US20210093929A1 - Golf balls - Google Patents

Golf balls Download PDF

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Publication number
US20210093929A1
US20210093929A1 US16/590,317 US201916590317A US2021093929A1 US 20210093929 A1 US20210093929 A1 US 20210093929A1 US 201916590317 A US201916590317 A US 201916590317A US 2021093929 A1 US2021093929 A1 US 2021093929A1
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Prior art keywords
hardness
shore
golf ball
inches
core
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Abandoned
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US16/590,317
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English (en)
Inventor
Scott Cooper
Brian Comeau
Matthew F. Hogge
Michael R. Madson
Donald A. Serino
Michael J. Sullivan
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Acushnet Co
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Acushnet Co
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Priority to US16/590,317 priority Critical patent/US20210093929A1/en
Assigned to ACUSHNET COMPANY reassignment ACUSHNET COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COMEAU, BRIAN, COOPER, SCOTT, HOGGE, MATTHEW F., MADSON, MICHAEL R., SERINO, DONALD A., SULLIVAN, MICHAEL J.
Assigned to WELLS FARGO BANK, N.A., AS ADMINISTRATIVE AGENT reassignment WELLS FARGO BANK, N.A., AS ADMINISTRATIVE AGENT SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ACUSHNET COMPANY
Priority to JP2020159454A priority patent/JP7090675B2/ja
Publication of US20210093929A1 publication Critical patent/US20210093929A1/en
Assigned to JPMORGAN CHASE BANK, N.A., AS SUCCESSOR ADMINISTRATIVE AGENT reassignment JPMORGAN CHASE BANK, N.A., AS SUCCESSOR ADMINISTRATIVE AGENT ASSIGNMENT OF SECURITY INTEREST IN PATENTS (ASSIGNS 051618-0777) Assignors: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS RESIGNING ADMINISTRATIVE AGENT
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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
    • A63B37/00—Solid balls; Rigid hollow balls; Marbles
    • A63B37/0003—Golf balls
    • A63B37/0023—Covers
    • A63B37/0029—Physical properties
    • A63B37/0033—Thickness
    • 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
    • A63B37/0004—Surface depressions or protrusions
    • A63B37/0006—Arrangement or layout of dimples
    • 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
    • A63B37/0022—Coatings, e.g. paint films; Markings
    • 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
    • A63B37/0022—Coatings, e.g. paint films; Markings
    • A63B37/00221—Coatings, e.g. paint films; Markings characterised by the material
    • 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
    • A63B37/0031—Hardness
    • 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
    • A63B37/0038—Intermediate layers, e.g. inner cover, outer core, mantle
    • A63B37/004—Physical properties
    • A63B37/0043—Hardness
    • 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
    • A63B37/0038—Intermediate layers, e.g. inner cover, outer core, mantle
    • A63B37/004—Physical properties
    • A63B37/0045—Thickness
    • 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
    • A63B37/006—Physical properties
    • A63B37/0062—Hardness
    • A63B37/00621—Centre hardness
    • 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
    • A63B37/006—Physical properties
    • A63B37/0062—Hardness
    • A63B37/00622—Surface hardness
    • 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
    • A63B37/006—Physical properties
    • A63B37/0062—Hardness
    • A63B37/0063—Hardness gradient
    • 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
    • A63B37/006—Physical properties
    • A63B37/0064—Diameter
    • 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
    • A63B37/0038—Intermediate layers, e.g. inner cover, outer core, mantle
    • A63B37/0039—Intermediate layers, e.g. inner cover, outer core, mantle characterised by the material
    • 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
    • A63B37/0051—Materials other than polybutadienes; Constructional details
    • 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
    • A63B37/006—Physical properties
    • A63B37/0062—Hardness
    • 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
    • A63B37/006—Physical properties
    • A63B37/0065—Deflection or compression
    • 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
    • A63B37/007—Characteristics of the ball as a whole
    • A63B37/0072—Characteristics of the ball as a whole with a specified number of layers
    • A63B37/0075—Three piece balls, i.e. cover, intermediate layer and core

Definitions

  • the present invention relates generally to golf balls having a thermoplastic cover layer formed from a thermoplastic polyurethane composition having desirable shear durability without the need for a secondary curing or treatment step.
