U.S. patent application number 13/732059 was filed with the patent office on 2013-05-16 for multi-piece solid golf ball.
This patent application is currently assigned to BRIDGESTONE SPORTS CO., LTD.. The applicant listed for this patent is Bridgestone Sports Co., Ltd.. Invention is credited to Akira KIMURA, Hideo WATANABE.
Application Number | 20130123045 13/732059 |
Document ID | / |
Family ID | 44143576 |
Filed Date | 2013-05-16 |
United States Patent
Application |
20130123045 |
Kind Code |
A1 |
WATANABE; Hideo ; et
al. |
May 16, 2013 |
MULTI-PIECE SOLID GOLF BALL
Abstract
The invention provides a multi-piece solid golf ball having a
solid core, at least one intermediate layer and a cover. The core
has a hardness which gradually increases from a core center to a
core surface, with the golf ball having specific values for the
hardness difference between the core center and the core surface;
the hardness difference (I)-(II) in JIS-C hardness units being not
more than .+-.2; the (hardness of intermediate layer
material)-(hardness of core surface); the (initial velocity of
sphere composed of core encased by intermediate layer)-(initial
velocity of core); the (deflection of sphere composed of core
encased by intermediate layer)/(deflection of core); and the
(hardness of cover material)-(hardness of intermediate layer
material).
Inventors: |
WATANABE; Hideo;
(Chichibu-shi, JP) ; KIMURA; Akira; (Chichibu-shi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bridgestone Sports Co., Ltd.; |
Tokyo |
|
JP |
|
|
Assignee: |
BRIDGESTONE SPORTS CO.,
LTD.
Tokyo
JP
|
Family ID: |
44143576 |
Appl. No.: |
13/732059 |
Filed: |
December 31, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12635327 |
Dec 10, 2009 |
8393978 |
|
|
13732059 |
|
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Current U.S.
Class: |
473/374 |
Current CPC
Class: |
A63B 37/0065 20130101;
A63B 37/0076 20130101; A63B 37/0046 20130101; A63B 37/0092
20130101; A63B 37/0075 20130101; A63B 37/0031 20130101; A63B
37/0063 20130101 |
Class at
Publication: |
473/374 |
International
Class: |
A63B 37/00 20060101
A63B037/00 |
Claims
1. A multi-piece solid golf ball comprising a solid core, at least
one intermediate layer and a cover, wherein the core has a hardness
which gradually increases from a core center to a core surface, the
hardness difference in JIS-C hardness units between the core center
and the core surface being at least 15 and, letting (I) be the
calculated average value of the cross-sectional hardness measured
at a position 15 mm from the core center and the cross-sectional
hardness measured at the core center and letting (II) be the
measured cross-sectional hardness at a position 7.5 mm from the
core center, the hardness difference (I)-(II) in JIS-C hardness
units being not more than .+-.2; the intermediate layer has a
material hardness and the core has a surface hardness which
together satisfy the condition (JIS-C hardness of intermediate
layer material)-(JIS-C hardness of core surface)>0; a sphere
composed of the core encased by the intermediate layer has an
initial velocity and the core has an initial velocity which
together satisfy the condition (initial velocity of sphere composed
of core encased by intermediate layer)-(initial velocity of
core).gtoreq.0; the sphere composed of the core encased by the
intermediate layer has a deflection and the core has a deflection
which together satisfy the condition 0.80.ltoreq.(deflection of
sphere composed of core encased by intermediate layer)/(deflection
of core); the cover is formed of a cover material composed
primarily of polyurethane; and the cover material has a Shore D
hardness and the intermediate layer material has a Shore D hardness
which together satisfy the condition (Shore D hardness of cover
material)-(Shore D hardness of intermediate layer
material).ltoreq.0; wherein thickness of the cover (mm) and
thickness of the intermediate layer (mm) satisfy the following
relationship: cover thickness.ltoreq.intermediate layer thickness;
wherein the ball has a deflection and the sphere composed of the
core encased by the intermediate layer has a deflection which
together satisfy the condition 0.85.ltoreq.(ball
deflection)/(deflection of sphere composed of core encased by
intermediate layer).ltoreq.0.97; and wherein the intermediate layer
material has a Shore D hardness of from 50 to 60.
2. The multi-piece solid golf ball of claim 1, wherein the
intermediate layer is formed primarily of a resin mixture obtained
by blending as essential components: 100 parts by weight of a resin
component composed of, in admixture, (A) a base resin of (a-1) an
olefin-unsaturated carboxylic acid random copolymer and/or a metal
ion neutralization product of an olefin-unsaturated carboxylic acid
random copolymer blended with (a-2) an olefin-unsaturated
carboxylic acid-unsaturated carboxylic acid ester random terpolymer
and/or a metal ion neutralization product of an olefin-unsaturated
carboxylic acid-unsaturated carboxylic acid ester random terpolymer
in a weight ratio of from 100:0 to 0:100, and (B) a non-ionomeric
thermoplastic elastomer in a weight ratio of from 100:0 to 50:50;
(C) from 5 to 120 parts by weight of a fatty acid and/or fatty acid
derivative having a molecular weight of from 228 to 1500; and (D)
from 0.1 to 17 parts by weight of a basic inorganic metal compound
capable of neutralizing un-neutralized acid groups in component A
and component C.
3. The multi-piece solid golf ball of claim 1, wherein the hardness
difference (I)-(II) in JIS-C units is not more than .+-.1.
4. The multi-piece solid golf ball of claim 1, wherein the initial
speed of the sphere composed of the core encased by the
intermediate layer and the initial speed of the core together
satisfy the condition (initial speed of sphere composed of core
encased by intermediate layer)-(initial speed of
core).gtoreq.0.2.
5. The multi-piece solid golf ball of claim 1, wherein the
deflection of the sphere composed of the core encased by the
intermediate layer and the deflection of the core together satisfy
the condition 0.80.ltoreq.(deflection of sphere composed of core
encased by intermediate layer)/(deflection of core).ltoreq.0.92.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a multi-piece solid golf
ball composed of a core on which an intermediate layer and a cover
have been formed as successive layers. More specifically, the
invention relates to a multi-piece solid golf ball which has an
excellent flight performance and feel and has a good durability to
repeated impact and a good scuff resistance.
[0002] The major performance attributes required of golf balls
include distance, controllability, durability and feel on impact;
balls having the highest levels of such attributes are constantly
being sought. In this context, there has emerged among recent golf
balls a succession of balls with multilayer structures--typically
three-piece balls. Providing a golf ball with a multilayer
structure makes it possible to combine many materials of differing
properties; by assigning various functions to the respective
layers, a wide diversity of ball designs can be achieved.
[0003] Among such golf balls, wide use is made of multi-piece solid
golf balls in which the hardness relationships between each layer,
such as an intermediate layer encasing the core and a cover layer,
have been optimized. In recent years, elements regarded to be
important in assessing ball performance include not only the flight
performance, but also the durability of the ball to cracking and
the scuff resistance--which is the ability to suppress burr
formation on the ball surface. Therefore, designing the thickness,
hardness and other properties of the respective ball layers in such
a way as to maximize these desirable effects is a major challenge.
Also, golf balls are commonly used not only by professionals and
other skilled golfers, by also by amateur golfers having a
relatively low head speed. Accordingly, there is a desire for the
development of golf balls which, even when used by amateur golfers,
enable a sufficient distance to be achieved.
[0004] Hence, there exists a need for golf balls which satisfy the
conflicting demands for improved distance, controllability,
durability and feel. In particular, there exists a desire for the
development of a golf ball which, on shots with a driver, increases
the distance by keeping the spin rate low and, on shots with an
iron, provides a suitable spin rate, exhibits good controllability,
and has an excellent durability to cracking and scuff
resistance.
[0005] Art relating to the present invention is disclosed in, for
example, JP-A 2003-190330, JP-A 2004-049913, JP-A 2002-315848, JP-A
2001-54588, JP-A 2002-85588, JP-A 2002-85589, JP-A 2002-85587, JP-A
2002-186686, JP-A 2009-34505 and JP-A 2005-211656. However, further
improvement has been desired.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to
provide a golf ball which, by optimizing the hardnesses of the
intermediate layer and the cover and optimizing the core hardness
profile, has an excellent flight performance and a soft feel when
played by amateur golfers, and moreover has a good scuff resistance
and a good durability to repeated impact.
[0007] The inventors have conducted extensive investigations in
order to achieve the above object. As a result, they have
discovered that, with regard to the hardness profile of the core in
a multi-piece solid golf ball having a core, an intermediate layer
and a cover, by focusing both on the hardness difference between
the core surface and the core center and on the hardness gradient
in the core and working to optimize these, and by also optimizing
the hardness relationship between the core and the respective
layers (intermediate layer and cover) encasing the core, a lower
spin rate can be achieved on full shots with a driver (W#1), giving
the ball an improved distance. In addition, the inventors have
found that, by combining with the above a cover formed primarily of
polyurethane, the ball can also be endowed with an excellent
durability to cracking on repeated impact and an excellent scuff
resistance.
[0008] Accordingly, the invention provides the following
multi-piece solid golf balls.
[1] A multi-piece solid golf ball comprising a solid core, at least
one intermediate layer and a cover, wherein the core has a hardness
which gradually increases from a core center to a core surface, the
hardness difference in JIS-C hardness units between the core center
and the core surface being at least 15 and, letting (I) be the
average value for the cross-sectional hardness at a position 15 mm
from the core center and the cross-sectional hardness at the core
center and letting (II) be the cross-sectional hardness at a
position 7.5 mm from the core center, the hardness difference
(I)-(II) in JIS-C hardness units being not more than .+-.2; the
intermediate layer has a material hardness and the core has a
surface hardness which together satisfy the condition
(JIS-C hardness of intermediate layer material)-(JIS-C hardness of
core surface)>0;
a sphere composed of the core encased by the intermediate layer has
an initial velocity and the core has an initial velocity which
together satisfy the condition
(initial velocity of sphere composed of core encased by
intermediate layer)-(initial velocity of core).gtoreq.0;
the sphere composed of the core encased by the intermediate layer
has a deflection and the core has a deflection which together
satisfy the condition
0.80.ltoreq.(deflection of sphere composed of core encased by
intermediate layer)/(deflection of core);
the cover is formed of a cover material composed primarily of
polyurethane; and the cover material has a Shore D hardness and the
intermediate layer material has a Shore D hardness which together
satisfy the condition
(Shore D hardness of cover material)-(Shore D hardness of
intermediate layer material).ltoreq.0.
