U.S. patent application number 14/066753 was filed with the patent office on 2015-04-30 for golf ball compositions.
This patent application is currently assigned to Acushnet Company. The applicant listed for this patent is Acushnet Company. Invention is credited to Mark L. Binette, Robert Blink, David A. Bulpett, Brian Comeau, Michael J. Sullivan.
Application Number | 20150119169 14/066753 |
Document ID | / |
Family ID | 52996040 |
Filed Date | 2015-04-30 |
United States Patent
Application |
20150119169 |
Kind Code |
A1 |
Sullivan; Michael J. ; et
al. |
April 30, 2015 |
GOLF BALL COMPOSITIONS
Abstract
Disclosed herein are multilayer golf balls having a layer with a
higher hardness and a lower flexural modulus than another
layer.
Inventors: |
Sullivan; Michael J.; (Old
Lyme, CT) ; Binette; Mark L.; (Mattapoisett, MA)
; Blink; Robert; (Newport, RI) ; Bulpett; David
A.; (Boston, MA) ; Comeau; Brian; (Berkley,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Acushnet Company |
Fairhaven |
MA |
US |
|
|
Assignee: |
Acushnet Company
Fairhaven
MA
|
Family ID: |
52996040 |
Appl. No.: |
14/066753 |
Filed: |
October 30, 2013 |
Current U.S.
Class: |
473/374 ;
473/377 |
Current CPC
Class: |
A63B 37/0076 20130101;
A63B 37/0049 20130101; A63B 37/0075 20130101; A63B 37/0092
20130101; A63B 37/0086 20130101; A63B 37/0043 20130101 |
Class at
Publication: |
473/374 ;
473/377 |
International
Class: |
A63B 37/00 20060101
A63B037/00 |
Claims
1. A golf ball comprising: a first layer formed from a first
composition and a second layer formed from a second composition,
wherein the Shore C hardness of the first composition is greater
than the Shore C hardness of the second composition, and wherein
the flexural modulus of the first composition is less than the
flexural modulus of the second composition.
2. The golf ball of claim 1, wherein the first composition has a
Shore C hardness of 86 or greater.
3. The golf ball of claim 1, wherein the first composition has a
flexural modulus of 40 ksi or less.
4. The golf ball of claim 1, wherein the second composition has a
Shore C hardness of 86 or less.
5. The golf ball of claim 1, wherein the second composition has a
flexural modulus of 41 ksi or greater.
6. A golf ball comprising: a solid, single layer core formed from a
first composition, an inner cover layer formed from a second
composition, and an outer cover layer, wherein the first
composition has a higher Shore C hardness than the second
composition, and wherein the first composition has a lower flexural
modulus than the second composition.
7. The golf ball of claim 6, wherein the first composition has a
Shore C hardness of 86 or greater.
8. The golf ball of claim 6, wherein the first composition has a
flexural modulus of 40 ksi or less.
9. The golf ball of claim 6, wherein the second composition has a
Shore C hardness of 86 or less.
10. The golf ball of claim 6, wherein the second composition has a
flexural modulus of 41 ksi or greater.
11. A golf ball comprising: an inner core layer, an outer core
layer, an inner cover layer, and an outer cover layer; wherein the
composition used to form the outer core layer has a higher Shore C
hardness than the composition used to form the inner cover layer;
and wherein the composition used to form the outer core layer has a
lower flexural modulus than the composition used to form the inner
cover layer.
12. The golf ball of claim 11, wherein the outer core layer
composition has a Shore C hardness of 86 or greater.
13. The golf ball of claim 11, wherein the outer core layer
composition has a flexural modulus of 46 ksi or less.
14. The golf ball of claim 11, wherein the inner cover layer
composition has a Shore C hardness of 86 or less.
15. The golf ball of claim 11, wherein the inner cover layer
composition has a flexural modulus of 48 ksi or greater.
16. A golf ball comprising: a solid, single layer core formed from
a first composition, an inner cover layer formed from a second
composition, and an outer cover layer, wherein the second
composition has a higher Shore C hardness than the first
composition, and wherein the second composition has a lower
flexural modulus than the first composition.
17. The golf ball of claim 16, wherein the first composition has a
Shore C hardness of 86 or less.
18. The golf ball of claim 16, wherein the first composition has a
flexural modulus of 41 ksi or greater.
19. The golf ball of claim 16, wherein the second composition has a
Shore C hardness of 86 or greater.
20. The golf ball of claim 16, wherein the second composition has a
flexural modulus of 40 ksi or less.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to golf balls
comprising a first layer having a higher hardness and a lower
flexural modulus than a second layer.
BACKGROUND OF THE INVENTION
[0002] For the vast majority of materials, hardness is used
synonymously with flexural modulus. Although both hardness and
flexural modulus reflect how a material feels to the touch,
hardness measures the resistance to indentation, while flexural
modulus measures the resistance to bending. Generally, flexural
modulus tends to increase with hardness in a predictable manner,
such that the flexural modulus of a material can be predicted based
on the material's hardness. Thus, if a first material has a higher
hardness than a second material, then the first material will
typically have a higher flexural modulus than the second material.
The present invention provides a novel golf ball construction
wherein the typical hardness/modulus relationship does not exist
between two of the layers. For example, if the composition used to
form a first layer has a higher hardness than the composition used
to form a second layer, then the composition used to form the first
layer will have a lower flexural modulus than the composition used
to form the second layer. Such compositions provide unique
properties of spin and feel to a golf ball.
SUMMARY OF THE INVENTION
[0003] In one embodiment, the present invention is directed to a
golf ball comprising a first layer and a second layer, wherein the
composition used to form the first layer has a higher Shore C
hardness and a lower flexural modulus than the composition used to
form the second layer.
[0004] In another embodiment, the present invention is directed to
a golf ball comprising a solid, single layer core formed from a
first composition, an inner cover layer formed from a second
composition, and an outer cover layer. The first composition has a
higher Shore C hardness and lower flexural modulus than the second
composition.
[0005] In another embodiment, the present invention is directed to
a golf ball comprising an inner core layer, an outer core layer, an
inner cover layer, and an outer cover layer. The composition used
to form the outer core layer has a higher Shore C hardness and a
lower flexural modulus than the composition used to form the inner
cover layer.
[0006] In another embodiment, the present invention is directed to
a golf ball comprising a solid, single layer core formed from a
first composition, an inner cover layer formed from a second
composition, and an outer cover layer. The second composition has a
higher Shore C hardness and lower flexural modulus than the first
composition.
DETAILED DESCRIPTION
[0007] Golf balls of the present invention are multilayer balls
(i.e., solid core of one or more layers and a cover of one or more
layers), having a novel construction wherein one layer has a higher
hardness and a lower flexural modulus than that of another layer.