  • Thermoplastic polyurethane (TPU) materials are known to be useful as golf ball cover materials.
  • TPU Thermoplastic polyurethane
  • secondary processes that crosslink the TPU material are required.
  • the polyurethane cover is treated with a secondary curing or treating agent, such as a solution containing one or more isocyanates, to improve the durability of the cover.
  • Secondary treatments with isocyanate add considerable costs to the manufacturing process.
  • the present invention provides a TPU cover material that has desirable shear durability without the need for a secondary curing or treatment step.
  • the present invention further provides particularly suitable golf ball constructions including such cover materials.
  • the present invention is directed to a method of making a golf ball, the method comprising providing a golf ball subassembly comprising a core and an intermediate layer and having an adhesive coating applied to the outer surface thereof; injection molding a thermoplastic polyurethane composition about the golf ball subassembly to form a golf ball cover disposed about the golf ball subassembly; and, optionally, applying one or more coating layers to the golf ball cover to form a finished golf ball.
  • the method does not include a step of treating the outer surface of the golf ball cover to further crosslink the thermoplastic polyurethane composition.
  • the injection molding step includes the use of a mold cavity that includes a plurality of retractable positioning pins to hold the subassembly in the spherical center of the mold during the injection molding process, and each retractable positioning pin forms one of a plurality of dimples on the outer surface of the golf ball.
  • the present invention is directed to a golf ball comprising a thermoset rubber core, a thermoplastic intermediate layer, and a thermoplastic outer cover layer.
  • the thermoset rubber core is formed from a diene rubber composition and has a diameter of from 1.530 inches to 1.580 inches, a compression of from 55 to 70, a center Shore C hardness of from 60 to 70, an outer surface Shore C hardness of from 75 to 85, and a positive hardness gradient wherein the difference between the Shore C hardness of the outer surface of the core and the Shore C hardness of the center of the core is from 10 to 20.
  • the thermoplastic intermediate layer is formed from an ionomer blend composition and has a thickness of from 0.020 inches to 0.040 inches and an outer surface Shore D hardness of greater than 65.
  • the thermoplastic outer cover layer is formed from a thermoplastic polyurethane composition having a material hardness of from 48 to 55 Shore D, preferably from 49 to 53 Shore D, and has a thickness of from 0.030 inches to 0.040 inches.
  • An adhesive layer is optionally disposed between the intermediate layer and the outer cover layer.
  • One or more coating layers is disposed about the outer cover layer.
  • the ratio of the molecular weight of the thermoplastic polyurethane composition prior to molding the outer cover layer to the molecular weight of the thermoplastic polyurethane composition after molding the outer cover layer is from 3 to 50.
  • the golf ball has a plurality of dimples on the spherical outer surface thereof, wherein the plurality of dimples are arranged in eight triangular dimple sections that are defined by projecting the eight faces of a square dipyramid onto the spherical outer surface of the ball, the eight triangular dimple sections being substantially identical in size and dimple arrangement.
  • thermoplastic outer cover layer formed from a thermoplastic polyurethane (TPU).
  • TPU thermoplastic polyurethane
  • the term “thermoplastic” in reference to a golf ball layer indicates that the entire layer, from inner surface to outer surface, is melt processable.
  • Conventional TPU compositions used to form golf ball cover layers require a secondary treatment step, which crosslinks at least a portion of the molded cover layer, in order to provide the golf ball cover with desirable shear durability.
  • TPU compositions of the present invention do not require such post-molding treatment step, thereby allowing for an entire layer formed therefrom to be fully melt processable.
  • Typical secondary treatment steps which are expressly meant to be excluded from the method of the present invention include known processes for treating a molded polyurethane golf ball cover to further crosslink the polyurethane.