[2] The multi-piece solid golf ball of [1], wherein the
intermediate layer is formed primarily of a resin mixture obtained
by blending as essential components:
[0009] 100 parts by weight of a resin component composed of, in
admixture, [0010] (A) a base resin of (a-1) an olefin-unsaturated
carboxylic acid random copolymer and/or a metal ion neutralization
product of an olefin-unsaturated carboxylic acid random copolymer
blended with (a-2) an olefin-unsaturated carboxylic
acid-unsaturated carboxylic acid ester random terpolymer and/or a
metal ion neutralization product of an olefin-unsaturated
carboxylic acid-unsaturated carboxylic acid ester random terpolymer
in a weight ratio of from 100:0 to 0:100, and [0011] (B) a
non-ionomeric thermoplastic elastomer in a weight ratio of from
100:0 to 50:50; [0012] (C) from 5 to 120 parts by weight of a fatty
acid and/or fatty acid derivative having a molecular weight of from
228 to 1500; and [0013] (D) from 0.1 to 17 parts by weight of a
basic inorganic metal compound capable of neutralizing
un-neutralized acid groups in component A and component C. [3] The
multi-piece solid golf ball of [1], wherein the hardness difference
(I)-(II) in JIS-C units is not more than .+-.1. [4] The multi-piece
solid golf ball of [1], wherein the initial speed of the sphere
composed of the core encased by the intermediate layer and the
initial speed of the core together satisfy the condition
[0013] (initial speed of sphere composed of core encased by
intermediate layer)-(initial speed of core).gtoreq.0.2.
[5] The multi-piece solid golf ball of [1], wherein the deflection
of the sphere composed of the core encased by the intermediate
layer and the deflection of the core together satisfy the
condition
0.80.ltoreq.(deflection of sphere composed of core encased by
intermediate layer)/(deflection of core).ltoreq.0.92.
[6] The multi-piece solid golf ball of [1], wherein the
intermediate layer material has a Shore D hardness of from 50 to
60. [7] The multi-piece solid golf ball of [1], wherein the ball
has a deflection and the sphere composed of the core encased by the
intermediate layer has a deflection which together satisfy the
condition
0.85.ltoreq.(ball deflection)/(deflection of sphere composed of
core encased by intermediate layer).ltoreq.0.97.
BRIEF DESCRIPTION OF THE DIAGRAMS
[0014] FIG. 1 is a schematic sectional view showing a multi-piece
solid golf ball (3-layer construction) according to the
invention.
[0015] FIG. 2 is a diagram illustrating positions at the interior
of the core.
[0016] FIG. 3 is a top view of a golf ball showing the arrangement
of dimples used in the examples of the invention and in the
comparative examples.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The invention is described in greater detail below.
[0018] The multi-piece solid golf ball of the present invention has
a solid core, at least one intermediate layer, and a cover. FIG. 1
shows an exemplary construction of a golf ball G according to the
present invention. Referring to FIG. 1, the golf ball G of the
invention has a plurality of layers, including at least a core 1,
an intermediate layer 2 which encases the core 1, and a cover 3
which encases the intermediate layer 2. The core 1 and the
intermediate layer 2 are not limited to single layers, and may each
be formed of a plurality of two more layers. The cover 3 typically
has a large number of dimples D formed on the surface thereto to
enhance the aerodynamic properties.
[0019] The core has a diameter which, while not subject to any
particular limitation, is generally from 35 to 41 mm, preferably
from 36 to 40 mm, and more preferably from 37 to 39 mm. At a core
diameter outside this range, the ball may have a lower initial
velocity or may have a less than adequate spin rate-lowering effect
after the ball is hit, as a result of which an increased distance
may not be achieved. As mentioned above, the core is not limited to
a single layer, and may have a multilayer construction of two or
more layers.
[0020] The core has a surface hardness which, while not subject to
any particular limitation, has a JIS-C hardness value of generally
from 68 to 90, preferably from 72 to 85, and more preferably form
75 to 82. The core has a center hardness which, while not subject
to any particular limitation, has a JIS-C hardness value of
generally from 50 to 70, preferably from 54 to 65, and more
preferably from 56 to 62. If the above value is too small, the
rebound of the core may be inadequate, as a result of which the
ball may not achieve an increased distance, and the durability of
the ball to cracking on repeated impact may worsen. On the other
hand, if the above value is too high, the ball may have an
excessively high spin rate on full shots, as a result of which an
increased distance may not be achieved.
[0021] In the present invention, it is essential that the core have
a hardness which gradually increases from the center to the surface
of the core, the hardness difference between the core center and
the core surface in JIS-C units being at least 15, preferably from
16 to 40, and more preferably from 18 to 35. If the hardness
difference is too small, the spin rate-lowering effect on shots
with a driver (W#1) may be inadequate, as a result of which the
desired distance may not be achieved. On the other hand, if the
hardness difference is too large, the initial velocity on impact
may decrease, possibly keeping the desired distance from being
achieved, and the durability to cracking on repeated impact may
worsen. Also, even when the hardness difference is within the
above-indicated range, cases in which the hardness is not fully
optimized and thus does not gradually increase from the core center
to the core surface are undesirable because the spin rate-lowering
effect on shots with a driver (W#1) will be inadequate.
[0022] Moreover, referring to FIG. 2, by optimizing the respective
cross-sectional hardnesses at the core center and at positions
located 7.5 mm and 15 mm from the core center, the spin
rate-lowering effect on shots taken with a driver (W#1) can be
enhanced. Specifically, letting (I) be the average value for the
cross-sectional hardness at a position 15 mm from the core center
and the cross-sectional hardness at the core center and letting
(II) be the cross-sectional hardness at a position 7.5 mm from the
core center, it is critical for the hardness difference (I)-(II)
therebetween in JIS-C hardness units to be not more than .+-.2.
This means that in a case where the core center has a JIS-C
hardness of 60 and the JIS-C hardness at a position 15 mm out from
the core center is 74, because the average (I) thereof is a JIS-C
hardness of 67, the JIS-C hardness (II) at a position 7.5 mm from
the core center (corresponding to a point midway between the core
center and the position 15 mm from the core center) is within a
range of .+-.2 of the above average value of 67. This parameter
serves in the inventive golf ball as an indicator showing that the
hardness has a slope at which it increases linearly from the core
center to the core surface.
[0023] The above hardness difference (I)-(II) is preferably not
more than .+-.1 JIS-C hardness unit, and is more preferably .+-.0;
that is, (II) is more preferably identical to the above average
value (I). If this hardness difference is too large, the core
hardness slope will not be linear, as a result of which the spin
rate-lowering effect on shots with a driver (W#1) may be inadequate
and the desired distance may not be achieved.
[0024] The deflection when the core is subjected to loading, i.e.,
the deflection (mm) of the core when compressed under a final load
of 1,275 N (130 kgf) from an initial load of 98 N (10 kgf), while
not subject to any particular limitation, is generally from 3.0 mm
to 6.0 mm, preferably from 3.4 mm to 5.0 mm, and more preferably
from 3.7 mm to 4.5 mm. If this value is too large, the core may
lack sufficient rebound, which may result in a less than
satisfactory distance, and the durability of the ball to cracking
on repeated impact may worsen. On the other hand, if this value is
too small, the ball may have an excessively hard feel on full
shots, and the spin rate may be too high, as a result of which an
increased distance may not be achieved.
[0025] In the present invention, as described above, it is
especially critical for the hardness to increase gradually from the
core center toward the core surface, and it is also essential for
the core cross-sectional hardness profile and the core deflection
to be optimized within the specified ranges. When sulfur, for
example, is included for this purpose in formulating the
core-forming material, although the outcome will vary also with the
various types of additives which are included and the vulcanization
conditions, there is a possibility that, during rubber
vulcanization, the region near the center of the core will end up
being soft, as a result of which the desired linear hardness
gradient may not be achieved.
[0026] A rubber material may be used as the primary material in the
above core-forming material. For example, the core may be formed of
a rubber composition containing, in addition to the rubber
material, a co-crosslinking agent, an organic peroxide, an inert
filler, an organosulfur compound and the like. It is preferable to
use polybutadiene as the base rubber of this rubber composition. In
the present invention, as mentioned above, it is critical for the
hardness to gradually increase from the core center to the core
surface, and it is essential for the core cross-sectional hardness
profile to be optimized in a specific way.
[0027] In the present invention, rubber compositions preferable for
forming the above solid core are exemplified by rubber compositions
formulated as shown below.
[0028] The core used in the present invention may be a rubber core
which has been molded and vulcanized from a rubber composition
composed primarily of a base rubber. Specifically, the core may be
formed using a molded and vulcanized rubber composition containing,
in addition to the base rubber: a co-crosslinking agent, an organic
peroxide, an inert filler, and an organosulfur compound.
[0029] Polybutadiene is preferably used as the base rubber of the
above core-forming rubber composition. It is desirable for this
polybutadiene to have a cis-1,4-bond content on the polymer chain
of at least 60 wt %, preferably at least 80 wt %, more preferably
at least 90 wt %, and most preferably at least 95 wt %. Too low a
cis-1,4-bond content among the bonds on the molecule may lead to a
lower resilience. Moreover, the polybutadiene has a 1,2-vinyl bond
content on the polymer chain of preferably not more than 2%, more
preferably not more than 1.7%, and even more preferably not more
than 1.5%. Too high a 1,2-vinyl bond content may lead to a lower
resilience.
[0030] To obtain a molded and vulcanized rubber composition of good
resilience, the polybutadiene used in the invention is preferably
one synthesized with a rare-earth catalyst or a Group VIII metal
compound catalyst. Polybutadiene synthesized with a rare-earth
catalyst is especially preferred.
[0031] Such rare-earth catalysts are not subject to any particular
limitation. Exemplary rare-earth catalysts include those made up of
a combination of a lanthanide series rare-earth compound with an
organoaluminum compound, an alumoxane, a halogen-bearing compound
and an optional Lewis base.
[0032] Examples of suitable lanthanide series rare-earth compounds
include halides, carboxylates, alcoholates, thioalcoholates and
amides of atomic number 57 to 71 metals.
[0033] In the practice of the invention, the use of a neodymium
catalyst in which a neodymium compound serves as the lanthanide
series rare-earth compound is particularly advantageous because it
enables a polybutadiene rubber having a high cis-1,4 bond content
and a low 1,2-vinyl bond content to be obtained at an excellent
polymerization activity. Suitable examples of such rare-earth
catalysts include those mentioned in JP-A 11-35633, JP-A 11-164912
and JP-A 2002-293996.
[0034] To enhance the resilience, it is preferable for the
polybutadiene synthesized using the lanthanide series rare-earth
compound catalyst to account for at least 10 wt %, preferably at
least 20 wt %, and more preferably at least 40 wt %, of the rubber
components.
[0035] Rubber components other than the above-described
polybutadiene may be included in the rubber composition insofar as
the objects of the invention are attainable. Illustrative examples
of rubber components other than the above-described polybutadiene
include other polybutadienes, and other diene rubbers, such as
styrene-butadiene rubber, natural rubber, isoprene rubber and
ethylene-propylene-diene rubber.
[0036] Examples of co-crosslinking agents include unsaturated
carboxylic acids and the metal salts of unsaturated carboxylic
acids.
[0037] Specific examples of unsaturated carboxylic acids include
acrylic acid, methacrylic acid, maleic acid and fumaric acid.
Acrylic acid and methacrylic acid are especially preferred.
[0038] The metal salts of unsaturated carboxylic acids, while not
subject to any particular limitation, are exemplified by the
above-mentioned unsaturated carboxylic acids neutralized with a
desired metal ion. Specific examples include the zinc and magnesium
salts of methacrylic acid and acrylic acid. The use of zinc
acrylate is especially preferred.