Such hardness/modulus relationship can be achieved by forming the
layers from the same material and adjusting the material's
hardness/modulus to a first desirable level for one layer and a
second desirable level for another layer (e.g., two polyurethane
layers having different isocyanate levels), or by forming the
layers from different materials (e.g., an ionomer layer and a
rubber layer), wherein each material's hardness is adjusted to the
desirable level. Thus, each layer of the ball is formed from a
composition independently selected from the following thermoset and
thermoplastic compositions, so long as the composition used to form
one layer has a higher hardness and a lower flexural modulus than
the composition used to form another layer.
[0008] Suitable thermoset compositions include, but are not limited
to, natural rubbers, polybutadienes, polyisoprenes, ethylene
propylene rubbers (EPR), ethylene-propylene-diene rubbers (EPDM),
styrene-butadiene rubbers, butyl rubbers, halobutyl rubbers,
polyurethanes, polyureas, acrylonitrile butadiene rubbers,
polychloroprenes, alkyl acrylate rubbers, chlorinated isoprene
rubbers, acrylonitrile chlorinated isoprene rubbers,
polyalkenamers, phenol formaldehydes, melamine formaldehydes,
polyepoxides, polysiloxanes, polyesters, alkyds, polyisocyanurates,
polycyanurates, polyacrylates, and combinations of two or more
thereof.
[0009] Suitable initiator agents include organic peroxides, high
energy radiation sources capable of generating free radicals, C-C
initiators, and combinations thereof. High energy radiation sources
capable of generating free radicals include, but are not limited
to, electron beams, ultra-violet radiation, gamma radiation, X-ray
radiation, infrared radiation, heat, and combinations thereof.
Suitable organic peroxides include, but are not limited to, dicumyl
peroxide; n-butyl-4,4-di(t-butylperoxy) valerate;
1,1-di(t-butylperoxy)3,3,5-trimethylcyclohexane;
2,5-dimethyl-2,5-di(t-butylperoxy) hexane; di-t-butyl peroxide;
di-t-amyl peroxide; t-butyl peroxide; t-butyl cumyl peroxide;
2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3;
di(2-t-butyl-peroxyisopropyl)benzene; dilauroyl peroxide; dibenzoyl
peroxide; t-butyl hydroperoxide; lauryl peroxide; benzoyl peroxide;
and combinations thereof.
[0010] Examples of suitable commercially available peroxides
include, but are not limited to Perkadox.RTM. BC dicumyl peroxide,
commercially available from Akzo Nobel, and Varox.RTM. peroxides,
such as Varox.RTM. ANS benzoyl peroxide and Varox.RTM. 231
1,1-di(t-butylperoxy)3,3,5-trimethylcyclohexane, commercially
available from RT Vanderbilt Company, Inc. Peroxide initiator
agents are generally present in the thermoset composition in an
amount of at least 0.05 parts by weight per 100 parts of the base
polymer, or an amount within the range having a lower limit of 0.05
parts or 0.1 parts or 0.8 parts or 1 part or 1.25 parts or 1.5
parts by weight per 100 parts of the base polymer, and an upper
limit of 2.5 parts or 3 parts or 5 parts or 6 parts or 10 parts or
15 parts by weight per 100 parts of the base polymer.
[0011] Coagents are commonly used with peroxides to increase the
state of cure. Suitable coagents include, but are not limited to,
metal salts of unsaturated carboxylic acids; unsaturated vinyl
compounds and polyfunctional monomers (e.g., trimethylolpropane
trimethacrylate); phenylene bismaleimide; and combinations thereof.
Particular examples of suitable metal salts include, but are not
limited to, one or more metal salts of acrylates, diacrylates,
methacrylates, and dimethacrylates, wherein the metal is selected
from magnesium, calcium, zinc, aluminum, lithium, nickel, and
sodium. In a particular embodiment, the coagent is selected from
zinc salts of acrylates, diacrylates, methacrylates,
dimethacrylates, and mixtures thereof. In another particular
embodiment, the coagent is zinc diacrylate. When the coagent is
zinc diacrylate and/or zinc dimethacrylate, the coagent is
typically included in the thermoset composition in an amount within
the range having a lower limit of 1 or 5 or 10 or 15 or 19 or 20
parts by weight per 100 parts of the base polymer, and an upper
limit of 24 or 25 or 30 or 35 or 40 or 45 or 50 or 60 parts by
weight per 100 parts of the base polymer. When one or more less
active coagents are used, such as zinc monomethacrylate and various
liquid acrylates and methacrylates, the amount of less active
coagent used may be the same as or higher than for zinc diacrylate
and zinc dimethacrylate coagents.
[0012] The thermoset composition optionally includes a curing
agent. Suitable curing agents include, but are not limited to,
sulfur; N-oxydiethylene 2-benzothiazole sulfenamide;
N,N-di-ortho-tolylguanidine; bismuth dimethyldithiocarbamate;
N-cyclohexyl 2-benzothiazole sulfenamide; N,N-diphenylguanidine;
4-morpholinyl-2-benzothiazole disulfide; dipentamethylenethiuram
hexasulfide; thiuram disulfides; mercaptobenzothiazoles;
sulfenamides; dithiocarbamates; thiuram sulfides; guanidines;
thioureas; xanthates; dithiophosphates; aldehyde-amines;
dibenzothiazyl disulfide; tetraethylthiuram disulfide;
tetrabutylthiuram disulfide; and combinations thereof.
[0013] The thermoset composition optionally contains one or more
antioxidants. Antioxidants are compounds that can inhibit or
prevent the oxidative degradation of the base polymer. Some
antioxidants also act as free radical scavengers; thus, when
antioxidants are included in the thermoset composition, the amount
of initiator agent used may be as high or higher than the amounts
disclosed herein. Suitable antioxidants include, for example,
dihydroquinoline antioxidants, amine type antioxidants, and
phenolic type antioxidants.
[0014] The thermoset composition optionally includes a soft and
fast agent. Preferably, the thermoset composition contains from
0.05 phr to 10.0 phr of a soft and fast agent. In one embodiment,
the soft and fast agent is present in an amount within a range
having a lower limit of 0.05 or 0.1 or 0.2 or 0.5 phr and an upper
limit of 1.0 or 2.0 or 3.0 or 5.0 phr. In another embodiment, the
soft and fast agent is present in an amount of from 2.0 phr to 5.0
phr, or from 2.35 phr to 4.0 phr, or from 2.35 phr to 3.0 phr.