  • Particular examples of excluded secondary treatment steps include applying a curing agent, such as a solution containing one or more isocyanates, by dipping, wiping, soaking, brushing, or spraying the molded golf ball cover in/with the solution; and applying energy from a suitable source to the molded golf ball cover using, e.g., gamma radiation, ultraviolet radiation, or electron beam radiation.
  • Polyurethanes generally comprise the reaction product of a polyisocyanate, a polyol, and a curing agent. Particularly suitable for the present invention are polyurethanes comprising the reaction product of an aliphatic or aromatic polyisocyanate, a polyether or polyester polyol, and a curing agent.
  • the polyurethane is the reaction product of an aromatic polyisocyanate, a polyether polyol, and a curing agent.
  • the aromatic polyisocyanate is selected from methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI), and naphthalene diisocyanate (NDI).
  • the polyether polyol is selected from polytetramethylene ether glycol (PTMEG), polypropylene glycol, polyethylene propylene glycol, polyoxypropylene glycol, polyoxyethylene glycol, poly(oxypropylene oxyethylene) glycol, and combinations of two or more thereof.
  • PTMEG polytetramethylene ether glycol
  • polypropylene glycol polyethylene propylene glycol
  • polyoxypropylene glycol polyoxyethylene glycol
  • polyoxyethylene glycol poly(oxypropylene oxyethylene) glycol
  • the curing agent may consist of a single curing agent or comprise a combination of two or more curing agents, and optionally includes a freezing point depressing agent.
  • Suitable curing agents include, but are not limited to, hydroxy-terminated curing agents, amine-terminated curing agents, and combinations thereof.
  • the curing agent may be saturated or unsaturated.
  • Non-limiting examples of suitable curatives include 1,4-butanediol; 1,3-butanediol; 1,2-butanediol; 2,3-butanediol; 2,3-dimethyl-2,3-butanediol; propylene glycol, dipropylene glycol; polypropylene glycol; 2-methyl-1,3-propanediol; 2-methyl-1,4-butanediol; ethylene glycol; diethylene glycol; polyethylene glycol; resorcinol-di(beta-hydroxyethyl)ether and its derivatives; hydroquinone-di(beta-hydroxyethyl)ether and derivatives thereof 2-propanol-1,1′-phenylaminobis; trimethylolpropane; 4,4′-methylenebis(2-chloroaniline); 3,5-dimethylthio-2,4-toluenediamine; 3,5-dimethylthio-2,6-tolu
  • the curing agent optionally comprises a freezing point depressing agent so that the freezing point of the blend is less than its normal freezing point temperature.
  • the freezing point depressing agent is preferably compatible with the curing agent.
  • hydroxy-terminated curing agents such as 1,4-butanediol, may be modified with a hydroxy-terminated freezing point depressing agent or a mixture of hydroxy-terminated freezing point depression agents.
  • hydroxy-terminated freezing point depressing agents include, but are not limited to, 1,3-propanediol, 2-methyl-1,3-propanediol, 2-methyl-1,4-butanediol, 1,2-butanediol, 1,3-butanediol, ethylene glycol, diethylene glycol, 1,5-pentanediol, polytetramethylene glycol, propylene glycol, dipropylene glycol, and combinations thereof.
  • amine-terminated curing agents such as hexamethylene diamine, may be modified with an amine-terminated freezing point depressing agent or a mixture of amine-terminated freezing point depressing agents.
  • amine-terminated freezing point depressing agents include, but are not limited to, ethylene diamine, 1,3-diaminopropane, dimethylamino propylamine, tetraethylene pentamine, 1,2-propylenediamine, diethylaminopropylamine, 2,2,4-trimethyl-1,6-hexanediamine, 2,4,4-trimethyl-1,6-hexanediamine, and combinations thereof.
  • the freezing point depressing agent is preferably added in an amount sufficient to reduce the freezing point of the curing agent by a suitable amount to prevent loss of pigment dispersion, but not affect the physical properties of the golf ball. Freezing point depressing agents are further disclosed, for example, in U.S. Pat. No. 7,888,449 to Wu, the entire disclosure of which is hereby incorporated herein by reference.
  • a catalyst is optionally employed to promote the reaction.