[0039] The unsaturated carboxylic acid and/or metal salt thereof is
included in an amount, per 100 parts by weight of the base rubber,
of preferably at least 5 parts by weight, more preferably at least
10 parts by weight, and even more preferably at least 15 parts by
weight. The amount included is preferably not more than 60 parts by
weight, more preferably not more than 50 parts by weight, even more
preferably not more than 40 parts by weight, and most preferably
not more than 30 parts by weight. Too much may make the core too
hard, giving the ball an unpleasant feel on impact, whereas too
little may lower the rebound.
[0040] The organic peroxide may be a commercially available
product, suitable examples of which include Percumyl D (available
from NOF Corporation), Perhexa 3M (NOF Corporation), Perhexa C40
(NOF Corporation) and Luperco 231XL (Atochem Co.). These may be
used singly.
[0041] The amount of organic peroxide included per 100 parts by
weight of the base rubber is preferably at least 0.1 part by
weight, more preferably at least 0.3 part by weight, even more
preferably at least 0.5 part by weight, and most preferably at
least 0.7 part by weight. The upper limit in the amount included is
preferably not more than 5 parts by weight, more preferably not
more than 4 parts by weight, even more preferably not more than 3
parts by weight, and most preferably not more than 2 parts by
weight. Too much or too little organic peroxide may make it
impossible to achieve a ball having a good feel, durability and
rebound.
[0042] Examples of suitable inert fillers include zinc oxide,
barium sulfate and calcium carbonate. These may be used singly or
as a combination of two or more thereof.
[0043] The amount of inert filler included per 100 parts by weight
of the base rubber is preferably at least 1 part by weight, and
more preferably at least 5 parts by weight. The upper limit in the
amount included is preferably not more than 100 parts by weight,
more preferably not more than 80 parts by weight, and even more
preferably not more than 60 parts by weight. Too much or too little
inert filler may make it impossible to achieve a proper weight and
a good rebound.
[0044] In addition, an antioxidant may be included if necessary.
Illustrative examples of suitable commercial antioxidants include
Nocrac NS-6, Nocrac NS-30 and Nocrac 200 (all available from Ouchi
Shinko Chemical Industry Co., Ltd.), and Yoshinox 425 (available
from Yoshitomi Pharmaceutical Industries, Ltd.). These may be used
singly or as a combination of two or more thereof.
[0045] The amount of antioxidant included may be set to more than
0, and may be set to an amount per 100 parts by weight of the base
rubber of preferably at least 0.05 part by weight, and especially
at least 0.1 part by weight. The upper limit in the amount
included, although not subject to any particular limitation, may be
set to an amount per 100 parts by weight of the base rubber of
preferably not more than 3 parts by weight, more preferably not
more than 2 parts by weight, even more preferably not more than 1
part by weight, and most preferably not more than 0.5 part by
weight. Too much or too little antioxidant may make it impossible
to achieve a suitable core hardness gradient, a good rebound and
durability, and a spin rate-lowering effect on full shots.
[0046] The rubber composition containing the various above
ingredients is prepared by mastication using a typical mixing
apparatus, such as a Banbury mixer or a roll mill. When this rubber
composition is used to mold the core, molding may be carried out by
compression molding or injection molding using a specific mold for
molding cores. The resulting molded body is then heated and cured
under temperature conditions sufficient for the organic peroxide
and co-crosslinking agent included in the rubber composition to
act, thereby giving a core having a specific hardness profile. The
vulcanization conditions in this case, while not subject to any
particular limitation, are generally set to conditions of about 130
to 170.degree. C., and especially 150 to 160.degree. C., for 10 to
40 minutes, and especially 12 to 20 minutes.
[0047] The golf ball of the present invention has at least one
intermediate layer which encases the above core, and has a cover
which encases the intermediate layer. These layers must each
satisfy the following conditions, and must fulfill the subsequently
described relationships with respect to other layers. First, the
respective conditions for the intermediate layer and the cover are
described.
[0048] The intermediate layer material has a Shore D hardness of
preferably at least 40, more preferably at least 45, and even more
preferably at least 50, with the upper limit value being preferably
not more than 70, more preferably not more than 60, and even more
preferably not more than 56. The intermediate layer material has a
hardness, expressed as the JIS-C hardness, of preferably at least
63, more preferably at least 70, and even more preferably at least
76, with the upper limit value being preferably not more than 100,
more preferably not more than 89, and even more preferably not more
than 84. If the intermediate layer material is too much softer than
the above range, on shots with a driver (W#1), the ball may have a
decreased rebound or the spin rate may rise excessively, as a
result of which a sufficient distance may not be achieved. On the
other hand, if the intermediate layer material is too hard, the
durability to cracking on repeated impact may worsen or the ball
may have a poor feel.
[0049] The intermediate layer has a thickness which, although not
subject to any particular limitation, may be set to preferably from
0.8 to 2.5 mm, more preferably from 1.0 to 1.8 mm, and even more
preferably from 1.2 to 1.6 mm. If the intermediate layer thickness
is too small, the durability to cracking on repeated impact may
worsen, or the ball rebound may decrease, as a result of which an
increased distance may not be achieved. On the other hand, if the
intermediate layer thickness is too large, the spin rate on shots
with a driver (W#1) may increase, as a result of which an increased
distance may not be achieved.
[0050] The structure of the above-described intermediate layer is
not limited to a single layer; where necessary, two or more like or
unlike intermediate layers may be formed within the above range. By
forming a plurality of intermediate layers, the spin rate on shots
with a driver can be further reduced, enabling an even greater
increase in distance to be achieved. In addition, the spin
properties and feel of the ball on impact can be further
improved.
[0051] The hardness of the cover material, in terms of the Shore D
hardness, is set to preferably from 35 to 65, more preferably from
40 to 60, and even more preferably from 45 to 55. If the above
hardness is too low, the spin rate on shots with a driver may
increase, lowering the distance traveled by the ball. On the other
hand, if the hardness is too high, the ball may not incur spin in
the short game, or cracking of the ball under repeated impact may
worsen.
[0052] The cover thickness, while not subject to any particular
limitation, is preferably from 0.4 to 2.0 mm, more preferably from
0.6 to 1.5 mm, and even more preferably from 0.8 to 1.0 mm. If the
cover thickness is too large, the ball may be too receptive to
spin, as a result of which an increased distance may not be
achieved. On the other hand, if the cover thickness is too small,
the ball may be too unreceptive to spin in the short game,
resulting in a poor controllability, or the scuff resistance may
worsen.
[0053] The construction of the above cover is not limited to one
layer. If necessary, a cover of two or more layers may be formed
using like or unlike materials.
[0054] Next, the relationships between the above core, intermediate
layer and cover are described in detail.
[0055] In the present invention, it is essential for the difference
between the hardness of the intermediate layer material and the
hardness of the core surface to satisfy the following condition:
(JIS-C hardness of intermediate layer material)-(JIS-C hardness of
core surface)>0. The range in this hardness difference is
preferably set to from 2 to 10, and more preferably from 3 to 7.
Outside of this range, the spin rate on impact with a driver (W#1)
may increase, making it impossible to achieve an increased
distance, the durability to cracking under repeated impact may
worsen, and the feel may worsen.
[0056] Also, it is essential for the difference between the Shore D
hardness of the cover material and the Shore D hardness of the
intermediate layer material to satisfy the following condition:
(Shore D hardness of cover material)-(Shore D hardness of
intermediate layer material).ltoreq.0. The range in this hardness
difference is preferably less than 0, more preferably from -1 to
-10, and even more preferably from -2 to -7. If this hardness
difference is a value larger than the above range, the ball may be
too receptive to spin in the short game, resulting in a poor
controllability, or the durability to cracking under repeated
impact may worsen. On the other hand, at a value smaller than the
above range in the hardness difference, the spin rate on shots with
a driver (W#1) may rise excessively, as a result of which a
sufficient distance may not be achieved.
[0057] It is also essential for the difference between the initial
velocity (m/s) of the sphere composed of the core encased by the
intermediate layer and the initial velocity (m/s) of the core to
satisfy the following condition: (initial velocity of sphere
composed of core encased by intermediate layer)-(initial velocity
of core).gtoreq.0. The range in this initial velocity difference is
preferably at least 0.2 m/s, and more preferably at least 0.4 m/s.
If this value is too small, the ball rebound may be inadequate, or
the spin rate-lowering effect on shots with a driver (W#1) may be
insufficient, as a result of which an increased distance may not be
achieved.
[0058] Furthermore, it is essential for the relationship between
the deflection of the sphere composed of the core encased by the
intermediate layer and the deflection of the core to satisfy the
following condition: 0.80.ltoreq.(deflection of sphere composed of
core encased by intermediate layer)/(deflection of core). The range
is preferably from 0.80 to 0.92, and more preferably from 0.85 to
0.90. This parameter serves in this invention as an indicator
expressing the influence of the hardness and thickness of the
intermediate layer. If the above value is too low, the spin rate on
shots with a driver (W#1) may increase or the rebound of the ball
may become low, as a result of which an increased distance may not
be achieved. On the other hand, if the above value is too large,
the durability to cracking on repeated impact may worsen or the
feel of the ball may be too hard. Here, the phrase "deflection of
sphere composed of core encased by intermediate layer" refers to
the deflection when the sphere composed of the core encased by the
intermediate layer is compressed under a final load of 1,275 N (130
kg) from an initial load of 98 N (10 kgf).
[0059] In addition, it is essential for the relationship between
the ball deflection and the deflection of a sphere composed of the
core encased by the intermediate layer to satisfy the following
condition: 0.85.ltoreq.(ball deflection)/(deflection of sphere
composed of core encased by intermediate layer).ltoreq.0.97. This
range is preferably set to from 0.87 to 0.95, and especially from
0.89 to 0.93. This parameter serves in this invention as an
indicator expressing the cover hardness and thickness. If the above
value is too small, the spin rate on shots with a driver (W#1) may
increase, as a result of which an increased distance may not be
achieved. On the other hand, if the value is too large, the
durability to cracking under repeated impact may worsen, the feel
of the ball may become too hard, or the spin rate on approach shots
may be too small, resulting in a poor controllability.
[0060] The ball obtained by means of the above-described
construction has an initial velocity of preferably at least 76.5
m/s, more preferably at least 76.8 m/s, and even more preferably at
least 77.0 m/s. On the other hand, the upper limit value in the
initial velocity is 77.724 m/s. If the initial velocity of the ball
is too low, an increase in distance may not be achieved. On the
other hand, if the initial velocity exceeds the upper limit of
77.724 m/s, it will fail to meet the standard set by the R&A
(USGA), and will thus be ineligible for registration as an official
ball.
[0061] The golf ball obtained by encasing the above core with the
above intermediate layer and cover has a deflection which, although
not subject to any particular limitation, is preferably from 2.5 to
4.0 mm, more preferably from 2.7 to 3.7 mm, and even more
preferably from 2.9 to 3.4 mm. If this value is too large, the ball
may have an inadequate rebound, making it difficult to increase the
distance, or the durability to cracking under repeated impact may
worsen. On the other hand, if this value is too small, the spin
rate on full shots may be too high, as a result of which an
increased distance may not be achieved, or the feel on impact may
become too hard. As used herein, the ball deflection is the
deflection when the ball is compressed under a final load of 1,275
N (130 kgf) from an initial load of 98 N (10 kgf).
