型。例如，可以將熱塑性或其它適合的材料注入球形模(未示出)中。本領域技術人員將熟知用於注塑成型球形的技術和設備。
可以在近似190℃至220℃範圍的溫度下對內球芯層220進行注塑。注塑成型工藝之後，可以將內球芯層220從注塑機中取出，並使其經歷冷卻工藝。在一些實施例中，內球芯層220可以在室溫下冷卻。在其它實施例中，內球芯層220可以在控制到預定條件的空調環境中冷卻。在一些情況下，冷卻工藝可以包括任何適合持續時間的冷卻時間。例如，可以確定冷卻時間使得注塑成型工藝之後內球芯層220的形狀得到保持。在一些情況下，冷卻時間可以是近似1至8小時。
外球芯層殼的模壓成型
外球芯層可以在兩個模壓成型(硫化)步驟中製成。首先，可以將外球芯層材料置於外球芯層形成模中並經歷第 一硫化步驟，以便產生一對半硫化半球形殼。在該第一硫化步驟之後，可以從壓模的一側將預製的內球芯層(例如，通過上述方式製成)置於半球形殼內，並且之後可以進一步將該結合從壓模的另一側與半球形殼結合。然後內球芯層和兩個外球芯層殼的組裝可以在第二硫化步驟中固化。
圖3是在上述第一硫化步驟中用於製成外球芯層殼以及在上述第二硫化步驟中用於固化內球芯層和外球芯層半球形殼的結合的示例性壓模300的分解圖。壓模300可以包括具有多個半球形腔310的底部模305以及實質上與底部模305相同並且包括多個對應於底部模305的腔310的半球形腔的頂部模(圖3中未示出)。此外，壓模300可以包括中間板315，該中間板315具有從中間板315的頂面325延伸以及從板315的底面330延伸的多個突出320。突出320可以對應於底部模305中的腔310，也可以對應於頂部模中的腔。為了說明的目的，所示的壓模300具有三個腔。根據本領域技術人員應當理解的製造考慮因素，可以改變壓模300中的腔的數量。
圖4是沿圖3的線4位置的壓模300的縱軸327的壓模300的橫截面圖。圖4中，所示的壓模300是組裝好的。如圖4所示，可以將中間板315置於底部模305的上方，使得突出320延伸至腔310中。此外，可以將具有腔340的頂部模335置於中間板315之上，使得突出320向上延伸至腔340中。以該方式組裝，壓模300可以限定半球形頂部空隙345和半球形底部空隙350。
可以在半球形頂部空隙345和半球形底部空隙350中將外球芯層材料模塑成半球形殼。例如，圖5表示第一半球形外球芯殼355和第二半球形外球芯殼360的橫截面圖，它們分別在壓模300的半球形頂部空隙345和半球形底部空隙350中製成。此外，圖5還表示以上述方式製成的內球芯層220的橫截面圖。
為了製成容納如前所述的直徑在近似19mm至30mm範圍內的內球芯層的尺寸的內殼腔，中間板315的突出320的直徑可以在近似19mm至30mm的範圍內。此外，底部模305的腔310和頂部模335的腔340的直徑可以是至少38mm。因此，可以將壓模300設置為製成至少4mm厚的半球形外球芯層殼。在一些實施例中，可以將壓模300設置為製成至少5mm厚的半球形外球芯層殼。
外球芯層殼圍繞內球芯層的模塑
以上簡要說明的第二硫化步驟表示在圖6中。如圖6所示，中間板315可以從壓模300中移除，並且半球形殼355和360可以在底部模305和頂部模335內圍繞內球芯層220組裝。在一些實施例中，內球芯層220的表面在置於半球形殼355和360中之前可以是粗糙的，以增加內球芯層220和外球芯層215之間的黏附。在一些實施例中，為了提高高爾夫球200的耐用性並提供增加的回彈，在將內球芯層220置於半球形殼355和360中之前，內球芯層220的表面可以預塗黏合劑。
