U.S. patent application number 10/825010 was filed with the patent office on 2005-10-20 for golf ball having a mechanically interlocked component.
This patent application is currently assigned to Callaway Golf Company. Invention is credited to Nesbitt, R. Dennis.
Application Number | 20050233835 10/825010 |
Document ID | / |
Family ID | 35096957 |
Filed Date | 2005-10-20 |
United States Patent
Application |
20050233835 |
Kind Code |
A1 |
Nesbitt, R. Dennis |
October 20, 2005 |
Golf ball having a mechanically interlocked component
Abstract
A golf ball with a mechanically interlocked component is
disclosed. The golf ball includes a core and a cover layer disposed
about the core. At least one intermediate layer is optionally
disposed between the core and the cover layer. The cover or
intermediate layer is mechanically interlocked to the core.
Inventors: |
Nesbitt, R. Dennis;
(Hernando, FL) |
Correspondence
Address: |
THE TOP-FLITE GOLF COMPANY, A WHOLLY OWNED
SUBSIDIARY OF CALLAWAY GOLF COMPANY
2180 RUTHERFORD ROAD
LEGAL DEPT
CARLSBAD
CA
92008-7328
US
|
Assignee: |
Callaway Golf Company
Carlsbad
CA
92008-7328
|
Family ID: |
35096957 |
Appl. No.: |
10/825010 |
Filed: |
April 15, 2004 |
Current U.S.
Class: |
473/371 |
Current CPC
Class: |
A63B 37/0074 20130101;
B29C 2045/14327 20130101; A63B 37/0075 20130101; A63B 37/0003
20130101; A63B 37/06 20130101; B29C 45/14311 20130101; A63B 37/0076
20130101 |
Class at
Publication: |
473/371 |
International
Class: |
A63B 037/06 |
Claims
1. A golf ball with mechanically interlocked components comprising:
a core; a cover layer disposed about the core; wherein the core has
small voids in the surface; and the cover layer fills the voids in
the core surface, thereby mechanically interlocking the core and
the cover.
2. The golf ball of claim 1, wherein the voids are formed by
particulate material that is molded into the core surface and then
subsequently removed by flushing or washing of the core with a
solvent.
3. The golf ball of claim 2, wherein the particulate material is
crystalline or amorphous in shape.
4. The golf ball of claim 2, wherein the solvent is aqueous.
5. The golf ball of claim 2, wherein the solvent is
non-aqueous.
6. The golf ball of claim 5, wherein the solvent is selected is an
organic solvent.
7. The golf ball of claim 2, wherein the particulate material has a
mesh U.S. standard size of from about 5 to about 400 mesh.
8. The golf ball of claim 7, wherein the particulate material has a
mesh U.S. standard size of from about 20 to about 60 mesh.
9. The golf ball of claim 2, wherein the particulate material is
selected from the group consisting of salts, sugars, agar, gelatin,
polyvinyl alcohol, thermoplastic particulate materials, and
combinations thereof.
10. The golf ball of claim 1, wherein the cover comprises at least
an inner and an outer cover layer.
11. The golf ball of claim 1, wherein the voids are formed by
hollow microspheres that are molded into the core surface and then
subsequently ground down to expose voids in the surface of the
core.
12. The golf ball of claim 11, wherein the hollow microspheres are
selected from ceramics, glass, phenolics, thermoplastics and
combinations thereof.
13. The golf ball of claim 1, wherein at least some of the voids in
the core comprise undercuts.
14. A golf ball with mechanically interlocked components
comprising: a core; a core layer disposed about the core; a cover
layer disposed about the core layer; wherein the core layer has
small voids in the surface; and the cover layer fills the voids in
the core layer surface, thereby mechanically interlocking the core
layer and the cover.
15. The golf ball of claim 14, wherein the voids are formed by
particulate material that is molded into the core surface and then
subsequently removed by flushing or washing of the core with a
solvent.
16. The golf ball of claim 15, wherein the solvent is aqueous.
17. The golf ball of claim 15, wherein the solvent is
non-aqueous.
18. The golf ball of claim 15, wherein the particulate material is
crystalline or amorphous in shape.
19. The golf ball of claim 14, wherein at least some of the voids
in the core comprise undercuts.
20. The golf ball of claim 14, wherein the voids are formed by
hollow microspheres that are molded into the core surface and then
subsequently ground down to expose voids in the surface of the
core.
21. A golf ball comprising: a core; and a cover layer disposed
about the core layer, wherein the core has depressions formed on
the surface of the core, and wherein the cover layer fills the
depressions on the surface of the core, thereby mechanically
interlocking the core and the cover.
22. The golf ball of claim 21, wherein the depressions are formed
by a fabric molded onto the core surface that is subsequently
dissolved in a solvent and removed, thereby leaving the depressions
on the core surface.
23. The golf ball of claim 22, wherein the fabric comprises fibers
woven into a fabric.
24. The golf ball of claim 23, wherein the fibers comprise
polyvinyl alcohol.
Description
FIELD OF THE INVENTION
[0001] The present invention pertains to the golf ball art, and,
more particularly, to a new golf ball with a cover or intermediate
layer mechanically interlocked to the core.
DESCRIPTION OF RELATED ART
[0002] Golf balls have typically been divided into four types based
on the construction of the balls. The first type of ball to be
developed was a one-piece golf ball that was essentially
constructed of the same material throughout the entire ball. To
improve performance, the second type of golf ball was then
developed. This ball consists of an elastomeric core around which a
polymeric cover is encapsulated. This is referred to as a two-piece
ball. A three-piece or wound ball comprises an elastomeric core
around which an elastomeric thread is wound and a tough, yet
resilient, cover over the core and thread.