[0015] Suitable soft and fast agents include, but are not limited
to, organosulfur and metal-containing organosulfur compounds;
organic sulfur compounds, including mono, di, and polysulfides,
thiol, and mercapto compounds; inorganic sulfide compounds; blends
of an organosulfur compound and an inorganic sulfide compound;
Group VIA compounds; substituted and unsubstituted aromatic organic
compounds that do not contain sulfur or metal; aromatic
organometallic compounds; hydroquinones; benzoquinones;
quinhydrones; catechols; resorcinols; and combinations thereof. In
a particular embodiment, the soft and fast agent is selected from
zinc pentachlorothiophenol, pentachlorothiophenol, ditolyl
disulfide, diphenyl disulfide, dixylyl disulfide,
2-nitroresorcinol, and combinations thereof.
[0016] The thermoset composition may contain one or more fillers.
Exemplary fillers include precipitated hydrated silica, clay, talc,
asbestos, glass fibers, aramid fibers, mica, calcium metasilicate,
zinc sulfate, barium sulfate, zinc sulfide, lithopone, silicates,
silicon carbide, diatomaceous earth, carbonates (e.g., calcium
carbonate, zinc carbonate, barium carbonate, and magnesium
carbonate), metals (e.g., titanium, tungsten, aluminum, bismuth,
nickel, molybdenum, iron, lead, copper, boron, cobalt, beryllium,
zinc, and tin), metal alloys (e.g., steel, brass, bronze, boron
carbide whiskers, and tungsten carbide whiskers), oxides (e.g.,
zinc oxide, tin oxide, iron oxide, calcium oxide, aluminum oxide,
titanium dioxide, magnesium oxide, and zirconium oxide),
particulate carbonaceous materials (e.g., graphite, carbon black,
cotton flock, natural bitumen, cellulose flock, and leather fiber),
microballoons (e.g., glass and ceramic), fly ash, core material
that is ground and recycled, nanofillers and combinations
thereof.
[0017] The thermoset composition may also contain one or more
additives selected from processing aids, such as transpolyisoprene
(e.g., TP-301 transpolyisoprene, commercially available from
Kuraray Co., Ltd.) and transbutadiene rubber; processing oils;
plasticizers; coloring agents; fluorescent agents; chemical blowing
and foaming agents; defoaming agents; stabilizers; softening
agents; impact modifiers; free radical scavengers; accelerators;
scorch retarders; and the like.
[0018] Non-limiting examples of suitable commercially available
thermoset rubbers are Buna CB high-cis neodymium-catalyzed
polybutadiene rubbers, such as Buna CB 23, and Buna CB high-cis
cobalt-catalyzed polybutadiene rubbers, such as Buna CB 1220 and
1221, commercially available from Lanxess Corporation; SE BR-1220,
commercially available from The Dow Chemical Company;
Europrene.RTM. NEOCIS.RTM. BR 40 and BR 60, commercially available
from Polimeri Europa.RTM.; UBEPOL-BR.RTM. rubbers, commercially
available from UBE Industries, Inc.; BR 01, commercially available
from Japan Synthetic Rubber Co., Ltd.; Neodene high-cis
neodymium-catalyzed polybutadiene rubbers, such as Neodene BR 40,
commercially available from Karbochem; TP-301 transpolyisoprene,
commercially available from Kuraray Co., Ltd.; Vestenamer.RTM.
polyoctenamer, commercially available from Evonik Industries; Butyl
065 and Butyl 288 butyl rubbers, commercially available from
ExxonMobil Chemical Company; Butyl 301 and Butyl 101-3,
commercially available from Lanxess Corporation; Bromobutyl 2224
and Chlorobutyl 1066 halobutyl rubbers, commercially available from
ExxonMobil Chemical Company; Bromobutyl X2 and Chlorobutyl 1240
halobutyl rubbers, commercially available from Lanxess Corporation;
BromoButyl 2255 butyl rubber, commercially available from Japan
Synthetic Rubber Co., Ltd.; Vistalon.RTM. 404 and Vistalon.RTM. 706
ethylene propylene rubbers, commercially available from ExxonMobil
Chemical Company; Dutral CO 058 ethylene propylene rubber,
commercially available from Polimeri Europa; Nordel.RTM. IP NDR
5565 and Nordel.RTM. IP 3670 ethylene-propylene-diene rubbers,
commercially available from The Dow Chemical Company; EPT1045 and
EPT1045 ethylene-propylene-diene rubbers, commercially available
from Mitsui Corporation; Buna SE 1721 TE styrene-butadiene rubbers,
commercially available from Lanxess Corporation; Afpol 1500 and
Afpol 552 styrene-butadiene rubbers, commercially available from
Karbochem; Nipol.RTM. DN407 and Nipol.RTM. 1041L acrylonitrile
butadiene rubbers, commercially available from Zeon Chemicals,
L.P.; Neoprene GRT and Neoprene AD30 polychloroprene rubbers;
Vamac.RTM. ethylene acrylic elastomers, commercially available from
E. I. du Pont de Nemours and Company; Hytemp.RTM. AR12 and AR214
alkyl acrylate rubbers, commercially available from Zeon Chemicals,
L.P.; and Hypalon.RTM. chlorosulfonated polyethylene rubbers,
commercially available from E. I. du Pont de Nemours and
Company.
[0019] Suitable types and amounts of base rubber, initiator agent,
coagent, filler, and additives are more fully described in, for
example, U.S. Pat. Nos. 6,566,483, 6,695,718, 6,939,907, 7,041,721
and 7,138,460, the entire disclosures of which are hereby
incorporated herein by reference. Particularly suitable diene
rubber compositions are further disclosed, for example, in U.S.
Patent Application Publication No. 2007/0093318, the entire
disclosure of which is hereby incorporated herein by reference.
[0020] Suitable thermoplastic compositions include, but are not
limited to, partially- and fully-neutralized ionomers, graft
copolymers of ionomer and polyamide, and the following
non-ionomeric polymers, including homopolymers and copolymers
thereof, as well as their derivatives that are compatibilized with
at least one grafted or copolymerized functional group, such as
maleic anhydride, amine, epoxy, isocyanate, hydroxyl, sulfonate,
phosphonate, and the like: [0021] (a) polyesters, particularly
those modified with a compatibilizing group such as sulfonate or
phosphonate, including modified poly(ethylene terephthalate),
modified poly(butylene terephthalate), modified poly(propylene
terephthalate), modified poly(trimethylene terephthalate), modified
poly(ethylene naphthenate), including, but not limited to, those
disclosed in U.S. Pat. Nos. 6,353,050, 6,274,298, and 6,001,930,
the entire disclosures of which are hereby incorporated herein by
reference; [0022] (b) polyamides, polyamide-ethers, and
polyamide-esters, including, but not limited to, those disclosed in
U.S. Pat. Nos. 6,187,864, 6,001,930, and 5,981,654, the entire
disclosures of which are hereby incorporated herein by reference;
[0023] (c) polyurethanes, polyureas, polyurethane-polyurea hybrids,
and blends of two or more thereof, including, but not limited to,
those disclosed in U.S. Pat. Nos. 5,334,673, 5,484,870, 6,506,851,
6,756,436, 6,835,794, 6,867,279, 6,960,630, and 7,105,623, U.S.