[0062] Also, in the inventive golf ball, although not subject to
any particular limitation, in addition to the above parameters, to
further enhance the flight performance, scuff resistance and
durability to repeated impact, it is preferable to form the ball so
that the cover and intermediate layer thicknesses (mm) satisfy the
following relationship:
cover thickness.ltoreq.intermediate layer thickness.
It is more preferable to satisfy the relationship:
cover thickness<intermediate layer thickness,
and even more preferable to satisfy the relationship:
cover thickness.times.1.2.ltoreq.intermediate layer
thickness.ltoreq.cover thickness.times.2.5.
By having the cover and intermediate layer thicknesses satisfy the
above relationship, the ball rebound can be enhanced, the spin rate
of the ball on full shots can be reduced, and the scuff resistance
and durability to repeated impact may be further improved.
[0063] In the present invention, illustrative, non-limiting,
examples of resin compositions preferable for forming the above
intermediate layer and cover include the resin compositions
formulated as shown below.
[0064] First, it is preferable to use as the intermediate
layer-forming resin composition a resin composition obtained by
blending:
100 parts by weight of a resin component composed of, in
admixture,
[0065] (A) a base resin of (a-1) an olefin-unsaturated carboxylic
acid random copolymer and/or a metal ion neutralization product of
an olefin-unsaturated carboxylic acid random copolymer blended with
(a-2) an olefin-unsaturated carboxylic acid-unsaturated carboxylic
acid ester random terpolymer and/or a metal ion neutralization
product of an olefin-unsaturated carboxylic acid-unsaturated
carboxylic acid ester random terpolymer in a weight ratio of from
100:0 to 0:100, and
[0066] (B) a non-ionomeric thermoplastic elastomer in a weight
ratio of from 100:0 to 50:50;
[0067] (C) from 5 to 120 parts by weight of a fatty acid and/or
fatty acid derivative having a molecular weight of from 228 to
1500; and
[0068] (D) from 0.1 to 17 parts by weight of a basic inorganic
metal compound capable of neutralizing un-neutralized acid groups
in component A and component C.
[0069] Components A to D are described below.
[0070] Component A is a base resin of the intermediate
layer-forming resin composition in which component (a-1) is an
olefin-unsaturated carboxylic acid random copolymer and/or a metal
ion neutralization product of an olefin-unsaturated carboxylic acid
random copolymer, and component (a-2) is an olefin-unsaturated
carboxylic acid-unsaturated carboxylic acid ester random terpolymer
and/or a metal ion neutralization product of an olefin-unsaturated
carboxylic acid-unsaturated carboxylic acid ester random
terpolymer.
[0071] Here, the olefins in above component (a-1) and component
(a-2) are olefins in which the number of carbons is generally at
least 2 but not more than 8, and preferably not more than 6.
Specific examples include ethylene, propylene, butene, pentene,
hexene, heptene and octene. Ethylene is especially preferred.
[0072] Examples of the unsaturated carboxylic acid include acrylic
acid, methacrylic acid, maleic acid and fumaric acid. Acrylic acid
and methacrylic acid are especially preferred.
[0073] The unsaturated carboxylic acid ester in above component
(a-2) is exemplified by lower alkyl esters of the above unsaturated
carboxylic acids. Illustrative examples include methyl
methacrylate, ethyl methacrylate, propyl methacrylate, butyl
methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate and
butyl acrylate. The use of butyl acrylate (n-butyl acrylate,
i-butyl acrylate) is especially preferred.
[0074] The olefin-unsaturated carboxylic acid random copolymer of
above component (a-1) and the olefin-unsaturated carboxylic
acid-unsaturated carboxylic acid ester random terpolymer of above
component (a-2) (these are sometimes referred to collectively below
as "random copolymers") can each be obtained by using a known
method to random copolymerize the above-described olefin,
unsaturated carboxylic acid and, where necessary, unsaturated
carboxylic acid ester.
[0075] It is desirable that the above random copolymers have
controlled unsaturated carboxylic acid contents (acid contents). In
this case, it is recommended that the content of unsaturated
carboxylic acid in component (a-1) be preferably at least 4 wt %,
more preferably at least 6 wt %, even more preferably at least 8 wt
%, and most preferably at least 10 wt %, but preferably not more
than 30 wt %, more preferably not more than 20 wt %, even more
preferably not more than 18 wt %, and most preferably not more than
15 wt %. It is recommended that the content of unsaturated
carboxylic acid in component (a-2) be preferably at least 4 wt %,
more preferably at least 6 wt %, and even more preferably at least
8 wt %, but preferably not more than 15 wt %, more preferably not
more than 12 wt %, and even more preferably not more than 10 wt %.
If the unsaturated carboxylic acid content in above component (a-1)
and/or component (a-2) is too low, the ball rebound may decrease,
whereas if it is too high, the processability of the resin material
may decrease.
[0076] The metal ion neutralization product of the
olefin-unsaturated carboxylic acid random copolymer of above
component (a-1) and the metal ion neutralization product of the
olefin-unsaturated carboxylic acid-unsaturated carboxylic acid
ester random terpolymer of above component (a-2) (these are
referred to collectively below as "metal ion neutralization
products of the random copolymers") can be obtained by neutralizing
some or all of the acid groups on the respective above random
copolymers with metal ions.
[0077] Illustrative examples of metal ions for neutralizing acid
groups in the above random copolymers include Na.sup.+, K.sup.+,
Li.sup.+, Zn.sup.++, Cu.sup.++, Mg.sup.++, Ca.sup.++, Co.sup.++,
Ni.sup.++ and Pb.sup.++. In the present invention, of these,
preferred use may be made of Na.sup.+, Li.sup.+, Zn.sup.++ and
Mg.sup.++; Mg.sup.++ and Zn.sup.++ are especially recommended. The
degree of neutralization of these random copolymers with the above
metal ions is not subject to any particular limitation. These
neutralization products may be obtained by a known method. For
example, compounds such as formates, acetates, nitrates,
carbonates, bicarbonates, oxides, hydroxides and alkoxides of the
aforementioned metal ions may be used by being introduced into the
above random copolymer.
[0078] Commercially available products may be used as above
component A. Examples of commercial products that may be used as
the random copolymer in above component (a-1) include Nucrel 1560,
Nucrel 1214 and Nucrel 1035 (all products of DuPont-Mitsui
Polychemicals Co., Ltd.), and Escor 5200, Escor 5100 and Escor 5000
(all products of ExxonMobil Chemical). Examples of commercial
products that may be used as the metal ion neutralization product
of the random copolymer in above component (a-1) include Himilan
1554, Himilan 1557, Himilan 1601, Himilan 1605, Himilan 1706 and
Himilan AM7311 (all products of DuPont-Mitsui Polychemicals Co.,
Ltd.), Surlyn 7930 (E.I. DuPont de Nemours & Co.), and Iotek
3110 and Iotek 4200 (ExxonMobil Chemical). Examples of commercial
products that may be used as the random copolymer in above
component (a-2) include Nucrel AN 4311, Nucrel AN 4318, Nucrel AN
4319 and Nucrel AN 4221C (all products of DuPont-Mitsui
Polychemicals Co., Ltd.), and Escor ATX325, Escor ATX320 and Escor
ATX310 (all products of ExxonMobil Chemical). Examples of
commercial products that may be used as the metal ion
neutralization product of the random copolymer in above component
(a-2) include Himilan 1855, Himilan 1856 and Himilan AM7316 (all
products of DuPont-Mitsui Polychemicals Co., Ltd.), Surlyn 6320,
Surlyn 8320, Surlyn 9320 and Surlyn 8120 (all products of E.I.
DuPont de Nemours & Co.), and Iotek 7510 and Iotek 7520 (both
products of ExxonMobil Chemical). These may be used singly or in
combinations of two or more thereof as the respective
components.
[0079] Examples of sodium-neutralized ionomeric resins, which are
preferred as the metal ion neutralization products of the above
random copolymers, include Himilan 1605, Himilan 1601 and Surlyn
8120.
[0080] Either of above component (a-1) and above component (a-2)
may be used singly, or both may be used together, as the base resin
of the resin composition for the above intermediate layer. The two
components are blended in a weight ratio of component (a-1) to
component (a-2) of from 100:0 to 0:100 which is not subject to any
particular limitation, although a weight ratio of from 50:50 to
0:100 is preferred.
[0081] The above-mentioned non-ionomeric thermoplastic elastomer
(B) is a component which is preferably included so as to further
improve the feel of the golf ball on impact and the ball rebound.
In the present invention, the base resin (component A) and the
non-ionomeric thermoplastic elastomer (component B) are sometimes
referred to collectively as "the resin component." Examples of this
component B include olefin elastomers, styrene elastomers,
polyester elastomers, urethane elastomers and polyamide elastomers.
In the present invention, to further increase the rebound, it is
especially preferable to use an olefin elastomer or a polyester
elastomer. A commercially available product may be used as
component B. Illustrative examples include the olefin elastomer
Dynaron (JSR Corporation) and the polyester elastomer Hytrel
(DuPont-Toray Co., Ltd.). These may be used singly or as
combinations of two or more thereof.
[0082] The amount of component B included, expressed as the weight
ratio A:B with above component A, may be set to from 100:0 to
50:50, and preferably from 100:0 to 60:40. If component B accounts
for more than 50 wt % of the above resin component, the
compatibility of respective components may decrease, which may
markedly lower the durability of the golf ball.
[0083] Component C is a fatty acid and/or fatty acid derivative
having a molecular weight of at least 228. This is a component
which helps to improve the flow properties of the resin
composition. Compared with the thermoplastic resin in the above
resin component, component C has a very low molecular weight and,
by suitably adjusting the melt viscosity of the mixture, helps in
particular to improve the flow properties. Because the fatty acid
(or fatty acid derivative) of the invention includes a high content
of acid groups (or derivatives thereof) having a molecular weight
of at least 228, there is little loss of resilience due to
addition.
[0084] The fatty acid or fatty acid derivative of component C has a
molecular weight of at least 228, preferably at least 256, more
preferably at least 280, and even more preferably at least 300. The
upper limit of the molecular weight is set to not more than 1500,
preferably not more than 1000, even more preferably not more than
600, and most preferably not more than 500. If the molecular weight
is too low, the heat resistance cannot be improved and the acid
group content becomes too high, which may result in a smaller
flow-improving effect due to interactions with acid groups present
in component A. On the other hand, if the molecular weight is too
high, a distinct flow-improving effect may not be achieved.
[0085] It is preferable to use as the fatty acid of component C an
unsaturated fatty acid containing a double bond or triple bond on
the alkyl moiety, or a saturated fatty acid in which the bonds on
the alkyl moiety are all single bonds. The number of carbons on one
molecule of the fatty acid may be set to at least 18, preferably at
least 20, more preferably at least 22, and even more preferably at
least 24. The upper limit in the number of carbons may be set to
not more than 80, preferably not more than 60, more preferably not
more than 40, and even more preferably not more than 30. Too few
carbons, in addition to possibly resulting in a poor heat
resistance, may also, by making the acid group content relatively
high, lead to excessive interactions with acid groups present in
the resin component, thereby diminishing the flow-improving effect.