[0003] The quest to continue to improve the performance of the golf
ball led to the development of the fourth type of ball, the
non-wound, multi-layered ball. This type of ball typically includes
an elastomeric core surrounded by one or more intermediate layers
and a tough cover. Traditionally, each component has had a
different composition from the others. In addition, the outer
surface of the core and the inner and outer surfaces of the
intermediate layers are usually smooth. Such a smooth interface
between spherical surfaces results in an inefficient transfer of
energy between the layers as well as poor adhesion between the
layers.
[0004] This inefficiency of energy transfer and poor adhesion
results in problems with the main purpose of the golf ball, its
playability. When a golf club strikes the outer surface of the golf
ball cover, only a portion of the entire sphere is contacted in
receiving energy. This energy is transferred to each layer of the
ball to the core. Because only a portion of the outer cover
initially receives energy, portions of each intermediate layer and
the core that are linearly related to the portion of the cover
receiving the direct contact are critical to the transfer of
energy. The smooth interfaces often poorly transfer this energy,
resulting in a lower total energy transfer to the entire golf ball
from the club. This lower energy transfer may result in a shorter
travel distance for the ball, less spin or reduction of other
similar playability characteristics. It may also result in a cover
not adhering properly to a core, which results in poor durability
of the golf ball.
[0005] A way to eliminate this problem is to change the smooth
interfaces of the golf ball components in a manner that allows for
better adhesion and a more efficient energy transfer. Some attempts
at such a solution have been made. For example, U.S. Pat. No.
5,984,807 issued to Ywai et al. and U.S. Pat. No. 5,836,834 issued
to Masutani et al. disclose the use of solid, geometrically
symmetrical projections on the core of a golf ball to improve the
interface between the core and its adjacent layer. U.S. Pat. No.
5,820,485 issued to Hwang teaches the use of solid, geometrically
symmetrical solid protrusions on an intermediate layer to improve
energy transfer to the core. U.S. Pat. No. 6,066,054 issued to
Masutani discloses the use of projections on the inner surface of
the cover layer of the golf ball to improve playability
characteristics. The inventions of the prior art, however, do not
provide the optimum adhesion or mechanical interlock between the
layers, or the optimum energy transfer, leading to the best
playability characteristics.
[0006] Accordingly, it is desirable to develop a new golf ball that
would overcome the foregoing difficulties by providing better
adhesion and a more efficient transfer of energy throughout the
ball.
SUMMARY OF THE INVENTION
[0007] In accordance with one embodiment of the present invention,
a golf ball with mechanically interlocked components is disclosed.
The golf ball includes a core and a cover layer disposed about the
core. At least one intermediate layer may optionally be disposed
between the core and the cover layer. At least one of the cover and
optional intermediate layer is mechanically interlocked to the
core.
[0008] In accordance with another embodiment of the present
invention, a golf ball with mechanically interlocked components is
disclosed. The golf ball includes a core, a mantle or intermediate
layer disposed about the core, and a cover layer disposed about the
mantle layer. The mantle layer is mechanically interlocked with the
core.
[0009] One advantage of the present invention is that the
mechanical interlock between the core and the cover or mantle layer
creates improved adhesion and an improved energy transfer,
resulting in improved playability characteristics.
[0010] Still further advantages of the present invention will
become apparent to those of ordinary skill in the art upon reading
and understanding the following detailed description of the
preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention may take form in certain parts and
arrangements of parts, preferred embodiments of which will be
described in detail in the specification and merely illustrated in
the accompanying drawings which form a part thereof, and
wherein:
[0012] FIG. 1 is a cross-sectional view of one embodiment of a golf
ball in accordance with the present invention;
[0013] FIG. 2 is a cross-sectional view of a second embodiment of a
golf ball in accordance with the present invention;
[0014] FIG. 3 is an exploded sectional view of a portion of the
golf ball of FIG. 1;
[0015] FIG. 4 is a front view, partially in section, of a third
embodiment of a golf ball in accordance with the present invention;
and
[0016] FIG. 5 is a front view, partially in section, of a forth
embodiment of a golf ball in accordance with the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Turning now to the drawings, which are provided for the
purpose of illustrating the invention and not limiting the same,
with reference to FIG. 1, a golf ball 10 includes a core 12 and a
cover 14 disposed about the core 12. The core 12 has small holes or
voids 16, some of which are undercut, extending inward and running
across its outer surface. This configuration of a rough core
surface and a cover layer disposed on the core creates an improved
interface between the core and the cover with improved adhesion and
a more efficient ability to transfer energy. The voids 16 may be
formed in the same processing step as the core 12 or a different
step, as will be described below. Each of the voids 16 is randomly
placed on the core surface and may vary in size. Since the voids 16
are randomly formed, as further described below, the distance
between each void 16 will vary.
[0018] Turning now to FIG. 2, a golf ball 18 according to the
present invention is shown. The golf ball 18 includes a core 20 and
a cover 22, as well as at least one intermediate layer 24. In this
embodiment, the core 20 is a dual core having an inner or central
core 21 and an outer core or core layer 23. Particular note is made
that although only one intermediate layer 24 is illustrated, more
than one intermediate layer may be present between the core 20 and
the cover 22. It is to be understood that the present invention
will be described with reference to one mantle or intermediate
layer 24, but any number of additional mantle or intermediate
layers are anticipated to be included. The core 20 includes small
holes or voids 26 extending inward and running across its outer
surface. The voids 26 may be formed in the same processing step as
the core 20 or a different step, as will be described below. Each
of the voids 26 is randomly placed on the core surface and may vary
in size. Since the voids 26 are randomly formed, as further
described below, the distance between each void 26 will vary.