Patent Application Publication No. 2007/0117923, and U.S. Patent
Application Ser. Nos. 60/401,047 and 13/613,095, the entire
disclosures of which are hereby incorporated herein by reference;
[0024] (d) fluoropolymers, including, but not limited to, those
disclosed in U.S. Pat. Nos. 5,691,066, 6,747,110 and 7,009,002, the
entire disclosures of which are hereby incorporated herein by
reference; [0025] (e) non-ionomeric acid polymers, such as O/X- and
O/X/Y-type copolymers, wherein O is an olefin (e.g., ethylene), X
is a carboxylic acid such as acrylic, methacrylic, crotonic,
maleic, fumaric, or itaconic acid, and Y is a softening comonomer
such as vinyl esters of aliphatic carboxylic acids wherein the acid
has from 2 to 10 carbons, alkyl ethers wherein the alkyl group has
from 1 to 10 carbons, and alkyl alkylacrylates such as alkyl
methacrylates wherein the alkyl group has from 1 to 10 carbons;
including, but not limited to, those disclosed in U.S. Pat. No.
6,872,774, the entire disclosure of which is hereby incorporated
herein by reference; [0026] (f) metallocene-catalyzed polymers,
including, but not limited to, those disclosed in U.S. Pat. Nos.
6,274,669, 5,919,862, 5,981,654, and 5,703,166, the entire
disclosures of which are hereby incorporated herein by reference;
[0027] (g) polystyrenes, such as poly(styrene-co-maleic anhydride),
acrylonitrile-butadiene-styrene, poly(styrene sulfonate),
polyethylene styrene; [0028] (h) polypropylenes, polyethylenes,
propylene elastomers, ethylene elastomers, copolymers of propylene
and ethylene, and blends of two or more thereof; [0029] (i)
polyvinyl chlorides, and blends of two or more thereof; [0030] (j)
polyvinyl acetates, preferably having less than about 9% of vinyl
acetate by weight, and blends of two or more thereof; [0031] (k)
polycarbonates, blends of
polycarbonate/acrylonitrile-butadiene-styrene, blends of
polycarbonate/polyurethane, blends of polycarbonate/polyester, and
blends of two or more thereof; [0032] (l) polyvinyl alcohols, and
blends of two or more thereof; [0033] (m) polyethers, such as
polyarylene ethers, polyphenylene oxides, block copolymers of
alkenyl aromatics with vinyl aromatics and poly(amic ester)s, and
blends of two or more thereof; [0034] (n) polyimides,
polyetherketones, polyamideimides, and blends of two or more
thereof; [0035] (o) polycarbonate/polyester copolymers and blends
of two or more thereof; and [0036] (p) combinations of any two or
more of the above thermoplastic polymers.
[0037] Suitable ionomer compositions include partially neutralized
ionomers and highly neutralized ionomers, including ionomers formed
from blends of two or more partially neutralized ionomers, blends
of two or more highly neutralized ionomers, and blends of one or
more partially neutralized ionomers with one or more highly
neutralized ionomers. Preferred ionomers are salts of O/X- and
O/X/Y-type acid copolymers, wherein O is an .alpha.-olefin, X is a
C.sub.3-C.sub.8 .alpha.,.beta.-ethylenically unsaturated carboxylic
acid, and Y is a softening monomer. O is preferably selected from
ethylene and propylene. X is preferably selected from methacrylic
acid, acrylic acid, ethacrylic acid, crotonic acid, and itaconic
acid. Methacrylic acid and acrylic acid are particularly preferred.
As used herein, "(meth) acrylic acid" means methacrylic acid and/or
acrylic acid. Likewise, "(meth) acrylate" means methacrylate and/or
acrylate. Y is preferably selected from (meth) acrylate and alkyl
(meth) acrylates wherein the alkyl groups have from 1 to 8 carbon
atoms, including, but not limited to, n-butyl (meth) acrylate,
isobutyl (meth) acrylate, methyl (meth) acrylate, and ethyl (meth)
acrylate. Particularly preferred O/X/Y-type copolymers are
ethylene/(meth) acrylic acid/n-butyl (meth) acrylate,
ethylene/(meth) acrylic acid/isobutyl (meth) acrylate,
ethylene/(meth) acrylic acid/methyl (meth) acrylate, and
ethylene/(meth) acrylic acid/ethyl (meth) acrylate. The acid is
typically present in the acid copolymer in an amount of 6 wt % or
greater, or 9 wt % or greater, or 10 wt % or greater, or 11 wt % or
greater, or 15 wt % or greater, or 16 wt % or greater, or in an
amount within a range having a lower limit of 1 or 4 or 6 or 8 or
10 or 11 or 12 or 15 wt % and an upper limit of 15 or 16 or 17 or
19 or 20 or 20.5 or 21 or 25 or 30 or 35 or 40 wt %, based on the
total weight of the acid copolymer. The acid copolymer is at least
partially neutralized with a cation source, optionally in the
presence of a high molecular weight organic acid, such as those
disclosed in U.S. Pat. No. 6,756,436, the entire disclosure of
which is hereby incorporated herein by reference. In a particular
embodiment, less than 40% of the acid groups present in the
composition are neutralized. In another particular embodiment, from
40% to 60% of the acid groups present in the composition are
neutralized. In another particular embodiment, from 60% to 70% of
the acid groups present in the composition are neutralized. In
another embodiment, 60% to 80% of the acid groups present in the
composition are neutralized. In another embodiment, from 80% to
100% of the acid groups present in the composition are neutralized.
Suitable cation sources include, but are not limited to, metal ion
sources, such as compounds of alkali metals, alkaline earth metals,
transition metals, and rare earth elements; ammonium salts and
monoamine salts; and combinations thereof. Preferred cation sources
are compounds of magnesium, sodium, potassium, cesium, calcium,
barium, manganese, copper, zinc, tin, lithium, and rare earth
metals. In a particular embodiment, the ionomer composition
includes a bimodal ionomer, for example, DuPont.RTM. AD1043
ionomers, and the ionomers disclosed in U.S. Patent Application
Publication No. 2004/0220343 and U.S. Pat. Nos. 6,562,906,
6,762,246 and 7,273,903, the entire disclosures of which are hereby
incorporated herein by reference. Suitable ionomers are further
disclosed, for example, in U.S. Patent Application Publication Nos.