On the other hand, too many carbons increases the molecular weight,
as a result of which a distinct flow-improving effect may not be
achieved.
[0086] Illustrative examples of the fatty acid of component C
include stearic acid, 12-hydroxystearic acid, behenic acid, oleic
acid, linoleic acid, linolenic acid, arachidic acid and lignoceric
acid. Of these, stearic acid, arachidic acid, behenic acid and
lignoceric acid are preferred.
[0087] The fatty acid derivative is exemplified by metallic soaps
in which the proton on the acid group of the fatty acid has been
replaced with a metal ion. Examples of metal ions that may be used
in the metal soap include Li.sup.+, Ca.sup.++, Mg.sup.++,
Zn.sup.++, Mn.sup.++, Al.sup.++, Ni.sup.++, Fe.sup.++, Fe.sup.+++,
Cu.sup.++, Sn.sup.++, Pb.sup.++ and Co.sup.++. Of these, Ca.sup.++,
Mg.sup.++ and Zn.sup.++ are especially preferred.
[0088] Specific examples of the fatty acid derivative of component
C include magnesium stearate, calcium stearate, zinc stearate,
magnesium 12-hydroxystearate, calcium 12-hydroxystearate, zinc
12-hydroxystearate, magnesium arachidate, calcium arachidate, zinc
arachidate, magnesium behenate, calcium behenate, zinc behenate,
magnesium lignocerate, calcium lignocerate and zinc lignocerate. Of
these, magnesium stearate, calcium stearate, zinc stearate,
magnesium arachidate, calcium arachidate, zinc arachidate,
magnesium behenate, calcium behenate, zinc behenate, magnesium
lignocerate, calcium lignocerate and zinc lignocerate are
preferred. These may be used singly or as combinations of two or
more thereof.
[0089] The amount of component C included per 100 parts by weight
of the above resin component which includes components A and B may
be set to at least 5 parts by weight, preferably at least 10 parts
by weight, more preferably at least 15 parts by weight, and even
more preferably at least 18 parts by weight. The upper limit is set
to not more than 120 parts by weight, preferably not more than 80
parts by weight, more preferably not more than 60 parts by weight,
and even more preferably not more than 50 parts by weight. If the
amount of component C included is too small, the melt viscosity may
decrease, lowering the processability. On the other hand, if the
amount of component C is too high, the durability may decrease.
[0090] In the present invention, use may also be made of, as a
mixture of the above-described components A and C, a known metallic
soap-modified ionomer (see, for example, U.S. Pat. No. 5,312,857,
U.S. Pat. No. 5,306,760, and International Disclosure WO
98/46671).
[0091] The basic inorganic metal compound of component D is
included for the purpose of neutralizing acid groups in above
components A and C. If component D is not included, particularly in
cases where a metal-modified ionomeric resin alone (e.g., a
metallic soap-modified ionomeric resin mentioned in the above-cited
patent publications, alone) is mixed under applied heat, the
metallic soap and un-neutralized acid groups present on the ionomer
undergo an exchange reaction as shown below, generating a fatty
acid. Because this generated fatty acid has a low thermal stability
and readily vaporizes during molding, not only does it cause
molding defects, when the generated fatty acid deposits on the
surface of the molding, it causes a marked decline in paint film
adhesion.
##STR00001##
[0092] (1) un-neutralized acid group present on ionomeric resin
[0093] (2) metallic soap
[0094] (3) fatty acid
[0095] X: metal cation
[0096] To solve this problem, a basic inorganic metal compound
(component D) which neutralizes acid groups present in above
components A and C is included as an essential component. By
including component D, acid groups present in above components A
and C are neutralized and, through synergistic effects from the
formulation of these respective components, the thermal stability
of the resin composition increases, along with which a good
moldability is imparted, thereby conferring the excellent property
of enhancing resilience as a golf ball material.
[0097] It is recommended that component D be a basic inorganic
metal compound which neutralizes acid groups in above components A
and C, and preferably a monoxide. Because it has a high reactivity
with the ionomeric resin and contains no organic matter in the
reaction by-products, the degree of neutralization of the resin
composition can be increased without a loss of thermal
stability.
[0098] Illustrative examples of the metal ion used here in the
basic inorganic metal compound include Li.sup.+, Na.sup.+, K.sup.+,
Ca.sup.++, Mg.sup.++, Zn.sup.++, Al.sup.+++, Ni.sup.++, Fe.sup.++,
Fe.sup.+++, Cu.sup.++, Mn.sup.++, Sn.sup.++, Pb.sup.++ and
Co.sup.++. Basic inorganic fillers containing these metal ions may
be used as the inorganic metal compound. Illustrative examples
include magnesium oxide, magnesium hydroxide, magnesium carbonate,
zinc oxide, sodium hydroxide, sodium carbonate, calcium oxide,
calcium hydroxide, lithium hydroxide and lithium carbonate. These
may be used singly or as combinations of two or more thereof. In
the present invention, of the above, a hydroxide or a monoxide is
especially recommended. Calcium hydroxide and magnesium oxide,
which have a high reactivity with component A, are preferred.
[0099] The amount of component D included per 100 parts by weight
of the above resin component may be set to at least 0.1 part by
weight, preferably at least 0.5 part by weight, more preferably at
least 1 part by weight, and even more preferably at least 2 parts
by weight. The upper limit is not more than 17 parts by weight,
preferably not more than 15 parts by weight, more preferably not
more than 13 parts by weight, and even more preferably not more
than 10 parts by weight. If the amount of component D included is
too small, improvements in the thermal stability and resilience may
not be observed. On the other hand, if it is too large, the
presence of excess basic inorganic metal compound may have the
opposite effect of lowering the heat resistance of the
composition.
[0100] The mixture obtained by mixing above components A to D has a
degree of neutralization, based on the total amount of acid groups
in the mixture, which is set to at least 50 mol %, preferably at
least 60 mol %, more preferably at least 70 mol %, and even more
preferably at least 80 mol %. With such a high degree of
neutralization, even in cases where, for example, a metallic
soap-modified ionomeric resin is used, exchange reactions between
the metallic soap and un-neutralized acid groups present in the
ionomeric resin are less likely to arise during mixture under
heating, thereby reducing the likelihood of declines in thermal
stability, moldability and resilience.
[0101] Various additives may be optionally included within the
resin composition containing above components A to D. For example,
additives such as pigments, dispersants, antioxidants, ultraviolet
absorbers and light stabilizers may be suitably included. These
additives are used in an amount which, although not subject to any
particular limitation, is generally at least 0.1 part by weight,
preferably at least 0.5 part by weight, and more preferably at
least 1 part by weight per 100 parts by weight of the above resin
component. The upper limit is not more than 10 parts by weight,
preferably not more than 6 parts by weight, and more preferably not
more than 4 parts by weight.
[0102] The resin composition may be obtained by mixing the
above-described components A to D under applied heat. For example,
the resin composition may be obtained by mixture using a known
mixing apparatus such as a kneading-type twin-screw extruder, a
Banbury mixer or a kneader at a heating temperature of from 150 to
250.degree. C. Alternatively, direct use may be made of a
commercial product, illustrative examples of which include those
available under the trade names HPF 1000, HPF 2000 and HPF AD1027,
as well as the experimental material HPF SEP1264-3, all produced by
E.I. DuPont de Nemours & Co.
[0103] The method of forming the intermediate layer may be a known
method and is not subject to any particular limitation. For
example, use may be made of a method which involves placing a
prefabricated core in a mold, and injection-molding the resin
composition prepared as described above.
[0104] The construction of the above-described intermediate layer
is not limited to a single layer; if necessary, two or more like or
unlike intermediate layers may be formed within the above range. By
forming a plurality of intermediate layers, the spin rate at the
time of impact with a driver can be further reduced, enabling a
further increase in the distance to be achieved. In addition, the
spin properties and feel at the time of impact can be further
improved.
[0105] Next, the resin composition used to form the cover of the
inventive golf ball is described. In the present invention, a resin
composition composed primarily of a polyurethane may be used as the
resin composition from which the cover is formed. Preferred use may
be made of a resin composition composed primarily of a
thermoplastic polyurethane. Formation from a single resin blend
composed primarily of (E) a thermoplastic polyurethane and (F) a
polyisocyanate compound is especially preferred. Golf balls that
use a cover formed of such a thermoplastic polyurethane have a high
rebound and an excellent spin performance and scuff resistance, in
addition to which the cover-forming material has a high flowability
and thus an excellent manufacturability.
[0106] As used herein, the phrase "single resin blend" signifies
that the resin blend is in the form of single resin pellets, and
that it is preferable to form the cover by furnishing such single
resin pellets to an injection molding machine.
[0107] This cover is composed primarily of the above (E)
thermoplastic polyurethane and (F) polyisocyanate compound.
Specifically, it is recommended that the combined weight of above
component E and component F be at least 60%, and preferably at
least 70%, of the overall weight of the cover.
[0108] The thermoplastic polyurethane serving as component E has a
structure which includes soft segments made of a polymeric polyol
that is a long-chain polyol (polymeric glycol), and hard segments
made of a chain extender and a polyisocyanate compound. Here, the
long-chain polyol used as a starting material is not subject to any
particular limitation, and may be any that is used in the prior art
relating to thermoplastic polyurethanes. Exemplary long-chain
polyols include polyester polyols, polyether polyols, polycarbonate
polyols, polyester polycarbonate polyols, polyolefin polyols,
conjugated diene polymer-based polyols, castor oil-based polyols,
silicone-based polyols and vinyl polymer-based polyols. These
long-chain polyols may be used singly or as combinations of two or
more thereof. Of the long-chain polyols mentioned here, polyether
polyols are preferred because they enable the synthesis of
thermoplastic polyurethanes having a high rebound resilience and
excellent low-temperature properties.
[0109] Illustrative examples of the above polyether polyol include
poly(ethylene glycol), poly(propylene glycol), poly(tetramethylene
glycol) and poly(methyltetramethylene glycol) obtained by the
ring-opening polymerization of a cyclic ether. The polyether polyol
may be used singly or as a combination of two or more polyether
polyols. Of these, poly(tetramethylene glycol) and/or
poly(methyltetramethylene glycol) are preferred.
[0110] It is preferable for these long-chain polyols to have a
number-average molecular weight in a range of 1,500 to 5,000. By
using a long-chain polyol having a number-average molecular weight
within this range, golf balls made of a thermoplastic polyurethane
composition having excellent properties such as resilience and
manufacturability can be reliably obtained. The number-average
molecular weight of the long-chain polyol is more preferably in a
range of 1,700 to 4,000, and even more preferably in a range of
1,900 to 3,000.
[0111] As used herein, "number-average molecular weight of the
long-chain polyol" refers to the number-average molecular weight
computed based on the hydroxyl number measured in accordance with
JIS K-1557.