[0019] Turning now to FIG. 3, the voids 16 in the core 12 are more
clearly shown. The core 12 has an outer surface 32 that defines
indentations or voids 16. The cover layer 14 has an inner surface
34 that defines slight projections 44 that are formed as the cover
layer fills the indentations or voids 16 in the core 12. Thus, the
contact surface area between the core and cover of the golf ball is
maximized, thereby forming a mechanical interlock and promoting
improved adhesion and an increased energy transfer interface
between the layers. This results in a greater response by the
entire ball to kinetic energy, such as a hit by a golf club, in
turn creating a more responsive ball with better playability
characteristics.
[0020] Although only a two-piece golf ball is shown in FIG. 3, the
same is true for a multi-layer golf ball such as the golf ball of
FIG. 2. For example, when the core 20 includes voids 26 in the
outer core 23, the inner surface 25 of the mantle layer 24 is in
proximate contact with the outer core 23 and defines the
corresponding projections.
[0021] Although the mechanical interlock is only shown between two
layers, it is understood that it may be present in multiple layers.
For example, for the golf ball shown in FIG. 2, both the inner core
21 and the outer core 23 may have holes or voids to promote
adhesion between the layers.
[0022] The cores, intermediate layers and cover layers of the
present invention are preferably made according to various molding
techniques, such as compression molding, casting, injection molding
and reaction injection molding, although any method known to one
skilled in the art may be used. Typically, the core is molded into
a spheroid shape and any intermediate layers are molded about the
core and the cover layer (or layers) is then molded about the final
intermediate layer. The holes or voids on the core surface or outer
core surface may be made in the same forming step as the core, or
they may be formed in a second step, as discussed below. The
forming techniques, as mentioned above, compression molding,
casting, injection molding and reaction injection molding, may be
used separately or in combination for each component of the golf
ball. For example, the core may be formed by compression molding,
an intermediate layer formed by injection molding, and the cover
layer by reaction injection molding, two or more layers may be made
by the same process, or all of the components may be formed using
the same process.
[0023] The golf balls of the invention are formed using a "lost
salt process" to create surface voids in the core and/or core
layer. Some or all of the surface voids have undercuts, allowing
the mantle or cover material to flow into the undercuts when
molded, thus locking the mantle or cover into the core to improve
adhesion between the layers.
[0024] As used herein, the lost salt process refers to a process
where the core material, such as the slug or preform, is coated
with a particulate material. The particulate material can be any
material known in the art that will easily be removed with an
aqueous or non-aqueous solvent. Examples of particulate materials
suitable for use in the invention include, but are not limited to,
crystalline and amorphous shaped particles, such as salts, sugars,
agar, gelatin, polyvinyl alcohol, thermoplastic particulate, and
the like. Combinations of any of these materials may also be used.
The core material may be coated in any manner, such as by rolling
the slug or preform in the particulate, or any other method known
in the art. The coated slugs or preforms are then molded into
cores, preferably spherical cores, using molding techniques known
in the art, such as compression molding. The molded cores have a
relatively smooth outer surface with the particulate molded into
the surface of the core. The cores are then flushed or washed with
an aqueous or non-aqueous solvent and dried, preferably blown dry.
Preferred solvents include, but are not limited to, water and
organic solvents such as alcohol, acetone, methyl ethyl ketone,
toluene, naptha, and the like, but other solvents may be used as
long as they do not damage or change the core matrix. By washing
the cores, the particulate is removed, and a large number of voids
or small holes remain on the surface of the cores. The size of the
voids will be determined by the size of the particulate used, but
will generally be very small. In a preferred embodiment, the
particulate material has a size of from about 5 to about 400 mesh
U.S. standard size, preferably about 10 to about 200, more
preferably about 20 to about 60 mesh U.S. standard size.
[0025] In an alternate embodiment, hollow microspheres, such as
ceramic, glass, phenolic or thermoplastic microspheres, may also be
used to coat the core material. After molding the hollow
microspheres into the core surface, the cores can be lightly ground
on a centerless grinding machine known in the art. This will expose
small hemispherical holes on the surface of the core. The
hemispherical holes on the surface of the core or core layer will
look similar to the voids 16 and 26 shown in FIGS. 1 to 3. When a
cover is disposed on the core, the cover and core will be
mechanically interlocked.
[0026] In another embodiment, small fibers, such as polyvinyl
alcohol fibers, can be woven into a fabric, and the fabric can be
used in the golf ball. In this embodiment, the fabric is inserted
into the mold cavities and then a core is molded using standard
molding techniques, such as compression molding. After molding, the
fabric will then be molded onto the core surface. The fabric can be
dissolved in a solvent, such as water, to remove the fibers,
creating a surface similar to a wound golf ball core surface. Any
suitable solvent may be used, as long as it dissolves the fibers
but does not change the core properties or core matrix. The fibers
of the fabric create depressions or impressions in the surface of
the core or core layer after the fabric is dissolved and washed
away. When a mantle or cover layer is then molded around the core,
the mantle or cover layer will be interlocked with the core because
the mantle or cover layer will fill in the depressions in the core
surface, thereby interlocking the core and the mantle or cover
layer.
[0027] Turning now to FIG. 4, a golf ball 58 having a core 52 and a
cover layer 54 disposed on the core 52 is shown. The core 52 has an
outer surface 60 that defines depressions 56 formed when the fabric
is dissolved and removed or washed away. The cover layer 54 fills
the depressions 56 in the core 52. Thus, the contact surface area
between the core and cover of the golf ball is maximized, thereby
forming a mechanical interlock and promoting improved adhesion and
an increased energy transfer interface between the layers. This
results in a greater response by the entire ball to kinetic energy,
such as a hit by a golf club, in turn creating a more responsive
ball with better playability characteristics. The cover layer 54
may be a single layer or a multi-layer cover as described
herein.