  • Suitable catalysts include, but are not limited to bismuth catalysts; zinc octoate; stannous octoate; tin catalysts, e.g., bis-butyltin dilaurate, bis-butyltin diacetate, stannous octoate, tin (II) chloride, tin (IV) chloride, bis-butyltin dimethoxide, dimethyl-bis[1-oxonedecyl)oxy]stannane, and di-n-octyltin bis-isooctyl mercaptoacetate; amine catalysts, e.g., triethylenediamine, triethylamine, and tributylamine; organic acids, e.g., oleic acid and acetic acid; delayed catalysts, e.g., Polycat® catalysts, commercially available from Air Products and Chemicals, Inc.;
  • thermoplastic polyurethanes under particular molding conditions provides for golf ball covers having good shear durability without the need for a secondary treatment step.
  • good shear durability results when using materials and molding conditions such that the ratio of the molecular weight of the TPU prior to molding a cover therefrom to that of the molded TPU cover is 3 or 5 or 10 or 50 or 60 or 75 or is within a range having an upper limit and a lower limit selected from these values.
  • the thermoplastic polyurethane cover composition is a high molecular weight polyurethane, preferably having a weight average molecular weight (absolute), prior to molding, of at least 100,000, or at least 120,000, or at least 125,000, or at least 130,000, or at least 140,000, or at least 150,000.
  • Suitable polyisocyanates, polyols, curing agents, and catalysts are further disclosed, for example, in U.S. Pat. No. 8,865,052 to Makal et al., U.S. Pat. No. 6,734,273 to Onder et al., U.S. Pat. No. 8,034,873 to Siddhamalli et al.; the entire disclosures of which are hereby incorporated herein by reference.
  • Suitable UV absorbers that are optionally included in the cover layer composition are further disclosed, for example, in U.S. Pat. No. 5,156,405 to Kitaoh; U.S. Pat. No. 5,840,788 to Lutz; and U.S. Pat. No. 7,722,483 to Morgan; the entire disclosures of which are hereby incorporated herein by reference.
  • Golf balls of the present invention are multilayer balls having a single- or dual-layer core, an outer cover layer, and, optionally one or more intermediate layers disposed between the core and the outer cover layer.
  • the outer cover layer is formed from a thermoplastic polyurethane, as further described above.
  • the core and optional intermediate layers are formed from any suitable golf ball composition, including thermosetting materials, such as polybutadiene, styrene butadiene, isoprene, polyisoprene, and trans-isoprene; and thermoplastics, such as ionomer resins, polyamides and polyesters.
  • thermosetting rubber compositions comprising a base polymer, an initiator agent, a coagent and/or a curing agent, and optionally one or more of a metal oxide, metal fatty acid or fatty acid, antioxidant, soft and fast agent, fillers, and additives.
  • Suitable base polymers include natural and synthetic rubbers including, but not limited to, polybutadiene, polyisoprene, ethylene propylene rubber (“EPR”), styrene-butadiene rubber, styrenic block copolymer rubbers (such as SI, SIS, SB, SBS, SIBS, and the like, where “S” is styrene, “I” is isobutylene, and “B” is butadiene), butyl rubber, halobutyl rubber, polystyrene elastomers, polyethylene elastomers, polyurethane elastomers, polyurea elastomers, metallocene-catalyzed elastomers and plastomers, copolymers of isobutylene and para-alkylstyrene, halogenated copolymers of isobutylene and para-alkylstyrene, acrylonitrile butadiene rubber, polych
  • Suitable initiator agents include organic peroxides, high energy radiation sources capable of generating free radicals, C-C initiators, and combinations thereof.
  • Suitable coagents include, but are not limited to, metal salts of unsaturated carboxylic acids; unsaturated vinyl compounds and polyfunctional monomers (e.g., trimethylolpropane trimethacrylate); phenylene bismaleimide; and combinations thereof.