[0112] Suitable chain extenders include those used in the prior art
relating to thermoplastic polyurethanes. For example,
low-molecular-weight compounds which have a molecular weight of 400
or less and bear on the molecule two or more active hydrogen atoms
capable of reacting with isocyanate groups are preferred.
Illustrative, non-limiting, examples of the chain extender include
1,4-butylene glycol, 1,2-ethylene glycol, 1,3-butanediol,
1,6-hexanediol and 2,2-dimethyl-1,3-propanediol. Of these chain
extenders, aliphatic diols having 2 to 12 carbons are preferred,
and 1,4-butylene glycol is especially preferred.
[0113] The polyisocyanate compound is not subject to any particular
limitation; preferred use may be made of one used in the prior art
relating to thermoplastic polyurethanes. Specific examples include
one or more selected from the group consisting of
4,4'-diphenylmethane diisocyanate, 2,4-toluene diisocyanate,
2,6-toluene diisocyanate, p-phenylene diisocyanate, xylylene
diisocyanate, naphthylene-1,5-diisocyanate, tetramethylxylene
diisocyanate, hydrogenated xylylene diisocyanate,
dicyclohexylmethane diisocyanate, tetramethylene diisocyanate,
hexamethylene diisocyanate, isophorone diisocyanate, norbornene
diisocyanate, trimethylhexamethylene diisocyanate and dimer acid
diisocyanate. Depending on the type of isocyanate used, the
crosslinking reaction during injection molding may be difficult to
control. In the practice of the invention, to provide a balance
between stability at the time of production and the properties that
are manifested, it is most preferable to use 4,4'-diphenylmethane
diisocyanate, which is an aromatic diisocyanate.
[0114] It is most preferable for the thermoplastic polyurethane
serving as component E to be a thermoplastic polyurethane
synthesized using a polyether polyol as the long-chain polyol,
using an aliphatic diol as the chain extender, and using an
aromatic diisocyanate as the polyisocyanate compound. It is
desirable, though not essential, for the polyether polyol to be a
polytetramethylene glycol having a number-average molecular weight
of at least 1,900, for the chain extender to be 1,4-butylene
glycol, and for the aromatic diisocyanate to be
4,4'-diphenylmethane diisocyanate.
[0115] The mixing ratio of activated hydrogen atoms to isocyanate
groups in the above polyurethane-forming reaction can be controlled
within a desirable range so as to make it possible to obtain a golf
ball which is composed in part of a thermoplastic polyurethane
composition and has various improved properties, such as rebound,
spin performance, scuff resistance and manufacturability.
Specifically, in preparing a thermoplastic polyurethane by reacting
the above long-chain polyol, polyisocyanate compound and chain
extender, it is desirable to use the respective components in
proportions such that the amount of isocyanate groups on the
polyisocyanate compound per mole of active hydrogen atoms on the
long-chain polyol and the chain extender is from 0.95 to 1.05
moles.
[0116] No particular limitation is imposed on the method of
preparing the thermoplastic polyurethane used as component E.
Production may be carried out by either a prepolymer process or a
one-shot process in which the long-chain polyol, chain extender and
polyisocyanate compound are used and a known urethane-forming
reaction is effected. Of these, a process in which melt
polymerization is carried out in a substantially solvent-free state
is preferred. Production by continuous melt polymerization using a
multiple screw extruder is especially preferred.
[0117] Illustrative examples of the thermoplastic polyurethane
serving as component E include commercial products such as Pandex
T8295, Pandex T8290, Pandex T8260, and Pandex T8295 (all available
from DIC Bayer Polymer, Ltd.).
[0118] Next, concerning the polyisocyanate compound used as
component F, it is essential that, in at least a portion thereof
prior to injection molding, all the isocyanate groups on the
molecule remain in an unreacted state. That is, polyisocyanate
compound in which all the isocyanate groups on the molecule remain
in a completely free state must be present in the single resin
blend prior to injection molding. Such a polyisocyanate compound
may be present together with a polyisocyanate compound in which
only some of the isocyanate groups on the molecule are in a free
state.
[0119] Various types of isocyanates may be employed without
particular limitation as this polyisocyanate compound. Illustrative
examples include one or more selected from the group consisting of
4,4'-diphenylmethane diisocyanate, 2,4-toluene diisocyanate,
2,6-toluene diisocyanate, p-phenylene diisocyanate, xylylene
diisocyanate, naphthylene-1,5-diisocyanate, tetramethylxylene
diisocyanate, hydrogenated xylylene diisocyanate,
dicyclohexylmethane diisocyanate, tetramethylene diisocyanate,
hexamethylene diisocyanate, isophorone diisocyanate, norbornene
diisocyanate, trimethylhexamethylene diisocyanate and dimer acid
diisocyanate. Of the above group of isocyanates, the use of
4,4'-diphenylmethane diisocyanate, dicyclohexylmethane diisocyanate
and isophorone diisocyanate is preferable in terms of the balance
between the influence on processability of such effects as the rise
in viscosity that accompanies the reaction with the thermoplastic
polyurethane serving as component E and the physical properties of
the resulting golf ball cover material.
[0120] In the cover of the inventive golf ball, although not an
essential constituent, a thermoplastic elastomer other than the
above-described thermoplastic polyurethane may additionally be
included as component G together with components E and F. Including
this component G in the above resin composition enables the
flowability of the resin composition to be further improved and
enables increases to be made in various properties required of golf
ball cover materials, such as resilience and scuff resistance.
[0121] Component G, which is a thermoplastic elastomer other than
the above thermoplastic polyurethane, is exemplified by one or more
thermoplastic elastomer selected from among polyester elastomers,
polyamide elastomers, ionomeric resins, styrene block elastomers,
hydrogenated styrene-butadiene rubbers,
styrene-ethylene/butylene-ethylene block copolymers and modified
forms thereof, ethylene-ethylene/butylene-ethylene block copolymers
and modified forms thereof, styrene-ethylene/butylene-styrene block
copolymers and modified forms thereof, ABS resins, polyacetals,
polyethylenes and nylon resins. The use of polyester elastomers,
polyamide elastomers and polyacetals is especially preferred
because the resilience and scuff resistance are enhanced, owing to
reactions with isocyanate groups, while at the same time a good
manufacturability is retained.
[0122] The relative proportions of above components E, F and G are
not subject to any particular limitation. However, to fully achieve
the objects of the invention, it is preferable for the weight ratio
E:F:G of the respective components to be from 100:2:50 to 100:50:0,
and more preferably from 100:2:50 to 100:30:8.
[0123] In the present invention, the cover-forming resin blend is
prepared by mixing together component E, component F, and also
component G. It is necessary to select the mixing conditions such
that at least some polyisocyanate compound in which all the
isocyanate groups on the molecule remain in an unreacted state is
present in the polyisocyanate compound. For example, treatment such
as mixture in an inert gas (e.g., nitrogen) or in a vacuum state
must be furnished. The resin blend is then injection-molded around
a core which has been placed in a mold. For easy, trouble-free
handling, it is preferable for the resin blend be formed into
pellets having a length of 1 to 10 mm and a diameter of 0.5 to 5
mm. Isocyanate groups in an unreacted state remain within these
resin pellets; while the resin blend is being injection-molded
about the core, or due to post-treatment such as annealing
thereafter, the unreacted isocyanate groups react with component E
or component G to form a crosslinked material.
[0124] In addition, if necessary, various additives may also be
included in this cover-forming resin blend. For example, pigments,
dispersants, antioxidants, light stabilizers, ultraviolet
absorbers, and parting agents may be suitably included.
[0125] The melt mass flow rate (MFR) of this resin blend at
210.degree. C. is not subject to any particular limitation.
However, to increase the flow properties and manufacturability, the
MFR is preferably at least 5 g/10 min, and more preferably at least
6 g/10 min. If the melt mass flow rate of the resin blend is low,
the flow properties will decrease, which may cause eccentricity
during injection molding and may also lower the degree of freedom
in the thickness of the cover that can be molded. The measured
value of the melt mass flow rate is obtained in accordance with JIS
K-7210 (1999 edition).
[0126] The method of molding the cover may involve feeding the
above-described resin blend to an injection-molding machine and
injecting the molten resin blend around the core. Although the
molding temperature in this case will vary depending on the type of
thermoplastic polyurethane, the molding temperature is generally in
a range of from 150 to 250.degree. C.
[0127] When injection molding is carried out, it is desirable
though not essential to carry out molding in a low-humidity
environment such as by purging with an inert gas (e.g., nitrogen)
or a low-humidity gas (e.g., low dew-point dry air), or by vacuum
treating, some or all places on the resin paths from the resin feed
area to the mold interior. Illustrative, non-limiting, examples of
the medium used for transporting the resin include low-humidity
gases such as low dew-point dry air or nitrogen. By carrying out
molding in such a low-humidity environment, reaction by the
isocyanate groups is kept from proceeding before the resin has been
charged into the mold interior. As a result, polyisocyanate in
which the isocyanate groups are to some degree in an unreacted
state can be included within the resin blend, thus making it
possible to reduce variable factors such as an unwanted rise in
viscosity and enabling the actual crosslinking efficiency to be
enhanced.
[0128] Techniques that may be used to confirm the presence of
polyisocyanate compound in an unreacted state within the resin
blend prior to injection molding about the core include those which
involve extraction with a suitable solvent that selectively
dissolves out only the polyisocyanate compound. An example of a
simple and convenient method is one in which confirmation is
carried out by simultaneous thermogravimetric and differential
thermal analysis (TG-DTA) measurement in an inert atmosphere. For
example, when the resin blend (cover material) used in the
invention is heated in a nitrogen atmosphere at a temperature
ramp-up rate of 10.degree. C./min, a gradual drop in the weight of
diphenylmethane diisocyanate can be observed from about 150.degree.
C. On the other hand, in a resin sample in which the reaction
between the thermoplastic polyurethane material and the isocyanate
mixture has been carried out to completion, a weight drop from
about 150.degree. C. is not observed, but a weight drop from about
230 to 240.degree. C. can be observed.
[0129] After the resin blend has been molded as described above to
form a cover, its properties as a golf ball cover can be further
improved by carrying out annealing so as to induce the crosslinking
reaction to proceed further. "Annealing," as used herein, refers to
aging the cover in a fixed environment for a fixed length of
time.
[0130] The structure of the above cover is not limited to a single
layer; if necessary, a cover of two or more layers may be formed of
like or unlike materials. In this case, it is recommended that the
cover have at least one layer that is formed of the above resin
blend composed primarily of above components E and F, and that the
hardness and thickness are adjusted so that these values for the
overall cover fall within the above-indicated ranges.
[0131] In the golf ball of the present invention, to further
enhance the aerodynamic properties and improve the distance, as in
ordinary golf balls, it is preferable for numerous dimples to be
formed on the surface of the cover. By optimizing such parameters
as the number of dimple types and the total number of dimples,
through synergistic effects with the above-described ball
construction, there can be obtained a golf ball having a more
stable trajectory and an improved distance performance. Moreover,
to improve the design and durability of the golf ball, various
treatments such as surface treatment, stamping and painting may be
carried on the cover.