應當注意的是，在一些實施例中，用半球形殼355和360 覆蓋內球芯層220可以在壓模300中進行。例如，內球芯層220與半球形殼355和360的組裝可以通過如下步驟完成：分別將半球形殼355和360留在腔340和310中，並在將頂部模335重新放置(半球形殼355依然在腔340中的適當位置)在內球芯層220的上方的適當位置並放在底部模305上之前，將內球芯層220置於底部半球形殼360中。作為選擇地，在一些實施例中，可以首先將半球形殼355和360從壓模300中移除，然後用手或工具將半球形殼355和360覆蓋在內球芯層220上，組裝好的部件可以置於腔310中，並且可以將頂部模335重新放置到組裝好的部件的上方的底部模305之上。組裝壓模300外面的部件時，在將其放置回壓模300中之前可以對該部件重新定向。例如，如圖6所示，可以將半球形殼355和360之間的界線定向為垂直於(或者以任何其它期望的角度)底部模305和頂部模335的界線。
一俟組裝好的部件固定在壓模300中，即可進行第二硫化步驟，在該步驟中，可以施加壓力，如箭頭365所示，並且可以加熱，如波浪線370所示。可以以任何適合的方式施加壓力。此外，還可以以任何適合的方式加熱，例如，通過外部加熱元件，或者結合在底部模305和/或頂部模335中的加熱元件。本領域技術人員應當認識到完成硫化的條件的適合的方式。壓力和熱的施加會導致半球形殼355和360的固化從而通過圍繞內球芯層220模壓成型殼355和360製成整體的外球芯層215。
在一些實施例中，半球形殼355和360圍繞內球芯層220 的固化可以在引起內球芯層220熔融的溫度下進行，如圖6中的內球芯層220的液態填充樣式所示。在一些實施例中，第二硫化步驟可以包括在高於內球芯層材料的熔點至少30℃的溫度下固化半球形殼355和360以通過使殼圍繞內球芯層220模壓成型製成整體的外球芯層215。因此，外球芯層215可以由具有高於內球芯層材料的熔點至少30℃的固化溫度的材料製成。在第二硫化步驟中，通過引起內球芯層220熔融，可以允許任何空氣或其它氣體從內球芯層220中逸出。
第二硫化步驟的適合條件可以包括120℃至190℃之間的固化溫度，以及5至20分鐘之間的固化時間。在一些實施例中，外球芯層215的固化溫度可以高出內球芯層220的熱塑性材料的熔點至少30℃。在一些實施例中，固化溫度可以是至少約140℃以獲得期望的橡膠交聯體並使內球芯層在硫化工藝中熔融。例如，在一些實施例中，固化溫度可以是近似140℃。
在一些實施例中，可能期望外球芯層215的厚度適於在內球芯層220處在熔融或部分熔融狀態時在後固化處理過程中阻止內球芯層220變形。在一些實施例中，為了在製造過程中對內球芯層220提供保護，外球芯層215的厚度可以是至少5mm。
外球芯層的材料
外球芯層215可以由熱固性材料製成。例如，在一些實施例中，外球芯層215可以通過交聯聚丁二烯橡膠組合物製 成。當其它橡膠與聚丁二烯結合使用時，聚丁二烯可以包括在內作為主成分。例如，整個基底橡膠中聚丁二烯的比例按重量計可以等於或大於50%，在一些實施例中，按重量計可以等於或大於80%。在一些實施例中，外球芯層215可以由聚丁二烯橡膠組合物製成，其中，聚丁二烯橡膠組合物包括具有順式-1,4鍵的比例等於或大於60mol%的比例的聚丁二烯。例如，在一些實施例中，該比例可以等於或大於80mol%。