[0028] Turning now to FIG. 5, a golf ball 68 having a core 62, a
core layer 63 and a cover layer 64 disposed on the core layer 63 is
shown. The core layer 63 has an outer surface 70 that defines
depressions 66 formed when the fabric is dissolved and removed or
washed away. The cover layer 64 fills the depressions 66 in the
core layer 63. Thus, the contact surface area between the core
layer and cover of the golf ball is maximized, thereby forming a
mechanical interlock and promoting improved adhesion and an
increased energy transfer interface between the layers. The cover
layer 64 may be a single layer or a multi-layer cover as described
herein.
[0029] These processes are advantageous because they allow the
layer covering the core, whether it is a mantle or cover layer, to
be interlocked with the core because the material can flow into the
voids, depressions, and/or undercuts formed in the core surface.
Molds having internal projections, such as those of the prior art,
are not able to produce undercuts, therefore the degree of
mechanical locking between the components is not as great.
[0030] The core and/or intermediate layer(s) (also known as mantle
layers) and/or cover layer(s) may be formed from a thermoset
material, a thermoplastic material, or combinations thereof, as
known to one skilled in the art.
[0031] A wide array of thermoset materials can be utilized in any
of the layers of the present invention. Examples of suitable
thermoset materials include butadiene or any natural or synthetic
elastomer, including metallocene polyolefins, polyurethanes,
silicones, polyamides, polyureas, or virtually any irreversibly
cross-linked resin system. Similarly a polybutadiene elastomer
could be further used. It is also contemplated that epoxy,
phenolic, and an array of unsaturated polyester resins could be
utilized.
[0032] The thermoplastic materials used in the present invention
golf ball layers include a wide assortment of thermoplastic
materials. Examples of typical thermoplastic materials for
incorporation in the golf balls of the present invention include,
but are not limited to, ionomers, polyurethane thermoplastic
elastomers, and combinations thereof. It is also contemplated that
a wide array of other thermoplastic materials could be utilized,
such as polysulfones, fluoropolymers, polyamide-imides,
polyarylates, polyaryletherketones, polyaryl sulfones/polyether
sulfones, polybenzimidazoles, polyether-imides, polyamides, liquid
crystal polymers, polyphenylene sulfides; and specialty
high-performance resins, which would include fluoropolymers,
polybenzimidazole, and ultrahigh molecular weight
polyethylenes.
[0033] Additional examples of suitable thermoplastics include
metallocenes, polyvinyl chlorides,
acrylonitrile-butadiene-styrenes, acrylics, styrene-acrylonitriles,
styrene-maleic anhydrides, polyamides (nylons), polycarbonates,
polybutylene terephthalates, polyethylene terephthalates,
polyphenylene ethers/polyphenylene oxides, reinforced
polypropylenes, and high-impact polystyrenes.
[0034] Any or all of the previously described components in the
layers of the preferred embodiment golf balls of the present
invention may be formed in such a manner, or have suitable fillers
added, so that their resulting density is decreased or increased.
For example, any of the components in the cores and/or mantle
layers could be formed or otherwise produced to be light in weight.
For instance, the components could be foamed, either separately or
in situ. Related to this, a foamed lightweight filler agent may be
added. In contrast, any of these components could be mixed with, or
otherwise receive, various high density filler agents or other
weighting components such as relatively high density fibers or
particulate agents in order to increase their mass or weight.
[0035] The cores generally have a weight of about 25 to 40 grams
and preferably about 30 to 40 grams, although this may vary
depending on the desired properties of the core and finished golf
ball. The cores can be molded from materials noted herein. For
example the core can be molded from a slug of uncured or lightly
cured elastomer composition comprising a high cis content
polybutadiene and a metal salt of an ethylenically unsaturated
carboxylic acid such as zinc mono- or diacrylate or methacrylate.
To achieve higher coefficients of restitution and/or to increase
hardness in the core, the manufacturer may increase the amount of
zinc diacrylate co-agent. In addition, larger amounts of metal
oxide such as zinc oxide may be included in order to increase the
core weight so that the finished ball more closely approaches the
U.S.G.A. upper weight limit of 1.620 ounces. Non-limiting examples
of other materials which may be used in the core composition
include compatible rubbers or ionomers, and low molecular weight
fatty acids such as stearic acid. Free radical initiator catalysts
such as peroxides are admixed with the core composition so that on
the application of heat and pressure, a curing or crosslinking
reaction takes place.
[0036] The cores and intermediate layers of the present invention
are preferably formed by compression molding techniques. However,
it is fully contemplated that liquid injection molding, blow
molding or transfer molding techniques could be utilized, in
addition to all of the previously described forming techniques.
[0037] Additionally, the core and/or intermediate layer
compositions of the invention may be based on polybutadiene,
natural rubber, metallocene catalyzed polyolefins, polyurethanes,
other thermoplastic or thermoset elastomers, and mixtures of one or
more of the above materials with each other and/or with other
elastomers.
[0038] In a preferred embodiment core, it is preferred that a base
elastomer having a relatively high molecular weight is used.
Polybutadiene has been found to be particularly useful because it
imparts to the golf balls a relatively high coefficient of
restitution. Polybutadiene can be cured using a free radical
initiator such as peroxide, or it can be sulfur cured. A broad
range for the molecular weight of preferred base elastomers is from
about 50,000 to about 500,000. A more preferred range for the
molecular weight of the base elastomer is from about 100,000 to
about 500,000. As a base elastomer for the core composition,
cis-1-4-polybutadiene is preferably employed, or a blend of
cis-1-4-polybutadiene with other elastomers may also be utilized.
Furthermore, the core may be comprised of a crosslinked natural
rubber, EPDM, metallocene-catalyzed polyolefin, or another
crosslinkable elastomer.