  • Suitable curing agents include, but are not limited to, sulfur; N-oxydiethylene 2-benzothiazole sulfenamide; N,N-di-ortho-tolylguanidine; bismuth dimethyldithiocarbamate; N-cyclohexyl 2-benzothiazole sulfenamide; N,N-diphenylguanidine; 4-morpholinyl-2-benzothiazole disulfide; dipentamethylenethiuram hexasulfide; thiuram disulfides; mercaptobenzothiazoles; sulfenamides; dithiocarbamates; thiuram sulfides; guanidines; thioureas; xanthates; dithiophosphates; aldehyde-amines; dibenzothiazyl disulfide; tetraethylthiuram disulfide; tetrabutylthiuram disulfide;
  • Suitable types and amounts of base polymer, initiator agent, coagent, filler, and additives are more fully described in, for example, U.S. Pat. Nos. 6,566,483, 6,695,718, 6,939,907, 7,041,721 and 7,138,460, the entire disclosures of which are hereby incorporated herein by reference.
  • Particularly suitable diene rubber compositions are further disclosed, for example, in U.S. Patent Application Publication No. 2007/0093318, the entire disclosure of which is hereby incorporated herein by reference.
  • Particularly suitable intermediate layer materials include, but are not limited to:
  • compositions comprising an ionomer or a blend of two or more E/X- and E/X/Y-type ionomers are particularly suitable intermediate layer materials.
  • Preferred E/X- and E/X/Y-type ionomeric compositions include:
  • Surlyn® 8150®, Surlyn® 8940, and Surlyn® 8140 are different grades of E/MAA copolymer in which the acid groups have been partially neutralized with sodium ions.
  • Surlyn® 9650, Surlyn® 9910, Surlyn® 9150, and Surlyn® 9120 are different grades of E/MAA copolymer in which the acid groups have been partially neutralized with zinc ions.
  • Surlyn® 7940 is an E/MAA copolymer in which the acid groups have been partially neutralized with lithium ions.
  • Surlyn® 6320 is a very low modulus magnesium ionomer with a medium acid content.
  • Nucrel® 960 is an E/MAA copolymer resin nominally made with 15 wt % methacrylic acid. Surlyn® ionomers, Fusabond® polymers, and Nucrel® copolymers are commercially available from E. I. du Pont de Nemours and Company.
  • Suitable E/X- and E/X/Y-type ionomeric cover materials are further disclosed, for example, in U.S. Pat. Nos. 6,653,382, 6,756,436, 6,894,098, 6,919,393, and 6,953,820, the entire disclosures of which are hereby incorporated by reference.
  • Suitable conventional polyurethanes, polyureas, and blends and hybrids of polyurethane/polyurea for use in forming layers other than the outer cover layer are further disclosed, for example, in U.S. Pat. Nos. 5,334,673, 5,484,870, 6,506,851, 6,756,436, 6,835,794, 6,867,279, 6,960,630, and 7,105,623; U.S. Patent Application Publication Nos. 2009/0011868 and 2007/0117923; and U.S. Patent Application No. 60/401,047, the entire disclosures of which are hereby incorporated herein by reference.
  • ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇
  • Golf ball cores of the present invention include single, dual, and multilayer cores, and preferably have an overall diameter within the range having a lower limit of 0.75 inches or 1 inch or 1.25 inches or 1.4 inches and an upper limit of 1.55 inches or 1.6 inches or 1.62 inches or 1.63 inches.
  • the core is a solid, single layer having a diameter within a range having a lower limit of 0.750 or 1.00 or 1.10 or 1.15 or 1.20 or 1.25 or 1.30 or 1.40 or 1.50 or 1.53 or 1.55 inches and an upper limit of 1.55 or 1.60 or 1.62 or 1.63 or 1.65 inches.
  • the core has a center Shore C hardness of 95 or less, or 90 or less, or 85 or less, or 80 or less, or a center Shore C hardness within a range having a lower limit of 20 or 25 or 30 or 35 or 40 or 45 or 50 or 55 or 60 or 65 or 70 or 75 and an upper limit of 60 or 65 or 70 or 75 or 80 or 83 or 85 or 90 or 95, wherein the upper limit is greater than the lower limit (e.g., when the lower limit is 65, the upper limit is 70, 75, 80, 83, 85, 90, or 95).