2005/0049367, 2005/0148725, 2005/0020741, 2004/0220343, and
2003/0130434, and U.S. Pat. Nos. 5,587,430, 5,691,418, 5,866,658,
6,100,321, 6,562,906, 6,653,382, 6,756,436, 6,777,472, 6,762,246,
6,815,480, 6,894,098, 6,919,393, 6,953,820, 6,994,638, 7,375,151,
and 7,652,086, the entire disclosures of which are hereby
incorporated herein by reference.
[0038] Also suitable are thermoplastic elastomers comprising a
silicone ionomer, as disclosed, for example, in U.S. Pat. No.
8,329,156, the entire disclosure of which is hereby incorporated
herein by reference.
[0039] The thermoplastic composition may contain additive(s) and/or
filler(s) in an amount of 50 wt % or less, or 30 wt % or less, or
20 wt % or less, or 15 wt % or less, based on the total weight of
the thermoplastic composition. Suitable additives and fillers
include, but are not limited to, chemical blowing and foaming
agents, optical brighteners, coloring agents, fluorescent agents,
whitening agents, UV absorbers, light stabilizers, defoaming
agents, processing aids, antioxidants, stabilizers, softening
agents, fragrance components, plasticizers, impact modifiers,
TiO.sub.2, acid copolymer wax, surfactants, performance additives
(e.g., A-C.RTM. performance additives, particularly A-C.RTM. low
molecular weight ionomers and copolymers, A-C.RTM. oxidized
polyethylenes, A-C.RTM. ethylene vinyl acetate waxes, and
AClyn.RTM. low molecular weight ionomers, commercially available
from Honeywell International Inc.), fatty acid amides (e.g.,
ethylene bis-stearamide and ethylene bis-oleamide), fatty acids and
salts thereof (e.g., stearic acid, oleic acid, zinc stearate,
magnesium stearate, zinc oleate, and magnesium oleate), oxides
(e.g., zinc oxide, tin oxide, iron oxide, calcium oxide, aluminum
oxide, titanium dioxide, magnesium oxide, and zirconium oxide),
carbonates (e.g., calcium carbonate, zinc carbonate, barium
carbonate, and magnesium carbonate), barium sulfate, zinc sulfate,
tungsten, tungsten carbide, silica, lead silicate, clay, mica,
talc, nano-fillers, carbon black, glass flake, milled glass, flock,
fibers, core material that is ground and recycled, and mixtures
thereof. Suitable additives and fillers are more fully described
in, for example, U.S. Patent Application Publication No.
2003/0225197, the entire disclosure of which is hereby incorporated
herein by reference. In a particular embodiment, the total amount
of additive(s) and filler(s) present in the thermoplastic
composition is 20 wt % or less, or 15 wt % or less, or 12 wt % or
less, or 10 wt % or less, or 9 wt % or less, or 6 wt % or less, or
5 wt % or less, or 4 wt % or less, or 3 wt % or less, or within a
range having a lower limit of 0 or 2 or 3 or 5 wt %, based on the
total weight of the thermoset composition, and an upper limit of 9
or 10 or 12 or 15 or 20 wt %, based on the total weight of the
thermoplastic composition. In a particular aspect of this
embodiment, the thermoplastic composition includes filler(s)
selected from carbon black, micro- and nano-scale clays and
organoclays, including (e.g., Cloisite.RTM. and Nanofil.RTM.
nanoclays, commercially available from Southern Clay Products,
Inc.; Nanomax.RTM. and Nanomer.RTM. nanoclays, commercially
available from Nanocor, Inc., and Perkalite.RTM. nanoclays,
commercially available from Akzo Nobel Polymer Chemicals), micro-
and nano-scale talcs (e.g., Luzenac HAR.RTM. high aspect ratio
talcs, commercially available from Luzenac America, Inc.), glass
(e.g., glass flake, milled glass, microglass, and glass fibers),
micro- and nano-scale mica and mica-based pigments (e.g.,
Iriodin.RTM. pearl luster pigments, commercially available from The
Merck Group), and combinations thereof. Particularly suitable
combinations of fillers include, but are not limited to,
micro-scale filler(s) combined with nano-scale filler(s), and
organic filler(s) with inorganic filler(s).
[0040] The thermoplastic composition optionally includes one or
more melt flow modifiers. Suitable melt flow modifiers include
materials which increase the melt flow of the composition, as
measured using ASTM D-1238, condition E, at 190.degree. C., using a
2160 gram weight. Examples of suitable melt flow modifiers include,
but are not limited to, fatty acids and fatty acid salts,
including, but not limited to, those disclosed in U.S. Pat. No.
5,306,760, the entire disclosure of which is hereby incorporated
herein by reference; fatty amides and salts thereof; polyhydric
alcohols, including, but not limited to, those disclosed in U.S.
Pat. No. 7,365,128, and U.S. Patent Application Publication No.
2010/0099514, the entire disclosures of which are hereby
incorporated herein by reference; polylactic acids, including, but
not limited to, those disclosed in U.S. Pat. No. 7,642,319, the
entire disclosure of which is hereby incorporated herein by
reference; and the modifiers disclosed in U.S. Patent Application
Publication No. 2010/0099514 and 2009/0203469, the entire
disclosures of which are hereby incorporated herein by reference.
Flow enhancing additives also include, but are not limited to,
montanic acids, esters of montanic acids and salts thereof,
bis-stearoylethylenediamine, mono- and polyalcohol esters such as
pentaerythritol tetrastearate, zwitterionic compounds, and
metallocene-catalyzed polyethylene and polypropylene wax, including
maleic anhydride modified versions thereof, amide waxes and
alkylene diamides such as bistearamides. Particularly suitable
fatty amides include, but are not limited to, saturated fatty acid
monoamides (e.g., lauramide, palmitamide, arachidamide behenamide,
stearamide, and 12-hydroxy stearamide); unsaturated fatty acid
monoamides (e.g., oleamide, erucamide, and ricinoleamide);
N-substituted fatty acid amides (e.g., N-stearyl stearamide,
N-behenyl behenamide, N-stearyl behenamide, N-behenyl stearamide,
N-oleyl oleamide, N-oleyl stearamide, N-stearyl oleamide, N-stearyl
erucamide, erucyl erucamide, and erucyl stearamide, N-oleyl
palmitamide, methylol amide (more preferably, methylol stearamide,
methylol behenamide); saturated fatty acid bis-amides (e.g.,
methylene bis-stearamide, ethylene bis-stearamide, ethylene
bis-isostearamide, ethylene bis-hydroxystearamide, ethylene
bis-behenamide, hexamethylene bis-stearamide, hexamethylene
bis-behenamide, hexamethylene bis-hydroxystearamide, N,N'-distearyl
adipamide, and N,N'-distearyl sebacamide); unsaturated fatty acid
bis-amides (e.g., ethylene bis-oleamide, hexamethylene
bis-oleamide, N,N'-dioleyl adipamide, N,N'-dioleyl sebacamide); and
saturated and unsaturated fatty acid tetra amides, stearyl
erucamide, ethylene bis stearamide and ethylene bis oleamide.