[0039] When polybutadiene is used for golf ball cores, it commonly
is crosslinked with an unsaturated carboxylic acid co-crosslinking
agent. The unsaturated carboxylic acid component of the core
composition typically is the reaction product of the selected
carboxylic acid or acids and an oxide or carbonate of a metal such
as zinc, magnesium, barium, calcium, lithium, sodium, potassium,
cadmium, lead, tin, and the like. Preferably, the oxides of
polyvalent metals such as zinc, magnesium and cadmium are used, and
most preferably, the oxide is zinc oxide.
[0040] Exemplary of the unsaturated carboxylic acids which find
utility in the core compositions are acrylic acid, methacrylic
acid, itaconic acid, crotonic acid, sorbic acid, and the like, and
mixtures thereof. Preferably, the acid component is either acrylic
or methacrylic acid. Usually, from about 5 to about 40, and
preferably from about 15 to about 30 parts by weight of the
carboxylic acid salt, such as zinc diacrylate, is included in the
core composition. The unsaturated carboxylic acids and metal salts
thereof are generally soluble in the elastomeric base, or are
readily dispersible.
[0041] The free radical initiator included in the core composition
is any known polymerization initiator (a co-crosslinking agent)
which decomposes during the cure cycle. The term "free radical
initiator" as used herein refers to a chemical which, when added to
a mixture of the elastomeric blend and a metal salt of an
unsaturated, carboxylic acid, promotes cross linking of the
elastomers by the metal salt of the unsaturated carboxylic acid.
The amount of the selected initiator present is dictated only by
the requirements of catalytic activity as a polymerization
initiator. Suitable initiators include peroxides, persulfates, azo
compounds and hydrazides. Peroxides, which are readily commercially
available, are conveniently used in the present invention,
generally in amounts of from about 0.1 to about 10.0 and preferably
in amounts of from about 0.3 to about 3.0 parts by weight per each
100 parts of elastomer.
[0042] Exemplary of suitable peroxides for the purposes of the
present invention are dicumyl peroxide, n-butyl 4,4'-bis
(butylperoxy) valerate, 1,1-bis(t-butylperoxy)-3,3,5-trimethyl
cyclohexane, di-t-butyl peroxide and 2,5-di-(t-butylperoxy)-2,5
dimethyl hexane and the like, as well as mixtures thereof. It will
be understood that the total amount of initiators used will vary
depending on the specific end product desired and the particular
initiators employed.
[0043] The core compositions of the present invention may
additionally contain any other suitable and compatible modifying
ingredients including, but not limited to, metal oxides, fatty
acids, and diisocyanates and polypropylene powder resin. For
example, Papi.RTM. 94, a polymeric diisocyanate, commonly available
from Dow Chemical Co., Midland, Mich., is an optional component in
the rubber compositions. It can range from about 0 to 5 parts by
weight per 100 parts by weight rubber (phr) component, and acts as
a moisture scavenger. In addition, it has been found that the
addition of a polypropylene powder resin results in a core which is
hard (exhibits high PGA compression) and thus allows for a
reduction in the amount of cross linking co-agent utilized to
soften the core to a normal or below normal compression.
[0044] Furthermore, because polypropylene powder resin can be added
to a core composition without an increase in weight of the molded
core upon curing, the addition of the polypropylene powder allows
for the addition of higher specific gravity fillers, such as
mineral fillers. Since the cross linking agents utilized in the
polybutadiene core compositions are expensive and/or the higher
specific gravity fillers are relatively inexpensive, the addition
of the polypropylene powder resin substantially lowers the cost of
the golf ball cores while maintaining, or lowering, weight and
compression.
[0045] Various activators may also be included in the compositions
of the present invention. For example, zinc oxide and/or magnesium
oxide are activators for the polybutadiene. The activator can range
from about 2 to about 30 parts by weight per 100 parts by weight of
the rubbers (phr) component.
[0046] Moreover, reinforcement agents may be added to the core
compositions of the present invention. Since the specific gravity
of polypropylene powder is very low, and when compounded, the
polypropylene powder produces a lighter molded core, when
polypropylene is incorporated in the core compositions, relatively
large amounts of higher specific gravity fillers may be added so
long as the specific core weight limitations are met. As indicated
above, additional benefits may be obtained by the incorporation of
relatively large amounts of higher specific gravity, inexpensive
mineral fillers such as calcium carbonate. Such fillers as are
incorporated into the core compositions should be in finely divided
form, as for example, in a size generally less than about 30 mesh
and preferably less than about 100 mesh U.S. standard size. The
amount of additional filler included in the core composition is
primarily dictated by weight restrictions and preferably is
included in amounts of from about 10 to about 100 parts by weight
per 100 parts rubber.
[0047] The preferred fillers are relatively inexpensive and heavy
and serve to lower the cost of the ball and to increase the weight
of the ball to closely approach the U.S.G.A. weight limit of 1.620
ounces. However, if thicker cover compositions are to be applied to
the core to produce larger than normal (greater than 1.680 inches
in diameter) balls, use of such fillers and modifying agents will
be limited in order to meet the U.S.G.A. maximum weight limitations
of 1.620 ounces. Limestone is ground calcium/magnesium carbonate
and is used because it is inexpensive, heavy filler. Ground flash
filler may be incorporated and is preferably 20 mesh ground up
center stock from the excess flash from compression molding. It
lowers the cost and may increase the hardness of the ball.
[0048] Fatty acids or metallic salts of fatty acids may also be
included in the compositions, functioning to improve moldability
and processing. Generally, free fatty acids having from about 10 to
about 40 carbon atoms, and preferably having from about 15 to about
20 carbon atoms, are used. Exemplary of suitable fatty acids are
stearic acid and linoleic acids, as well as mixtures thereof. An
example of a suitable metallic salt of a fatty acid is zinc
stearate. When included in the core compositions, the metallic
salts of fatty acids are present in amounts of from about 1 to
about 25, preferably in amounts from about 2 to about 15 parts by
weight based on 100 parts rubber (elastomer). It is preferred that
the core compositions include stearic acid as the fatty acid
adjunct in an amount of from about 2 to about 5 parts by weight per
100 parts of rubber.