在一些實施例中，順式-1,4-聚丁二烯可以用作基底橡膠並且與其它成分混合。在一些實施例中，順式-1,4-聚丁二烯的量基於100重量份的橡膠化合物可以是至少50重量份。可以在基底橡膠中加入各種添加劑製成化合物。添加劑可以包括交聯劑和填充料。在一些實施例中，交聯劑可以是丙烯酸鋅、丙烯酸鎂、甲基丙烯酸鋅或甲基丙烯酸鎂。在一些實施例中，丙烯酸鋅可以提供有利的彈性性能。
在一些實施例中，填充料可以包括氧化鋅、硫酸鋇、碳酸鈣或碳酸鎂。在一些實施例中，可以選擇氧化鋅，原因在於其有利的性能。在一些實施例中，可以將填充料用於增加材料的比重。例如，金屬粉末，如鎢，可以選擇地用作填充料以實現期望的比重。在一些實施例中，外球芯層215的比重可以在約1.05g/cm^3至約1.35g/cm^3的範圍內。
在一些實施例中，優選利用稀土元素催化劑合成的聚丁二烯。利用這樣的聚丁二烯可以提供具有增加的彈性的 高爾夫球200。稀土元素催化劑的例子包括鑭系稀土元素化合物、有機鋁化合物和鋁氧烷(alumoxane)以及含鹵素的化合物。優選鑭系稀土元素化合物。通過利用基於鑭系稀土的催化劑獲得的聚丁二烯通常採用鑭稀土元素(原子序數57至71)化合物的結合，但尤其優選釹化合物。
在一些實施例中，聚丁二烯橡膠組合物可以包含至少約0.5重量份至約5重量份的鹵代有機硫化合物。在一些實施例中，聚丁二烯橡膠組合物可以包含至少約1重量份至約4重量份的鹵代有機硫化合物。鹵代有機硫化合物選自由五氯苯硫酚、2-氯苯硫酚、3-氯苯硫酚、4-氯苯硫酚、2,3-氯苯硫酚、2,4-氯苯硫酚、3,4-氯苯硫酚、3,5-氯苯硫酚、2,3,4-氯苯硫酚、3,4,5-氯苯硫酚、2,3,4,5-四氯苯硫酚(2,3,4,5-tetrachlorothiophcnol)、2,3,5,6-四氯苯硫酚、五氟苯硫酚、2-氟苯硫酚、3-氟苯硫酚、4-氟苯硫酚、2,3-氟苯硫酚、2,4-氟苯硫酚、3,4-氟苯硫酚、3,5-氟苯硫酚、2,3,4-氟苯硫酚、3,4,5-氟苯硫酚、2,3,4,5-四氟苯硫酚(2,3,4,5-tetrafluorothiophenol)、2,3,5,6-四氟苯硫酚、4-氯-四氟苯硫酚(4-chlorotetrafluorothiophenol)、五碘苯硫酚(pentaiodothiophenol)、2-碘苯硫酚(2-iodothiophenol)、3-碘苯硫酚、4-碘苯硫酚、2,3-碘苯硫酚、2,4-碘苯硫酚、3,4-碘苯硫酚、3,5-碘苯硫酚、2,3,4-碘苯硫酚、3,4,5-碘苯硫酚、2,3,4,5-四碘苯硫酚、2,3,5,6-四碘苯硫酚、五溴苯硫酚(pentabromothiophenol)、2-溴苯硫酚、3-溴苯硫酚、4-溴苯硫酚、2,3-溴苯硫酚、2,4-溴苯硫酚、3,4-溴苯硫酚、3,5- 溴苯硫酚、2,3,4-溴苯硫酚、3,4,5-溴苯硫酚、2,3,4,5-四溴苯硫酚、2,3,5,6-四溴苯硫酚、以及它們的鋅鹽、它們的金屬鹽和它們的混合物組成的群組。
內球芯層的材料
本發明的工藝適用於任何熔點小於120℃的熱塑性材料。在一些實施例中，適合的熱塑性材料可以包括，例如，離聚物樹脂，如由杜邦公司(E.I.Dupont de Nemous and Company)生產的沙林(Surlyn)。在一些實施例中，內球芯層可以由高度中和的酸性聚合物組合物製成。適於製成內球芯層的示例性高度中和的酸性聚合物組合物可以包括，例如，像由杜邦公司生產的HPF1000、HPF2000、HPF AD1024、HPF AD1027、HPF AD1030、HPF AD1035、HPF AD1040這樣的HPF樹脂。