[0132] Here, it is recommended that the number of dimple types,
which refers to the number of dimple types of mutually differing
diameter and/or depth, be preferably at least two types, and more
preferably at least three types. It is recommended that the upper
limit be not more than eight types, and in particular not more than
six types.
[0133] Because the golf ball of the present invention, owing to the
above-described ball construction, tends to have a decreased spin
rate at the time of impact, and thus a lower trajectory, it is
preferable to carry out dimple design in such a way as to enable a
large lift to be obtained.
[0134] First, the total number of dimples is from 280 to 360,
preferably from 300 to 350, and more preferably from 320 to 340. If
the number of dimples is higher than the above range, the ball
trajectory may decrease, as a result of which a sufficient distance
may not be achieved. On the other hand, if the number of dimples is
lower than the above range, the trajectory may become too high, as
a result of which an increased distance may not be achieved.
[0135] Nor is any particular limitation imposed on the geometrical
arrangement of the dimples; use may be made of a known arrangement,
such as an octahedral or an icosahedral arrangement. At this time,
from the standpoint of reducing variability in the flight of the
ball, preferred use may be made of a dimple arrangement such that
the surface of the ball has thereon not even a single great circle
which intersects no dimples. The dimple shapes are not limited to
circular shapes, and may be of one or more types which are suitably
selected from among polygonal, teardrop, oval and other shapes. The
dimple diameter (in polygonal shapes, the diagonal length) is
preferably from 2.5 to 6.5 mm. The dimple depth, although not
subject to any particular limitation, is preferably set to from
0.08 to 0.30 mm.
[0136] The value V.sub.0 obtained by dividing the spatial volume of
each dimple below the flat plane circumscribed by the edge of that
dimple by the volume of a cylinder whose base is the flat plane and
whose height is the maximum depth of the dimple from the base,
while not subject to any particular limitation, may be set in the
present invention to from 0.35 to 0.80.
[0137] The ratio SR of the sum of the individual dimple surface
areas, each defined by the border of the flat plane circumscribed
by the edge of a dimple, with respect to the spherical surface area
of the ball were it to be free of dimples, is not subject to any
particular limitation. However, to reduce the air resistance, the
ratio SR is preferably from 60 to 90%. This SR value can be
increased by raising the number of dimples formed, interspersing a
plurality of dimple types of differing diameter, and using dimple
shapes in which the distance between neighboring dimples (land
width) becomes substantially 0.
[0138] The ratio VR of the sum of the volumes of the individual
dimples formed below the flat plane circumscribed by the dimple
edge with respect to the volume of the ball sphere were it to have
no dimples thereon, although not subject to any particular
limitation, may be set in the present invention to from 0.6 to
1.
[0139] In the present invention, by setting these V.sub.0, SR and
VR values in the above-indicated ranges, the air resistance is
reduced and a trajectory is easily obtained that enables a good
distance to be achieved, thus making it possible to enhance the
flight performance.
[0140] The golf ball of the invention may be made to conform with
the Rules of Golf for competitive play, and may be formed to a
diameter of not less than 42.67 mm. The weight may be set to
generally not less than 45.0 g, and preferably not less than 45.2
g. It is preferable for the upper limit to be set to not more than
45.93 g.
EXAMPLES
[0141] The following Examples and Comparative Examples are provided
by way of illustration and not by way of limitation.
Examples 1 to 3, Comparative Examples 1 to 7
Formation of Core
[0142] Solid cores were fabricated by preparing the rubber
compositions shown in Table 1 below, then molding and vulcanizing
at 155.degree. C. for 15 minutes.
TABLE-US-00001 TABLE 1 Example Comparative Example Formulation
(pbw) 1 2 3 1 2 3 4 5 6 7 Polybutadiene A 0 0 0 0 0 0 0 100 0 0
Polybutadiene B 80 80 80 80 80 80 80 0 80 80 Polybutadiene C 20 20
20 20 20 20 20 0 20 20 Zinc acrylate 29.5 27.0 27.0 29.5 27.0 29.5
29.5 27 29.5 29.5 Peroxide (1) 0 0 0 0 0 0 0 0.6 0 0 Peroxide (2)
1.2 1.2 1.2 1.2 1.2 1.2 1.2 0.6 1.2 1.2 Antioxidant 0.1 0.1 0.1 0.1
0.1 0.1 0.1 0.1 0.1 0.1 Barium sulfate 19.6 20.6 20.6 19.6 20.6
19.6 25.9 0 19.5 19.6 Zinc oxide 5 5 5 5 5 5 5 23.9 5 5 Zinc salt
of 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 pentachloro- thiophenol
Details on the materials in Table 1 are given below. Polybutadiene
A Available under the trade name "BR 01" from JSR Corporation.
Polybutadiene B Available under the trade name "BR 730" from JSR
Corporation. Polybutadiene C Available under the trade name "BR 51"
from JSR Corporation. Peroxide (1) Available under the trade name
"Percumyl D" from NOF Corporation. Peroxide (2) A mixture of
1,1-di(t-butylperoxy)cyclohexane and silica; available under the
trade name "Perhexa C-40" from NOF Corporation. Antioxidant
2,2'-Methylenebis(4-methyl-6-t-butylphenol); available under the
trade name "Nocrac NS-6" from Ouchi Shinko Chemical Industry Co.,
Ltd. Barium sulfate Available under the trade name "Precipitated
Barium Sulfate #300" from Sakai Chemical Industry Co., Ltd. Zinc
Stearate Available under the trade name "Zinc Stearate G" from NOF
Corporation.
Formation of Intermediate Layer and Cover
[0143] Next, using the various resin ingredients formulated as
shown in Table 2, an intermediate layer and a cover were
successively injection-molded around the core obtained as described
above, thereby producing three-piece solid golf balls having an
intermediate layer and a cover over the core. In Formulations (5),
(6), (7) and (9) in Table 2, the respective starting materials
(units: parts by weight) shown in Table 2 were worked together
under a nitrogen gas atmosphere by a twin-screw extruder to give a
cover resin blend. This resin blend was obtained in the form of
pellets having a length of 3 mm and a diameter of 1 to 2 mm.
[0144] The dimples shown in FIG. 3 were formed at this time on the
cover surface. Details of the dimples in FIG. 3 are shown in Table
3.
TABLE-US-00002 TABLE 2 Formulation (pbw) (1) (2) (3) (4) (5) (6)
(7) (8) (9) Himilan AM7331 50 Himilan 1557 30 Himilan 1855 20
Himilan 1605 35 100 Surlyn 9945 35 AN4319 30 100 AN4221C 60 Dynaron
6100P 10 30 Magnesium stearate 60 0.31 100 1 Kyowamag MF150 1.3 2.8
Polytail 4 4 TMP 1 0.7 Titanium dioxide 0.5 2.2 T8260 100 T8295 75
25 T8290 25 75 75 T8283 25 Hytrel 4001 15 15 15 15 Titanium oxide
3.5 3.5 3.5 3.5 Polyethylene wax 1.5 1.5 1.5 1.5 Isocyanate
compound 9 9 9 9 Details on the materials in Table 2 are given
below. Himilan An ionomeric resin available from DuPont-Mitsui
Polychemicals Co., Ltd. Surlyn An ionomeric resin available from E.
I. DuPont de Nemours & Co. AN4319, AN4221C Available under the
trade name "Nucrel" from DuPont-Mitsui Polychemicals Co., Ltd.
Dynaron 6100P A hydrogenated polymer available from JSR
Corporation. Kyowamag MF150 Magnesium oxide available from Kyowa
Chemical Industry Co., Ltd. Polytail A low-molecular-weight
polyolefin polyol available from Mitsubishi Chemical Corporation.
TMP Trimethylolpropane, available from Mitsubishi Gas Chemical Co.,
Ltd. T8260, T8295, T8290, T8293 MDI-PTMG type thermoplastic
polyurethanes, available under the trade name "Pandex" from DIC
Bayer Polymer. Polyethylene Wax Available under the trade name
"Sanwax 161P" from Sanyo Chemical Industries, Ltd. Isocyanate
Compound 4,4'-Diphenylmethane diisocyanate. Hytrel 4001 A polyester
elastomer available from DuPont-Toray Co., Ltd.
TABLE-US-00003 TABLE 3 Number of Diameter Depth No. dimples (mm)
(mm) V.sub.0 SR VR 1 12 4.6 0.15 0.47 0.81 0.783 2 234 4.4 0.15
0.47 3 60 3.8 0.14 0.47 4 6 3.5 0.13 0.46 5 6 3.4 0.13 0.46 6 12
2.6 0.10 0.46 Total 330 Dimple Definitions Diameter: Diameter of
flat plane circumscribed by edge of dimple. Depth: Maximum depth of
dimple from flat plane circumscribed by edge of dimple. V.sub.0:
Spatial volume of dimple below flat plane circumscribed by dimple
edge, divided by volume of cylinder whose base is the flat plane
and whose height is the maximum depth of dimple from the base. SR:
Sum of individual dimple surface areas, each defined by the border
of the flat plane circumscribed by the edge of a dimple, as a
percentage of surface area of ball sphere were it to have no
dimples thereon. VR: Sum of volumes of individual dimples formed
below flat plane circumscribed by the edge of the dimple, as a
percentage of volume of ball sphere were it to have no dimples
thereon.
[0145] The golf balls obtained in Examples 1 to 3 of the invention
and in Comparative Examples 1 to 7 were evaluated according to the
criteria described below with regard to the following: properties
such as thickness, hardness and deflection of each layer, flight
performance and durability to repeated impact. The results are
shown in Tables 4 and 5.
Evaluation of Ball Properties
(1) Deflection (mm) of Core, Sphere Composed of Core Encased by
Intermediate Layer, and Finished Ball
[0146] The core, the sphere composed of the core encased by the
intermediate layer, and the finished golf ball were placed on a
hard plate, and the deflection of each when compressed under a
final load of 1,275 N (130 kgf) from an initial load of 98 N (10
kgf) was measured.
(2) Surface Hardness of Core (JIS-C Hardness)
[0147] The surface of the core is spherical. The durometer indenter
was set substantially perpendicular to this spherical surface, and
JIS-C hardness measurements (in accordance with JIS-K6301) were
taken at two randomly selected points on the surface of the core.
The average of the two measurements was used as the core surface
hardness.
(3) Cross-Sectional Hardness of Core (JIS-C Hardness)
[0148] The core was cut in half, thereby forming a flat plane.
[0149] The durometer indenter was set substantially perpendicular
to this flat plane, and the JIS-C hardness (in accordance with
JIS-K6301) was measured.
(4) Material Hardness (JIS-C Hardness) of Intermediate Layer and
Cover
[0150] The resin materials for the intermediate layer and the cover
were formed into sheets having a thickness of about 2 mm, and the
JIS-C hardness was measured in accordance with JIS-K6301.
(5) Material Hardness of Intermediate Layer and Cover (Shore D
Hardness)
[0151] The resin materials for the intermediate layer and the cover
were formed into sheets having a thickness of about 2 mm, and the
hardness was measured with a Type D durometer in accordance with
ASTM-2240.