[0049] Diisocyanates may also be optionally included in the core
compositions. When utilized, the diisocyanates are included in
amounts of from about 0.2 to about 5.0 parts by weight based on 100
parts rubber. Exemplary of suitable diisocyanates is
4,4'-diphenylmethane diisocyanate and other polyfunctional
isocyanates known in the art.
[0050] Furthermore, the dialkyl tin difatty acids set forth in U.S.
Pat. No. 4,844,471, the dispensing agents disclosed in U.S. Pat.
No. 4,838,556, and the dithiocarbamates set forth in U.S. Pat. No.
4,852,884 may also be incorporated into the polybutadiene
compositions of the present invention. The specific types and
amounts of such additives are set forth in the above identified
patents, which are incorporated herein by reference.
[0051] As noted, cores according to the present invention can be
manufactured using techniques such as injection molding, blow
molding, compression molding and reaction injection molding, or any
other technique known to one skilled in the art.
[0052] The cover layer(s) of golf balls according to the present
invention may comprise any material suitable for use in a golf ball
cover, such as those previously described. Examples of preferred
materials include, but are not limited to, ionomer resins,
polyurethane materials, and nylon compositions.
[0053] It is appreciated that the following described materials may
be used in a single layer cover or a multi-layer cover as any of an
outer cover layer or an inner cover layer. Additionally, the cover
materials described herein are also suitable for forming an
intermediate or mantle layer.
[0054] With respect to a preferred ionomeric cover composition of
the invention, ionomeric resins are polymers containing interchain
ionic bonding. As a result of their toughness, durability, and
flight characteristics, various ionomeric resins sold by E.I.
DuPont de Nemours & Company under the trademark Surlyn.RTM. and
by the Exxon Corporation (see U.S. Pat. No. 4,911,451, incorporated
herein by reference) under the trademarks Escor.RTM. and
Iotek.RTM., have become the materials of choice for the
construction of golf ball covers over the traditional "balata"
(transpolyisoprene, natural or synthetic) rubbers. Ionomeric resins
are generally ionic copolymers of an olefin, such as ethylene, and
a metal salt of an unsaturated carboxylic acid, such as acrylic
acid, methacrylic acid or maleic acid. In some instances, an
additional softening comonomer such as an acrylate can also be
included to form a terpolymer. The pendent ionic groups in the
ionomeric resins interact to form ion-rich aggregates contained in
a non-polar polymer matrix. The metal ions, such as sodium, zinc,
magnesium, lithium, potassium, calcium, and the like, are used to
neutralize some portion of the acid groups in the copolymer
resulting in a thermoplastic elastomer exhibiting enhanced
properties, for example, improved durability, for golf ball
construction over balata.
[0055] The ionomeric resins utilized to produce cover compositions
can be formulated according to known procedures such as those set
forth in U.S. Pat. No. 3,421,766 or British Patent No. 963,380,
with neutralization effected according to procedures disclosed in
Canadian Patent Nos. 674,595 and 713,631, all of which are hereby
incorporated by reference, wherein the ionomer is produced by
copolymerizing the olefin and carboxylic acid to produce a
copolymer having the acid units randomly distributed along the
polymer chain. Broadly, the ionic copolymer generally comprises one
or more .alpha.-olefins and from about 9 to about 20 weight percent
of .alpha.,.beta.-ethylenically unsaturated mono- or dicarboxylic
acid, the basic copolymer neutralized with metal ions to the extent
desired.
[0056] At least about 20% of the carboxylic acid groups of the
copolymer are neutralized by the metal ions (such as sodium,
potassium, zinc, calcium, magnesium, and the like) and exist in the
ionic state. Suitable olefins for use in preparing the ionomeric
resins include ethylene, propylene, butene-1, hexene-1 and the
like. Unsaturated carboxylic acids include acrylic, methacrylic,
ethacrylic, .alpha.-chloroacrylic, crotonic, maleic, fumaric,
itaconic acids, and the like. The ionomeric resins utilized in the
golf ball industry are generally copolymers of ethylene with
acrylic (for example, lotek.RTM.) and/or methacrylic (for example,
Surlyn.RTM.) acid. In addition, two or more types of ionomeric
resins may be blended into the cover compositions in order to
produce the desired properties of the resulting golf balls.
[0057] Examples of suitable cover compositions which may be used in
making the preferred embodiment golf balls of the present invention
are set forth in detail but not limited to those in U.S. Pat. Nos.
6,267,693, and 5,688,869, incorporated herein by reference. Of
course, the cover compositions are not limited in any way to those
compositions set forth in the patents. The cover layer(s) may
include a blend of hard and soft (low acid) ionomer resins such as
those described in U.S. Pat. Nos. 4,884,814 and 5,120,791, both
incorporated herein by reference. Other cover layer(s) may include
those as described in U.S. Pat. Nos. 6,210,293; 6,213,894;
6,224,498; and 6,287,217, incorporated herein by reference.
[0058] Other soft, relatively low modulus non-ionomeric
thermoplastic elastomers may also be utilized to produce the outer
cover layer as long as the non-ionomeric thermoplastic elastomers
produce the playability and durability characteristics desired
without adversely effecting the enhanced spin characteristics
produced by the low acid ionomer resin compositions. These include,
but are not limited to thermoplastic polyurethanes such as:
Texin.RTM. thermoplastic polyurethanes from Mobay Chemical Co.,
Pellethane.RTM. thermoplastic polyurethanes from Dow Chemical Co.
and Estane.RTM. polyester polyurethane from B.F. Goodrich Company;
Ionomer/rubber blends such as those in U.S. Pat. Nos. 4,986,545;
5,098,105 and 5,187,013; Hytrele polyester elastomers from DuPont;
and Pebax.RTM. polyetheramides from Elf Atochem S. A.