Suitable examples of commercially available fatty amides include,
but are not limited to, Kemamide.RTM. fatty acids, such as
Kemamide.RTM. B (behenamide/arachidamide), Kemamide.RTM. W40
(N,N'-ethylenebisstearamide), Kemamide.RTM. P181 (oleyl
palmitamide), Kemamide.RTM. S (stearamide), Kemamide.RTM. U
(oleamide), Kemamide.RTM. E (erucamide), Kemamide.RTM. O
(oleamide), Kemamide.RTM. W45 (N,N'-ethylenebisstearamide),
Kenamide.RTM. W20 (N,N'-ethylenebisoleamide), Kemamide.RTM. E180
(stearyl erucamide), Kemamide.RTM. E221 (erucyl erucamide),
Kemamide.RTM. S180 (stearyl stearamide), Kemamide.RTM. 5221 (erucyl
stearamide), commercially available from Chemtura Corporation; and
Crodamide.RTM. fatty amides, such as Crodamide.RTM. OR (oleamide),
Crodamide.RTM. ER (erucamide), Crodamide.RTM. SR (stereamide),
Crodamide.RTM. BR (behenamide), Crodamide.RTM. 203 (oleyl
palmitamide), and Crodamide.RTM. 212 (stearyl erucamide),
commercially available from Croda Universal Ltd.
[0041] Non-limiting examples of suitable commercially available
thermoplastics are Surlyn.RTM. ionomers and DuPont.RTM. HPF 1000
and HPF 2000 highly neutralized ionomers, commercially available
from E. I. du Pont de Nemours and Company; Clarix .RTM. ionomers,
commercially available from A. Schulman, Inc.; Iotek.RTM. ionomers,
commercially available from ExxonMobil Chemical Company;
Amplify.RTM. IO ionomers, commercially available from The Dow
Chemical Company; Amplify.RTM. GR functional polymers and
Amplify.RTM. TY functional polymers, commercially available from
The Dow Chemical Company; Fusabond.RTM. functionalized polymers,
including ethylene vinyl acetates, polyethylenes, metallocene-
catalyzed polyethylenes, ethylene propylene rubbers, and
polypropylenes, commercially available from E. I. du Pont de
Nemours and Company; Exxelor.RTM. maleic anhydride grafted
polymers, including high density polyethylene, polypropylene,
semi-crystalline ethylene copolymer, amorphous ethylene copolymer,
commercially available from ExxonMobil Chemical Company;
ExxonMobil.RTM. PP series polypropylene impact copolymers, such as
PP7032E3, PP7032KN, PP7033E3, PP7684KN, commercially available from
ExxonMobil Chemical Company; Vistamaxx.RTM. propylene-based
elastomers, commercially available from ExxonMobil Chemical
Company; Vistalon.RTM. EPDM rubbers, commercially available from
ExxonMobil Chemical Company; Exact.RTM. plastomers, commercially
available from ExxonMobil Chemical Company; Santoprene.RTM.
thermoplastic vulcanized elastomers, commercially available from
ExxonMobil Chemical Company; Nucrel.RTM. acid copolymers,
commercially available from E. I. du Pont de Nemours and Company;
Escor.RTM. acid copolymers, commercially available from ExxonMobil
Chemical Company; Primacor.RTM. acid copolymers, commercially
available from The Dow Chemical Company; Kraton.RTM. styrenic block
copolymers, commercially available from Kraton Performance Polymers
Inc.; Septon.RTM. styrenic block copolymers, commercially available
from Kuraray Co., Ltd.; Lotader.RTM. ethylene acrylate based
polymers, commercially available from Arkema Corporation;
Polybond.RTM. grafted polyethylenes and polypropylenes,
commercially available from Chemtura Corporation; Royaltuf.RTM.
chemically modified EPDM, commercially available from Chemtura
Corporation; Vestenamer.RTM. polyoctenamer, commercially available
from Evonik Industries; Pebax.RTM. polyether and polyester amides,
commercially available from Arkema Inc.; polyester-based
thermoplastic elastomers, such as Hytrel.RTM. polyester elastomers,
commercially available from E. I. du Pont de Nemours and Company,
and Riteflex.RTM. polyester elastomers, commercially available from
Ticona; Estane.RTM. thermoplastic polyurethanes, commercially
available from The Lubrizol Corporation; Grivory.RTM. polyamides
and Grilamid.RTM. polyamides, commercially available from EMS
Grivory; Zytel.RTM. polyamide resins and Elvamide.RTM. nylon
multipolymer resins, commercially available from E. I. du Pont de
Nemours and Company; and Elvaloy.RTM. acrylate copolymer resins,
commercially available from E. I. du Pont de Nemours and
Company.
[0042] Golf balls of the present invention have at least one layer
with a higher hardness and a lower flexural modulus than that of
another layer. For purposes of the present disclosure, such a layer
having an atypical relative hardness/modulus relationship with at
least one other layer of the ball is referred to herein as an
atypical hardness/modulus layer. In a particular embodiment, the
golf ball includes an atypical hardness/modulus layer formed from a
soft and stiff composition, as disclosed in U.S. Patent Application
Publication Nos. 2012/0115633 and 2012/0115640, the entire
disclosures of which are hereby incorporated herein by reference,
and/or an atypical hardness/modulus layer formed from a hard and
flexible composition, as disclosed in U.S. Patent Application
Publication Nos. 2012/0115634 and 2012/0115635, the entire
disclosures of which are hereby incorporated herein by
reference.
[0043] For purposes of the present invention, a first layer has a
higher hardness than a second layer if the Shore C hardness of the
first layer is at least 1 Shore C unit greater than the Shore C
hardness of the second layer. In a particular embodiment, the Shore
C hardness of the first layer is at least 2 Shore C units, or at
least 3 Shore C units, or at least 5 Shore C units, or at least 7
Shore C units, or at least 8 Shore C units, or at least 10 Shore C
units, or at least 12 Shore C units, or at least 15 Shore C units,
or at least 20 Shore C units greater than the Shore C hardness of
the second layer. For purposes of the present invention, a first
layer has a lower flexural modulus than a second layer if the
flexural modulus of the first layer is at least 1 ksi unit or less
than the flexural modulus of the second layer. In a particular
embodiment, the flexural modulus of the first layer is at least 2
ksi units, or at least 3 ksi units, or at least 5 ksi units, or at
least 7 ksi units, or at least 8 ksi units, or at least 10 ksi
units, or at least 12 ksi units, or at least 15 ksi units, or at
least 20 ksi units less than the flexural modulus of the second
layer.