  • the core has an outer surface Shore C hardness of 50 or greater, or 55 or greater, or 60 or greater, or 65 or greater, or 70 or greater, or an outer surface Shore C hardness within a range having a lower limit of 40 or 45 or 50 or 55 or 60 or 65 or 70 or 74 and an upper limit of 60 or 65 or 70 or 74 or 75 or 78 or 80 or 85 or 90 or 95, wherein the upper limit is greater than the lower limit (e.g., when the lower limit is 65, the upper limit is 70, 74, 75, 78, 80, 85, 90, or 95).
  • the core has a low negative, low positive, or zero hardness gradient.
  • the core is formed from a substantially homogeneous formulation and has a hardness gradient wherein the difference between the Shore C hardness of the outer surface and the Shore C hardness of the center of the core is within a range having a lower limit of -8 or -5 or -3 or 0 and an upper limit of 0 or 3 or 5 or 8 or 10 or 15 or 18 or 20 or 25 or 30.
  • the core has a compression of 90 or less, or 80 or less, or 75 or less, or 70 or less, or a compression within a range having a lower limit of 50 or 55 or 60 or 65 and an upper limit of 65 or 70 or 75 or 80 or 90.
  • the core comprises an inner core layer and an outer core layer, the inner core layer having a diameter within a range having a lower limit of 0.900 or 0.910 or 0.920 or 0.930 or 0.940 or 0.950 or 0.960 or 0.970 or 0.980 or 0.990 or 1.000 or 1.010 or 1.020 inches and an upper limit of 1.020 or 1.030 or 1.040 or 1.050 or 1.060 or 1.070 or 1.080 or 1.090 or 1.100 or 0.110 or 1.120 or 1.130 inches, and the outer core having a thickness within the range having a lower limit of 0.050 or 0.100 or 0.200 or 0.250 inches and an upper limit of 0.280 or 0.310 or 0.440 or 0.500 inches.
  • the inner core layer has a center Shore C hardness of 95 or less, or 90 or less, or 85 or less, or 80 or less, or 75 or less, or a center Shore C hardness within a range having a lower limit of 20 or 25 or 30 or 35 or 40 or 45 or 50 or 55 or 60 or 65 or 70 or 75 and an upper limit of 60 or 65 or 70 or 75 or 80 or 83 or 85 or 90 or 95, wherein the upper limit is greater than the lower limit (e.g., when the lower limit is 65, the upper limit is 70, 75, 80, 83, 85, 90, or 95).
  • the inner core layer has an outer surface Shore C hardness of 50 or greater, or 55 or greater, or 60 or greater, or 65 or greater, or an outer surface Shore C hardness within a range having a lower limit of 40 or 45 or 50 or 55 or 60 or 65 or 70 or 74 and an upper limit of 60 or 65 or 70 or 74 or 75 or 78 or 80 or 85 or 90 or 95, wherein the upper limit is greater than the lower limit (e.g., when the lower limit is 65, the upper limit is 70, 74, 75, 78, 80, 85, 90, or 95).
  • the inner core layer has a negative or zero hardness gradient.
  • the inner core layer is formed from a substantially homogeneous formulation and the difference between the Shore C hardness of the outer surface of the inner core layer and the Shore C hardness of the center of the inner core layer is within a range having a lower limit of ⁇ 20 or ⁇ 15 or ⁇ 10 and an upper limit of ⁇ 10 or ⁇ 5 or 0.
  • the inner core layer has a compression of 50 or less, or 40 or less, or 30 or less, or a compression within a range having a lower limit of 10 or 15 or 20 or 25 and an upper limit of 25 or 30 or 40 or 50 or 65.
  • the outer core layer has an outer surface Shore C hardness within a range having a lower limit of 70 or greater, or 75 or greater, or 80 or greater, or 85 or greater, or 89 or greater, or an outer surface Shore C hardness within a range having a lower limit of 70 or 75 or 80 or 85 or 89 and an upper limit of 80 or 85 or 90 or 93 or 95, wherein the upper limit is greater than the lower limit (e.g., when the lower limit is 85, the upper limit is 90, 93, or 95).