[0059] Polyurethanes are polymers that are used to form a broad
range of products. They are generally formed by mixing two primary
ingredients during processing. For the most commonly used
polyurethanes, the two primary ingredients are a polyisocyanate
(for example, diphenyl methane diisocyanate monomer ("MDI") and
toluene diisocyanate ("TDI") and their derivatives) and a polyol
(for example, a polyester polyol or a polyether polyol).
[0060] A wide range of combinations of polyisocyanates and polyols,
as well as other ingredients, are available. Furthermore, the
end-use properties of polyurethanes can be controlled by the type
of polyurethane utilized, that is, whether the material is
thermoset (crosslinked molecular structure) or thermoplastic
(linear molecular structure).
[0061] Crosslinking occurs between the isocyanate groups (--NCO)
and the polyol's hydroxyl end-groups (--OH). Additionally, the
end-use characteristics of polyurethanes can also be controlled by
different types of reactive chemicals and processing parameters.
For example, catalysts are utilized to control polymerization
rates. Depending upon the processing method, reaction rates can be
very quick (as in the case for some reaction injection molding
systems ("RIM")) or may be on the order of several hours or longer
(as in several coating systems). Consequently, a great variety of
polyurethanes are suitable for different end uses.
[0062] Polyurethane has been used for golf balls and other game
balls as a cover material. Commercially available polyurethane golf
balls have been made of thermoset and thermoplastic polyurethanes.
A polyurethane becomes irreversibly "set" when a polyurethane
prepolymer is cross linked with a polyfunctional curing agent, such
as polyamine and polyol. The prepolymer typically is made from
polyether or polyester. Diisocyanate polyethers are preferred for
some embodiments because of their water resistance.
[0063] The physical properties of thermoset polyurethanes are
controlled substantially by the degree of cross linking. Tightly
cross linked polyurethanes are fairly rigid and strong. A lower
amount of cross linking results in materials that are flexible and
resilient. Thermoplastic polyurethanes have some cross linking, but
purely by physical means. The crosslinkings bonds can be reversibly
broken by increasing temperature, as occurs during molding or
extrusion. In this regard, thermoplastic polyurethanes can be
injection molded, and extruded as sheet and blown film. They can be
used up to about 350.degree. F. and are available in a wide range
of hardnesses.
[0064] Polyurethane materials suitable for the present invention
are generally formed by the reaction of a polyisocyanate, a polyol,
and optionally one or more chain extending diols. The
polyisocyanate is selected, for example, from the group including,
but not limited to, diphenyl methane diisocyanate ("MDI"); toluene
diisocyanate ("TDI"); xylene diisocyanate ("XDI"); methylene
bis-(4-cyclohexyl isocyanate) ("HMDI"); hexamethylene diisocyanate;
and naphthalene-1,5,-diisocyanate ("NDI").
[0065] Further examples of suitable polyurethanes include
polyurethane systems formed via reaction injection molding (RIM).
RIM processing to form various layers of a golf ball is described
in detail U.S. Pat. No. 6,290,614, incorporated herein by
reference.
[0066] The golf balls of the present invention can be produced, at
least in part, by molding processes currently known in the golf
ball art. Specifically, golf balls can be produced by injection
molding or compression molding an intermediate layer about molded
cores to produce an intermediate golf ball generally having a
diameter of about 1.50 to 1.67 inches. The cover layer is
subsequently molded over the intermediate layer to produce a golf
ball having a diameter of 1.680 inches or more. If no intermediate
layer is desired, the cover layer can be molded directly over the
core. For golf balls having a dual core, a core layer or layers is
molded over a center core component to form the core, and the
intermediate and/or cover layer(s) are then molded over the
core.
[0067] For polyurethane components, a preferred method of forming
the polyurethane component is by reaction injection molding
("RIM"). RIM is a process by which highly reactive liquids are
injected into a closed mold, mixed usually by impingement and/or
mechanical mixing in an in-line device such as a "peanut mixer,"
where they polymerize primarily in the mold to form a coherent,
one-piece molded article. The RIM processes usually involve a rapid
reaction between one or more reactive components such as
polyether--or polyester--polyol, polyamine, or other material with
an active hydrogen, and one or more isocyanate--containing
constituents, often in the presence of a catalyst. The constituents
are stored in separate tanks prior to molding and may be first
mixed in a mix head upstream of a mold and then injected into the
mold. The liquid streams are metered in the desired weight to
weight ratio and fed into an impingement mix head, with mixing
occurring under high pressure, for example, about 1500 to 3000 psi.
The liquid streams impinge upon each other in the mixing chamber of
the mix head and the mixture is injected into the mold. One of the
liquid streams typically contains a catalyst for the reaction. The
constituents react rapidly after mixing to gel and form
polyurethane polymers. Polyureas, epoxies, and various unsaturated
polyesters also can be molded by RIM.
[0068] In addition to the above noted ionomers and non-ionomers,
compatible additive materials may also be added to produce the
cover compositions of the present invention. These additive
materials include dyes (for example, Ultramarine Blue.TM. sold by
Whitaker, Clark, and Daniels of South Plainfield, N.J.), and
pigments such as white pigments such as titanium dioxide (for
example Unitane.TM. 0-110) zinc oxide, and zinc sulfate, as well as
fluorescent pigments. As indicated in U.S. Pat. No. 4,884,814, the
amount of pigment and/or dye used in conjunction with the polymeric
cover composition depends on the particular base ionomer or
non-ionomer mixture utilized and the particular pigment and/or dye
utilized. The concentration of the pigment in the polymeric cover
composition can be from about 1% to about 10% as based on the
weight of the base ionomer or non-ionomer mixture. A more preferred
range is from about 1% to about 5% as based on the weight of the
base ionomer or non-ionomer mixture. The most preferred range is
from about 1% to about 3% as based on the weight of the base
ionomer or non-ionomer mixture. The most preferred pigment for use
in accordance with this invention is titanium dioxide.