[0044] In a particular embodiment, the golf ball includes a solid,
single layer core and a single cover layer. In a particular aspect
of this embodiment, the core has a higher hardness and a lower
flexural modulus than that of the cover, and, optionally, the core
has a Shore C hardness of 86 or greater, or greater than 86, and a
flexural modulus of 40 kpsi or less, or less than 40 kpsi, or 35
kpsi or less, or less than 35 kpsi and/or the cover layer has a
Shore C hardness of 86 or less, or less than 86 and a flexural
modulus of 41 kpsi or greater, or greater than 41 kpsi, or 45 kpsi
or greater, or greater than 45 kpsi. In another particular aspect
of this embodiment, the core has a lower Shore C hardness and a
higher flexural modulus than that of the cover, and, optionally,
the core has a Shore C hardness of 88 or less, or less than 88, and
a flexural modulus of 41 kpsi or greater, or greater than 41 kpsi,
or 45 kpsi or greater, or greater than 45 kpsi, and/or the cover
layer has a Shore C hardness of 88 or greater, or greater than 88,
and a flexural modulus of 40 kpsi or less, or less than 40 kpsi, or
35 kpsi or less, or less than 35 kpsi.
[0045] In another particular embodiment, the golf ball includes a
solid, single layer core, an inner cover layer, and an outer cover
layer. In a particular aspect of this embodiment, the core has a
higher hardness and a lower flexural modulus than the inner cover
layer, and, optionally, the core has a Shore C hardness of 86 or
greater, or greater than 86, and a flexural modulus of 40 kpsi or
less, or less than 40 kpsi, or 35 kpsi or less, or less than 35
kpsi, and/or the inner cover layer has a Shore C hardness of 86 or
less, or less than 86 and a flexural modulus of 41 kpsi or greater,
or greater than 41 kpsi, or 45 kpsi or greater, or greater than 45
kpsi. The inner cover layer is optionally formed from a composition
comprising an ionomer and a functionalized polyethylene, and
optionally comprising one or more of an additional ionomer, an
additional functionalized polyethylene, or a filler, such as talc,
in an amount of from 5 to 30 wt %, based on the total weight of the
inner cover layer composition. In another particular aspect of this
embodiment, the core has a lower hardness and a higher flexural
modulus than the inner cover layer, and, optionally, the core has a
Shore C hardness of 88 or less, or less than 88, and a flexural
modulus of 41 kpsi or greater, or greater than 41 kpsi, or 45 kpsi
or greater, or greater than 45 kpsi, and/or the inner cover layer
has a Shore C hardness of 88 or greater, or greater than 88, and a
flexural modulus of 40 kpsi or less, or less than 40 kpsi, or 35
kpsi or less, or less than 35 kpsi. The core is optionally formed
from a composition comprising an ionomer and a functionalized
polyethylene, and optionally comprising one or more of an
additional ionomer, an additional functionalized polyethylene, or a
filler, such as talc, in an amount of from 5 to 30 wt %, based on
the total weight of the core composition.
[0046] In another particular embodiment, the golf ball includes an
inner core layer, an outer core layer, an inner cover layer, and an
outer cover layer. In a particular aspect of this embodiment, the
outer core layer has a higher hardness and a lower flexural modulus
than the inner cover layer, and, optionally, the outer core layer
has a Shore C hardness of 86 or greater, or greater than 86, and a
flexural modulus of 40 kpsi or less, or less than 40 kpsi, or 35
kpsi or less, or less than 35 kpsi, and/or the inner cover layer
has a Shore C hardness of 86 or less, or less than 86 and a
flexural modulus of 41 kpsi or greater, or greater than 41 kpsi, or
45 kpsi or greater, or greater than 45 kpsi. The inner cover layer
is optionally formed from a composition comprising an ionomer and a
functionalized polyethylene, and optionally comprising one or more
of an additional ionomer, an additional functionalized
polyethylene, or a filler, such as talc, in an amount of from 5 to
30 wt %, based on the total weight of the inner cover layer
composition. In another particular aspect of this embodiment, the
outer core layer has a lower Shore C hardness and a higher flexural
modulus than the inner cover layer, and, optionally, the outer core
layer has a Shore C hardness of 88 or less, or less than 88, and a
flexural modulus of 41 kpsi or greater, or greater than 41 kpsi, or
45 kpsi or greater, or greater than 45 kpsi, and/or the inner cover
layer has a Shore C hardness of 88 or greater, or greater than 88,
and a flexural modulus of 40 kpsi or less, or less than 40 kpsi, or
35 kpsi or less, or less than 35 kpsi. The outer core layer is
optionally formed from a composition comprising an ionomer and a
functionalized polyethylene, and optionally comprising one or more
of an additional ionomer, an additional functionalized
polyethylene, or a filler, such as talc, in an amount of from 5 to
30 wt %, based on the total weight of the outer core layer
composition.
[0047] Golf balls of the present invention are typically finished
by applying one or more finishing coats over the cover. For
example, a primer and a topcoat may be applied. Either or both of
the primer and topcoat compositions may be pigmented or clear.
Several coats of clear or pigmented coatings may be applied.
[0048] Primer compositions are typically a solvent-borne or
water-borne material, particularly selected from, but not limited
to, polyurethanes, polyureas, acrylic polyurethanes, polyesters,
polyester acrylics, and epoxies. In a particular embodiment, the
primer composition is a two-part solvent-borne polyurethane
comprising a resin component and an isocyanate component. In a
particular aspect of this embodiment, the isocyanate component is
present in an amount of from 31 parts to 35 parts, by weight per
100 parts of the resin component. In another particular aspect of
this embodiment, the resin component comprises from 50 to 58 wt %
solids and the isocyanate component comprises from 46 to 53 wt %
solids.
[0049] Topcoat compositions are typically a solvent-borne material
particularly selected from, but not limited to, polyurethanes,
polyureas, acrylic polyurethanes, polyesters, polyester acrylics,
and epoxies. In a particular embodiment, the topcoat composition is
a two-part solvent-borne polyurethane comprising a resin component
and an isocyanate component. In a particular aspect of this
embodiment, the isocyanate component is present in an amount of
from 68 parts to 71 parts, by weight per 100 parts of the resin
component. In another particular aspect of this embodiment, the
resin component comprises from 46 to 52 wt % solids and the
isocyanate component comprises from 46 to 53 wt % solids.
[0050] Primer and topcoat compositions optionally include additives
including, but not limited to, pigments, tints, dyes, fillers,
reaction enhancers or catalysts, crosslinking agents, optical
brighteners, propylene carbonates, such as those disclosed in U.S.