(6) Initial Velocity of Core, Sphere Composed of Core Encased by
Intermediate Layer, and Finished Ball
[0152] The initial velocity was measured using an initial velocity
measuring apparatus of the same type as the USGA drum rotation-type
initial velocity instrument approved by the R&A. The ball was
held isothermally at a temperature of 23.+-.1.degree. C. for at
least 3 hours, then tested in a room temperature (23.+-.2.degree.
C.) chamber. The ball was hit using a 250-pound (113.4 kg) head
(striking mass) at an impact velocity of 143.8 ft/s (43.83 m/s). A
dozen balls were each hit four times. The time taken for the balls
to traverse a distance of 6.28 ft (1.91 m) was measured and used to
compute the initial velocity. This cycle was carried out over a
period of about 15 minutes.
(7) Flight
[0153] The distance traveled by the ball when shot at a head speed
of 40 m/s with a driver (W#1) mounted on a golf swing robot was
measured. The club used was a TourStage X-Drive 701 driver (loft
angle, 10.5.degree.) manufactured by Bridgestone Sports Co., Ltd.
The results were rated according to the criteria indicated below.
The initial velocity and spin rate were values obtained by
measuring the ball, immediately after impact, with an apparatus for
measuring initial conditions.
[0154] Good: Total distance was 190 m or more
[0155] NG: Total distance was less than 190 m
(8) Approach
[0156] The spin rate of a ball hit at a head speed of 20 m/s with a
sand wedge (SW) mounted on a golf swing robot was measured. The
club used was a TourStage TW-01 manufactured by Bridgestone Sports
Co., Ltd. The results were rated according to the criteria
indicated below.
[0157] Good: Spin rate of 5,700 rpm or more
[0158] NG: Spin rate of less than 5,700 rpm
(9) W#1 Feel, Putter Feel
[0159] Sensory evaluations by ten amateur golfers having head
speeds of 35 to 45 m/s with a driver (W#1) were carried out, and
the feel was rated according to the following criteria.
[0160] Good: The ball had a good, soft feel
[0161] NG: The ball felt hard
(10) Durability to Repeated Impact
[0162] The ball was repeatedly hit at a head speed of 40 m/s with a
W#1 club mounted on a golf swing robot. The balls in the respective
examples were rated as shown below relative to an arbitrary
durability index of 100 for the number of shots taken with the ball
in Example 3 before the initial velocity fell below 97% of the
average initial velocity for the first 10 shots. The average value
for N=3 balls was used as the basis for evaluation in each
example.
[0163] Good: Durability index was 90 or more
[0164] NG: Durability index was less than 90
(11) Scuff Resistance
[0165] A non-plated pitching sand wedge was set in a swing robot,
and the ball was hit once at a head speed of 35 m/s, following
which the surface state of the ball was visually examined and rated
as follows.
[0166] Good: Can be used again
[0167] NG: Cannot be used again
TABLE-US-00004 TABLE 4 Example 1 2 3 Core Diameter (mm) 37.35 37.30
37.30 Weight (g) 32.2 32.1 32.1 Deflection, 10-130 kgf (mm) 3.83
4.20 4.20 Initial velocity (m/s) 78.0 78.2 78.2 JIS-C surface
hardness (S) 80 78 78 JIS-C hardness 15 mm from center 74 72 72
JIS-C hardness 7.5 mm from center 67 65 65 JIS-C center hardness
(C) 60 58 58 Average (I) of JIS-C hardnesses 67 64 64 at center and
15 mm from center (I) - JIS-C hardness 0 -1 -1 7.5 mm from center
(S) - (C), JIS-C hardness 20 20 20 Intermediate Material (type) (1)
(1) (1) layer Thickness (mm) 1.64 1.66 1.66 Specific gravity 0.94
0.94 0.94 Shore D hardness of sheet 55 55 55 JIS-C hardness of
sheet 83 83 83 Intermediate Diameter (mm) 40.62 40.61 40.61
layer-encased Weight (g) 39.6 39.5 39.5 sphere Deflection, 10-130
kgf (mm) 3.37 3.64 3.64 Initial velocity (m/s) 78.2 78.4 78.4
Initial velocity of intermediate layer-encased 0.3 0.2 0.2 sphere -
initial velocity of core (m/s) JIS-C hardness of intermediate layer
material - 3 5 5 JIS-C hardness of core surface (Deflection of
intermediate layer-encased 0.88 0.87 0.87 sphere)/(core deflection)
Cover Material (type) (5) (5) (6) Thickness (mm) 1.03 1.03 1.03
Shore D hardness of sheet 53 53 50 Ball Diameter (mm) 42.67 42.66
42.66 Weight (g) 45.5 45.4 45.4 Deflection, 10-130 kgf (mm) 3.09
3.29 3.36 Initial velocity (m/s) 77.3 77.3 77.3 Shore D hardness of
cover material - Shore D -2 -2 -5 hardness of intermediate layer
material Initial velocity of ball - initial velocity -1.0 -1.1 -1.1
of intermediate layer-encased sphere (m/s) (Ball
deflection)/(Deflection of intermediate 0.92 0.90 0.92
layer-encased sphere) Flight Spin rate (rpm) 2924 2836 2974 (W#1,
Total distance (m) 191.5 192.5 190.7 HS 40 m/s) Rating good good
good Spin on Spin rate (rpm) 5867 5746 5921 approach shots Rating
good good good Feel W#1 good good good Putter good good good
Durability to Rating good good good repeated impact Scuff Rating
good good good resistance
TABLE-US-00005 TABLE 5 Comparative Example 1 2 3 4 5 6 7 Core
Diameter (mm) 37.35 37.30 37.35 37.40 37.40 37.40 37.35 Weight (g)
32.2 32.1 32.2 33.2 32.2 32.2 32.2 Deflection, 10-130 kgf (mm) 3.83
4.20 3.83 3.80 3.70 3.83 3.83 Initial velocity (m/s) 78.0 78.2 78.0
77.9 77.8 78.0 78.0 JIS-C surface hardness (S) 80 78 80 80 75 80 80
JIS-C hardness 15 mm from center 74 72 74 74 76 74 74 JIS-C
hardness 7.5 mm from center 67 65 67 67 70 67 67 JIS-C center
hardness (C) 60 58 60 60 64 60 60 Average (I) of JIS-C hardnesses
67 64 67 67 70 67 67 at center and 15 mm from center (I) - JIS-C
hardness 0 -1 0 0 0 0 0 7.5 mm from center (S) - (C), JIS-C
hardness 20 20 20 20 11 20 20 Intermediate Material (type) (2) (1)
(3) (1) (1) (4) (3) layer Thickness (mm) 1.63 1.66 1.63 1.60 1.60
1.60 1.63 Specific gravity 0.94 0.94 0.96 0.94 0.94 0.95 0.96 Shore
D hardness of sheet 55 55 48 55 55 62 48 JIS-C hardness of sheet 83
83 74 83 83 92 74 Intermediate Diameter (mm) 40.60 40.61 40.60
40.60 40.60 40.60 40.60 layer-encased Weight (g) 39.5 39.5 39.6
40.4 39.4 39.4 39.6 sphere Deflection, 10-130 kgf (mm) 3.40 3.64
3.42 3.37 3.30 3.00 3.42 Initial velocity (m/s) 77.6 78.4 78.0 78.1
78.1 78.2 78.0 Initial velocity of intermediate layer-encased -0.4
0.2 0.1 0.2 0.3 0.2 0.1 sphere - initial velocity of core (m/s)
JIS-C hardness of intermediate layer material - 3 5 -6 3 8 12 -6
JIS-C hardness of core surface (Deflection of intermediate
layer-encased 0.89 0.87 0.89 0.89 0.89 0.78 0.89 sphere)/(core
deflection) Cover Material (type) (5) (7) (5) (8) (5) (5) (9)
Thickness (mm) 1.05 1.05 1.03 1.05 1.05 1.05 1.03 Shore D hardness
of sheet 53 61 53 53 53 53 47 Ball Diameter (mm) 42.70 42.70 42.67
42.70 42.70 42.70 42.67 Weight (g) 45.5 45.5 45.6 45.5 45.5 45.5
45.6 Deflection, 10-130 kgf (mm) 3.10 3.00 3.25 3.10 3.09 2.75 3.41
Initial velocity (m/s) 76.8 77.2 77.1 77.3 77.2 77.3 77.1 Shore D
hardness of cover material - Shore D -2 6 5 -2 -2 -9 -1 hardness of
intermediate layer material Initial velocity of ball - initial
velocity -0.8 -1.2 -0.9 -0.8 -0.9 -0.9 -0.9 of intermediate
layer-encased sphere (m/s) (Ball deflection)/(Deflection of
intermediate 0.91 0.82 0.95 0.92 0.94 0.92 1.00 layer-encased
sphere) Flight (W#1, Spin rate (rpm) 3025 2842 3005 3111 3015 2977
3275 HS 40 m/s) Total distance (m) 188.8 192.9 189.8 188.8 189.3
190.5 187.0 Rating NG good NG NG NG good NG Spin on Spin rate (rpm)
5877 5345 5870 5835 5879 5785 6015 approach shots Rating good NG
good good good good good Feel W#1 good good good good good good
good Putter good NG good good good good good Durability to Rating
good good good good good NG good repeated impact Scuff resistance
Rating good NG good NG good good good
[0168] From the results in Tables 4 and 5, the golf balls in
Examples 1 to 3 according to the invention were better from the
standpoint of all of the following: flight performance, spin on
approach shots, feel, durability to repeated impact, and scuff
resistance. The following results were obtained for the golf balls
in the comparative examples.
[0169] The golf ball in Comparative Example 1 had a poor distance
because the initial velocity of the sphere composed of the core
encased by the intermediate layer was lower than the initial
velocity of the core.
[0170] In the golf ball in Comparative Example 2, the cover was
harder than the intermediate layer. As a result, the ball had a
poor receptivity to spin on approach shots, and had a hard feel on
shots with a putter. In addition, the ball had a poor durability to
repeated impact.
[0171] In the golf ball in Comparative Example 3, the JIS-C
hardness at the core surface was higher than the JIS-C hardness of
the intermediate layer. As a result, the spin rate increased on
shots with a W#1, preventing a sufficient distance from being
achieved.
[0172] In the golf ball in Comparative Example 4, the cover was
made of an ionomer. This ball had a poor scuff resistance, in
addition to which the spin rate-lowering effect on shots with a W#1
was poor, as a result of which a sufficient distance was not
achieved.
[0173] In the golf ball in Comparative Example 5, the JIS-C
hardness difference (core surface hardness)-(core center hardness)
was less than 15, as a result of which the spin rate was high,
preventing a sufficient distance from being achieved.
[0174] In the golf ball in Comparative Example 6, the ratio
(deflection of sphere composed of core encased by intermediate
layer)/(core deflection) was less than 0.80, resulting in a poor
durability to repeated impact.
[0175] In the golf ball in Comparative Example 7, the JIS-C
hardness at the core surface was greater than the JIS-C hardness of
the intermediate layer, as a result of which the spin rate on shots
with a W#1 increased, preventing a sufficient distance from being
achieved.
* * * * *