  • the core has an overall dual core compression within a range having a lower limit of 60 or 70 or 80 or 85 and an upper limit of 85 or 90 or 95.
  • Golf balls of the present invention preferably have a compression of 70 or 75 or 80 or 85 or 100 or 105 or a compression within a range having an upper limit and a lower limit selected from these values.
  • Golf ball of the present invention preferably have a coefficient of restitution (COR) of 0.770 or 0.780 or 0.800 or 0.820 or a COR within a range having an upper limit and a lower limit selected from these values.
  • COR coefficient of restitution
  • golf balls of the present invention have a thermoset rubber core, a thermoplastic intermediate layer, and a thermoplastic outer cover layer formed from a thermoplastic polyurethane composition.
  • the core is preferably formed from a diene rubber composition, and preferably has a diameter of 1.500 or 1.510 or 1.530 or 1.550 or 1.560 or 1.580 inches or a diameter within a range having an upper limit and a lower limit selected from these values.
  • the core preferably has a compression of 50 or 55 or 60 or 65 or 70 or 75 or a compression within a range having an upper limit and a lower limit selected from these values.
  • the core preferably has a center Shore C hardness of 50 or 60 or 65 or 70 or 80 or a center Shore C hardness within a range having an upper limit and a lower limit selected from these values.
  • the core preferably has an outer surface Shore C hardness of 65 or 70 or 75 or 80 or 85 or 90 or 95 or an outer surface Shore C hardness within a range having an upper limit and a lower limit selected from these values.
  • the core preferably has an overall positive hardness gradient wherein the Shore C hardness of the outer surface of the core is greater than the Shore C hardness of the center of the core and the difference there between is 5 or 10 or 15 or 18 or 20 or 25 or 30 or the difference there between is within a range having an upper limit and a lower limit selected from these values.
  • the intermediate layer is preferably formed from an ionomer blend composition and has a thickness of 0.010 or 0.020 or 0.030 or 0.040 or 0.050 inches or a thickness within a range having an upper limit and a lower limit selected from these values.
  • the intermediate layer preferably has an outer surface Shore D hardness of greater than 55 or greater than 60 or greater than 65.
  • a golf ball subassembly consisting of the core and the intermediate layer has an outer diameter of 1.580 or 1.590 or 1.600 or 1.610 or 1.620 inches or an outer diameter within a range having an upper limit and a lower limit selected from these values.
  • the outer cover layer is formed from a thermoplastic polyurethane composition and preferably has a thickness of 0.020 or 0.030 or 0.035 or 0.040 or a thickness within a range having an upper limit and a lower limit selected from these values.
  • the outer cover layer composition preferably has a material hardness of 45 or 48 or 50 or 55 or 60 Shore D or a material hardness within a range having an upper limit and a lower limit selected from these values.
  • the outer cover layer preferably has an outer surface hardness of 80 or 82 or 85 or 88 Shore C or an outer surface hardness within a range having an upper limit and a lower limit selected from these values.
  • a primer and a topcoat may be applied.
  • Either or both of the primer and topcoat compositions may be pigmented or clear.
  • Several coats of clear or pigmented coatings may be applied.
  • Primer and topcoat compositions are typically a solvent-borne or water-borne material, particularly selected from, but not limited to, polyurethanes, polyureas, acrylic polyurethanes, polyesters, polyester acrylics, and epoxies.
  • golf balls of the present invention comprise at least one coat of primer and at least one coat of topcoat.
  • the primer is a clear waterborne composition and the topcoat is a clear solventborne composition.
  • the topcoat composition includes an optical brightener in a concentration of about 0.01 to about 0.20 weight %, and, optionally, does not include a light stabilizer.
  • the topcoat composition is a two-part solvent-borne polyurethane comprising a resin component and an isocyanate component, wherein the isocyanate component is present in an amount of from 68 parts to 71 parts, by weight per 100 parts of the resin component, the resin component comprises from 46 to 52 wt % solids, and the isocyanate component comprises from 46 to 53 wt % solids.