可以用例如鎂、鈉、鋅或鉀這樣的適合的陽離子源將酸性聚合物中和至80%或更高，包括中和至100%。製造內球芯層所使用的適合的高度中和的酸性聚合物組合物可以包括高度中和的酸性聚合物組合物並且可選地可以包括添加劑、填充料和/或熔體流動改性劑。
適合的添加劑和填充劑包括例如發泡劑或起泡劑、螢光增白劑、著色劑、螢光劑、增白劑、紫外線吸收劑、抗光劑、消泡劑、加工助劑、抗氧化劑、穩定劑、軟化劑、香氣成分、增塑劑、抗沖改性劑、酸共聚物蠟、表面活性劑。在一些實施例中，添加劑和填充料可以包括例如無機填充劑，如氧化鋅、二氧化鈦、氧化錫、氧化鈣、氧化鎂、 硫酸鋇、硫酸鋅、碳酸鈣、碳酸鋅、碳酸鋇、雲母、滑石、黏土、矽石、矽酸鉛和其它類型的有機填料；在一些實施例中，添加劑和填充料可以包括例如高比重的金屬粉末填充劑，如鎢粉、鉬粉等等；在一些實施例中，添加劑和填充料可以包括二次粉碎物料，即研磨並重新利用的球芯材料。
高度中和的酸性聚合物組合物中可以包括任何適合的熔體流動改性劑。示例性適合的熔體流動改性劑可以包括例如脂肪酸及其鹽、聚醯胺、聚酯、聚丙烯酸酯、聚氨酯、聚醚、聚脲、多元醇、以及它們的組合。
可以通過任何適合的工藝製成內球芯層，例如注射成型或模壓成型。在製成內球芯層的示例性注射成型工藝中，可以將注塑機的溫度設定在近似190℃至220℃的範圍內。
實施例
進行測試研究公開的高爾夫球製造方法與其它方法相比在阻止內球芯層中形成氣泡方面的效果。在測試中，生產100個由100% HPF 2000製成的內球芯層，然後分為兩組，每一組50個樣品。每一個內球芯層的直徑為24mm。
外球芯層由化合物A製成，其組分如下表I所示：
如表I所示，橡膠化合物A由作為基底橡膠的TAIPOL BR0150與包括在內作為填充料和添加劑的丙烯酸鋅、氧化鋅、硫酸鋇和過氧化物製成。填充料和添加劑以所列出的量(以每一百鎊TAIPOL BR0150的鎊數計)包括在內。
50個兩組的測試如下進行。對於測試組A，對50件內球芯層進行上述硫化工藝(在高於內球芯層的熔點至少30℃的溫度下進行第二硫化步驟以圍繞內球芯層固化外球芯層殼)。對於測試組B，在最初注塑成型之後不對內球芯層進行進一步的處理。將100件中的每一件剪開以檢查內球芯層的切面中的任何空隙(氣泡)。組A中的50件中沒有任何氣泡。相反，組B中的50件中，確定六件有氣泡。(注意：對於組B，如果內球芯足夠透明，沒有必要剪開，因為僅在光下就可以檢查內球芯層。)
表層
圖7表示完整的高爾夫球200，包括如前所述在硫化工藝中完全固化的外球芯層215。如圖7所示，可以模塑一個或多個表層將外球芯層25包圍。
如圖7所示，高爾夫球200可以包括外表層205和內表層210。圖7還表示可以在外表層205中形成的凹坑230。如上所述，凹坑230可以具有任何適合的形狀。
在一些實施例中，表層可以由熱塑性或熱固性材料製成。例如，在一些實施例中，內表層210和/或外表層205可以由熱塑性材料製成，該熱塑性材料包括離聚物樹脂、高度中和的酸性聚合物組合物、聚醯胺樹脂、聚酯樹脂和聚氨酯樹脂中的至少一種。在一些實施例中，離聚物樹脂、聚氨酯樹脂或高度中和的酸性聚合物組合物可以優選用於內表層210或外表層205。在一些實施例中，內表層210可以由與外表層205相同類型的材料製成。在其它實施例中，內表層210可以由與外表層205不同類型的材料製成。