[0069] Moreover, since there are various hues of white, such as
blue white, yellow white, and the like, trace amounts of blue
pigment may be added to the cover stock composition to impart a
blue white appearance thereto. However, if different hues of the
color white are desired, different pigments can be added to the
cover composition at the amounts necessary to produce the color
desired.
[0070] In addition, it is within the purview of this invention to
add to the cover compositions of this invention compatible
materials that do not affect the basic novel characteristics of the
composition of this invention. Among such materials are
antioxidants (for example, Santonox.RTM. R), antistatic agents,
stabilizers and processing aids. The cover compositions of the
present invention may also contain softening agents, such as
plasticizers, and reinforcing materials such as glass fibers and
inorganic fillers, as long as the desired properties produced by
the golf ball covers of the invention are not impaired.
[0071] Furthermore, optical brighteners, such as those disclosed in
U.S. Pat. No. 4,679,795, herein incorporated by reference, may also
be included in the cover composition of the invention. Moreover,
since many optical brighteners are colored, the percentage of
optical brighteners utilized must not be excessive in order to
prevent the optical brightener from functioning as a pigment or dye
in its own right.
[0072] The various cover composition layers of the present
invention may be produced according to conventional melt blending
procedures or other conventional procedures. For example, when a
blend of hard and soft, low acid ionomer resins are utilized, the
hard ionomer resins are blended with the soft ionomeric resins and
with a masterbatch containing the desired additives in a
Banbury.RTM. mixer, two-roll mill, or extruder prior to molding.
The blended composition is then formed into slabs and maintained in
such a state until molding is desired. Alternatively, a simple dry
blend of the pelletized or granulated resins and color masterbatch
may be prepared and fed directly into the injection molding machine
where homogenization occurs in the mixing section of the barrel
prior to injection into the mold. If necessary, further additives
such as an inorganic filler, may be added and uniformly mixed
before initiation of the molding process.
[0073] Often, fillers are used in one or more layers of a golf
ball. If desired, any layer of the golf ball may contain at least
one part by weight of a filler. Fillers preferably are used to
adjust the density, flex modulus, mold release, and/or melt flow
index of a layer. More preferably, at least when the filler is for
adjustment of density or flex modulus of a layer, it is present in
an amount of at least five parts by weight based upon 100 parts by
weight of the layer composition. With some fillers, up to about 200
parts by weight probably can be used.
[0074] A density adjusting filler according to the invention
preferably is a filler which has a specific gravity which is at
least 0.05 and more preferably at least 0.1 higher or lower than
the specific gravity of the layer composition. Particularly
preferred density adjusting fillers have specific gravities that
are higher than the specific gravity of the resin composition by
0.2 or more, even more preferably by 2.0 or more.
[0075] A flex modulus adjusting filler according to the invention
is a filler which, when used in an amount of about 1 to 100 parts
by weight based upon 100 parts by weight of resin composition, will
raise or lower the flex modulus (ASTM D-790) of the resin
composition by at least 1% and preferably at least 5% as compared
to the flex modulus of the resin composition without the inclusion
of the flex modulus adjusting filler.
[0076] The layers may contain coupling agents that increase
adhesion of materials within a particular layer, such as to couple
a filler to a resin composition, or between adjacent layers.
Non-limiting examples of coupling agents include titanates,
zirconates and silanes. Coupling agents typically are used in
amounts of 0.1 to 2 weight percent based upon the total weight of
the composition in which the coupling agent is included. Coupling
agents and other chemical adhesives may be used in addition to the
mechanical interlocking of the invention.
[0077] The density-increasing fillers for use in the invention
preferably have a specific gravity in the range of 1.0 to 20. The
density-reducing fillers for use in the invention preferably have a
specific gravity of 0.06 to 1.4, and more preferably 0.06 to 0.90.
The flex modulus increasing fillers have a reinforcing or
stiffening effect due to their morphology, their interaction with
the resin, or their inherent physical properties. The flex modulus
reducing fillers have an opposite effect due to their relatively
flexible properties compared to the matrix resin. The melt flow
index increasing fillers have a flow enhancing effect due to their
relatively high melt flow versus the matrix. The melt flow index
decreasing fillers have an opposite effect due to their relatively
low melt flow index versus the matrix.
[0078] Fillers which may be employed in layers other than the outer
cover layer may be or are typically in a finely divided form, for
example, in a size generally less than about 20 mesh, preferably
less than about 100 mesh U.S. standard size, except for fibers and
flock, which are generally elongated. Flock and fiber sizes should
be small enough to facilitate processing. Filler particle size will
depend upon desired effect, cost, ease of addition, and dusting
considerations. Examples of fillers that may be used in the
invention include, but are not limited to, precipitated hydrated
silica, clay, talc, asbestos, glass fibers, aramid fibers, mica,
calcium metasilicate, barium sulfate, zinc sulfide, lithopone,
silicates, silicon carbide, diatomaceous earth, polyvinyl chloride,
carbonates, metals, metal alloys, tungsten carbide, metal oxides,
metal stearates, particulate carbonaceous materials, micro
balloons, and combinations thereof.
[0079] The foregoing description is, at present, considered to be
the preferred embodiments of the present invention. However, it is
contemplated that various changes and modifications apparent to
those skilled in the art, may be made without departing from the
present invention. Therefore, the foregoing description is intended
to cover all such changes and modifications encompassed within the
spirit and scope of the present invention, including all equivalent
aspects.
* * * * *