  • Non-limiting examples of suitable coatings are further disclosed, for example, in U.S. Pat. Nos. 5,409,233; 5,459,220; 5,494,291; 5,820,491; 5,669,831; 5,817,735; and 7,935,421, the entire disclosure of which are hereby incorporated herein by reference
  • the present invention is also directed to a method of making a golf ball.
  • the method comprises the steps of providing a golf ball subassembly comprising a core and an intermediate layer and, optionally, an adhesive coating applied to the outer surface of the subassembly; injection molding a thermoplastic polyurethane composition about the golf ball subassembly to form a dimpled, unfinished golf ball; and applying one or more coating layers to the dimpled, unfinished golf ball to form a finished golf ball.
  • the method does not include a step of treating the outer surface of the unfinished golf ball to further crosslink the thermoplastic polyurethane composition.
  • the injection molding step includes the use of a mold cavity that includes a plurality of retractable positioning pins to hold the subassembly in the spherical center of the mold during the injection molding process, and each retractable positioning pin forms one of a plurality of dimples on the outer surface of the golf ball.
  • each retractable positioning pin forms one of a plurality of dimples on the outer surface of the golf ball.
  • four retractable positioning pins are used on each mold half.
  • the retractable pins form four of the dimples on each hemisphere of the golf ball.
  • the overall dimple pattern on the golf ball is defined by a square dipyramid wherein the dimples are arranged in eight triangular dimple sections that are defined by projecting the eight faces of a square dipyramid onto the spherical outer surface of the ball, the eight triangular dimple sections being substantially identical in size and dimple arrangement.
  • the dimple arrangement within each of the eight triangular sections is not rotationally symmetric about the center of the section.
  • from 2% to 10% of the dimples have an elliptical plan shape.
  • the dimples having an elliptical plan shape correspond to the dimples formed by the retractable positioning pins during the injection molding process.
  • Suitable dimple patterns based on a square dipyramid are further disclosed, for example in U.S. patent application Ser. No. 16/587,298, filed Sep. 30, 2019, U.S. patent application Ser. No. 16/587,321, filed Sep. 30, 2019, and U.S. patent application Ser. No. 16/587,455, filed Sep. 30, 2019, the entire disclosures of which are hereby incorporated herein by reference.
  • Golf balls of the present invention preferably have an overall dimple surface coverage of 75% or greater, or 78% or greater, or 80% or greater, and, preferably, the total number of dimples is 320 or 322 or 328 or 330 or 336 or 338 or 344 or 346 or 352 or 354 or 360 or 362 or 368 or 370 or the total number of dimples is within a range having a lower limit and an upper limit selected from these values.
  • the outer cover layer material that is left within the runners leading to the ball cavity mold is optionally ground and added back into the TPU composition for use during another injection molding cycle.
  • This material is referred to in the examples below as regrind.
  • Table 1 shows the absolute molecular weight values, relative molecular weight values, and polydispersity (PD), prior to and after molding, of Texin® 1049 aromatic polyether-based polyurethane, commercially available from Covestro.
  • Table 2 shows the absolute molecular weight values, relative molecular weight values, and polydispersity (PD), prior to and after molding, of Estane ® ETE 50DT3 aromatic polyether-based polyurethane, commercially available from Lubrizol.
  • covered golf balls were formed by injection molding the TPU outer cover layer materials about a cased core such that the cover has a thickness of about 0.350 inches.
  • the cased core consists of a 1.550 inch diameter polybutadiene core having a center hardness of about 64 Shore C, an outer surface hardness of about 79 Shore C, and a compression of about 65, and an intermediate layer formed from a 50/50 blend of Surlyn® 8150/Surlyn® 9120 and having a thickness of about 0.030 inches and an outer surface hardness of about 68 Shore D.

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EP4501418A1 (en) 2023-08-03 2025-02-05 Acushnet Company Golf ball having at least one radar detectable mark

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EP4501418A1 (en) 2023-08-03 2025-02-05 Acushnet Company Golf ball having at least one radar detectable mark

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