儘管已經描述了本發明的各種不同的實施例，但是本說明書旨在作為範例，而不是限制，對於本領域普通的技術人員來說，在本發明範圍內還可以有更多的實施例和實施方式是顯而易見的。因此，本發明除申請專利範圍外不受限制。本發明說明的任何實施例的特徵可以包括在本發明說明的任何其它實施例中。另外，在申請專利範圍內可以作出各種改進和變換。
100‧‧‧高爾夫球
105‧‧‧表層
110‧‧‧外球芯層
115‧‧‧內球芯層
120‧‧‧直徑

Claims (20)

  1. 一種製造高爾夫球的方法，其特徵在於，包含：製成球形內球芯層；在壓模中製成兩個半球形殼；將兩個半球形殼圍繞內球芯層組裝成外球芯層；以及在引起內球芯層熔融的溫度下固化兩個半球形殼以通過使殼圍繞內球芯層模壓成型從而製成整體的外球芯層。
  2. 根據申請專利範圍第1項所述的方法，其特徵在於，製成內球芯層包括模塑熱塑性塑膠。
  3. 根據申請專利範圍第1項所述的方法，其特徵在於，熱塑性塑膠是高度中和的酸性聚合物組合物。
  4. 根據申請專利範圍第1項所述的方法，其特徵在於，製成內球芯層包括注塑成型直徑為近似21mm至30mm範圍內的內球芯層。
  5. 根據申請專利範圍第1項所述的方法，其特徵在於，外球芯層包括聚丁二烯橡膠並且具有至少4mm的厚度。
  6. 根據申請專利範圍第1項所述的方法，其特徵在於，模壓成型包括在近似120℃至190℃之間的固化溫度下對外球芯層硫化一段近似5至20分鐘的範圍內的時間。
  7. 根據申請專利範圍第1項所述的方法，其特徵在於，包括在高於內球芯層的熔點近似30℃的固化溫度下進行兩個半球形殼的固化。
  8. 根據申請專利範圍第1項所述的方法，其特徵在於，包 括在近似140℃下進行兩個半球形殼的固化。
  9. 一種製造高爾夫球的方法，其特徵在於，包含：製成球形內球芯層；在壓模中製成兩個半球形殼；將兩個半球形殼圍繞內球芯層組裝成外球芯層；以及在高於內球芯層材料的熔點至少30℃的溫度下固化兩個半球形殼以通過使殼圍繞內球芯層模壓成型從而製成整體的外球芯層。
  10. 根據申請專利範圍第9項所述的方法，其特徵在於，製成內球芯層包括模塑熱塑性塑膠。
  11. 根據申請專利範圍第9項所述的方法，其特徵在於，熱塑性塑膠是高度中和的酸性聚合物組合物。
  12. 根據申請專利範圍第9項所述的方法，其特徵在於，製成內球芯層包括注塑成型內球芯層。
  13. 根據申請專利範圍第9項所述的方法，其特徵在於，外球芯層包括聚丁二烯橡膠。
  14. 根據申請專利範圍第9項所述的方法，其特徵在於，模壓成型包括在近似120℃至190℃之間的固化溫度下對外球芯層硫化一段近似5至20分鐘的範圍內的時間。
  15. 根據申請專利範圍第9項所述的方法，其特徵在於，包括在近似140℃下進行兩個半球形殼的固化。
  16. 一種高爾夫球，其特徵在於，包含：表層；在表層的徑向向內設置的外球芯層；以及 在外球芯層徑向向內設置的內球芯層；其中，外球芯層由具有高於內球芯層的熔點至少30℃的固化溫度的材料製成。
  17. 根據申請專利範圍第16項所述的高爾夫球，其特徵在於，內球芯層由熱塑性塑膠製成。
  18. 根據申請專利範圍第16項所述的高爾夫球，其特徵在於，熱塑性塑膠是高度中和的酸性聚合物組合物。
  19. 根據申請專利範圍第16項所述的高爾夫球，其特徵在於，內球芯層是注塑成型的。
  20. 根據申請專利範圍第16項所述的高爾夫球，其特徵在於，外球芯層包括聚丁二烯橡膠。
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