Pat. No. 5,840,788, which is incorporated in its entirety by
reference herein, coloring agents, fluorescent agents, whitening
agents, UV absorbers, hindered amine light stabilizers, defoaming
agents, processing aids, mica, talc, nano-fillers, wetting agents,
solvents, and other conventional additives. Non-limiting examples
of suitable coatings are further disclosed, for example, in U.S.
Pat. Nos. 5,409,233; 5,459,220; 5,494,291; 5,820,491; 5,669,831;
5,817,735; and 7,935,421, the entire disclosure of which are hereby
incorporated herein by reference.
[0051] In a particular embodiment, golf balls of the present
invention comprise at least one coat of primer and at least one
coat of topcoat. In a particular aspect of this embodiment, the
primer is a solvent-borne composition and the topcoat is a
solvent-borne composition.
[0052] Dimensions of golf ball components, i.e., thickness and
diameter, may vary depending on the desired properties.
[0053] Golf ball cores of the present invention include single,
dual, and multilayer cores, and preferably have an overall diameter
within the range having a lower limit of 0.75 inches or 1 inch or
1.25 inches or 1.4 inches and an upper limit of 1.55 inches or 1.6
inches or 1.62 inches or 1.63 inches.
[0054] In a particular embodiment, the core is a solid, single
layer having a diameter within a range having a lower limit of
0.750 or 1.00 or 1.10 or 1.15 or 1.20 or 1.25 or 1.30 or 1.40 or
1.50 or 1.53 or 1.55 inches and an upper limit of 1.55 or 1.60 or
1.62 or 1.63 or 1.65 inches. In a particular aspect of this
embodiment, the core has a compression of 90 or less, or 80 or
less, or 75 or less, or 70 or less, or a compression within a range
having a lower limit of 50 or 55 or 60 or 65 and an upper limit of
65 or 70 or 75 or 80 or 90.
[0055] In another particular embodiment, the core comprises an
inner core layer and an outer core layer, the inner core layer
having a diameter within a range having a lower limit of 0.900 or
0.910 or 0.920 or 0.930 or 0.940 or 0.950 or 0.960 or 0.970 or
0.980 or 0.990 or 1.000 or 1.010 or 1.020 inches and an upper limit
of 1.020 or 1.030 or 1.040 or 1.050 or 1.060 or 1.070 or 1.080 or
1.090 or 1.100 or 0.110 or 1.120 or 1.130 inches, and the outer
core having a thickness within the range having a lower limit of
0.050 or 0.100 or 0.200 or 0.250 inches and an upper limit of 0.280
or 0.310 or 0.440 or 0.500 inches. In a particular aspect of this
embodiment, the core has an overall dual core compression within a
range having a lower limit of 60 or 70 or 80 or 85 and an upper
limit of 85 or 90 or 95.
[0056] Golf ball covers of the present invention include single,
dual, and multilayer covers, and preferably have an overall
thickness within the range having a lower limit of 0.03 inches or
0.04 inches or 0.045 inches or 0.05 inches or 0.06 inches and an
upper limit of 0.07 inches or 0.08 inches or 0.09 inches or 0.10
inches. Dual and multilayer covers have an inner cover layer and an
outer cover layer, and multilayer covers additionally have at least
one intermediate cover layer disposed between the inner cover layer
and the outer cover layer. In a particular embodiment, the cover is
a single layer having a thickness within a range having a lower
limit of 0.020 or 0.025 or 0.030 inches and an upper limit of 0.030
or 0.040 or 0.045 or 0.050 or 0.070 or 0.100 or 0.120 or 0.150 or
0.350 or 0.400 or inches. In another particular embodiment, the
cover comprises an inner cover layer and an outer cover layer, the
inner cover having a thickness within a range having a lower limit
of 0.020 or 0.025 or 0.030 or 0.035 inches and an upper limit of
0.035 or 0.040 or 0.045 or 0.050 or 0.100 inches, and the outer
cover having a thickness within a range having a lower limit of
0.020 or 0.025 or 0.030 inches and an upper limit of 0.035 or 0.040
or 0.045 inches.
[0057] The present invention is not limited by any particular
dimple pattern, dimple plan shape, dimple cross-sectional profile,
or dimple size. Examples of suitable dimple patterns include, but
are not limited to, phyllotaxis-based patterns; polyhedron-based
patterns; and patterns based on multiple copies of one or more
irregular domain(s) as disclosed in U.S. Pat. No. 8,029,388, the
entire disclosure of which is hereby incorporated herein by
reference; and particularly dimple patterns suitable for packing
dimples on seamless golf balls. Non-limiting examples of suitable
dimple patterns are further disclosed in U.S. Pat. Nos. 7,927,234,
7,887,439, 7,503,856, 7,258,632, 7,179,178, 6,969,327, 6,702,696,
6,699,143, 6,533,684, 6,338,684, 5,842,937, 5,562,552, 5,575,477,
5,957,787, 5,249,804, 5,060,953, 4,960,283, and 4,925,193, and U.S.
Patent Application Publication Nos. 2006/0025245, 2011/0021292,
2011/0165968, and 2011/0183778, the entire disclosures of which are
hereby incorporated herein by reference. Non-limiting examples of
seamless golf balls and methods of producing such are further
disclosed, for example, in U.S. Pat. Nos. 6,849,007 and 7,422,529,
the entire disclosures of which are hereby incorporated herein by
reference. In a particular embodiment, the dimple pattern is based
on a spherically tiled tetrahedron. The dimples may have a variety
of shapes and sizes including different depths and perimeters. In
particular, the dimples may be concave hemispheres, or they may be
triangular, square, hexagonal, catenary, polygonal or any other
shape known to those skilled in the art. They may also have a
cross-sectional profile based on any known dimple profile shape
including, but not limited to, parabolic curves, ellipses,
spherical curves, saucer-shapes, sine curves, truncated cones,
flattened trapezoids, and catenary curves.
[0058] Golf balls of the present invention typically have a dimple
count within a limit having a lower limit of 250 and an upper limit
of 350 or 400 or 450 or 500. In a particular embodiment, the dimple
count is 252 or 272 or 302 or 312 or 320 or 328 or 332 or 336 or
340 or 352 or 360 or 362 or 364 or 372 or 376 or 384 or 390 or 392
or 432.
[0059] For purposes of the present disclosure, the hardness of a
thermoplastic composition or a thermoplastic golf ball layer is
measured according to the following procedure. Hardness buttons of
the composition (or layer) are compression molded under sufficient
temperature and pressure for a sufficient amount of time to produce
void- and defect-free parts. The buttons are surface ground soon
after the part reaches room temperature after demolding, to produce
smooth, flat and parallel surfaces. The finished buttons are
approximately 1.25 inches in diameter and at least 6 mm in
thickness. The buttons are then aged for 10 days at 23.degree. C.
in a dessicator before testing. Hardness measurements are then made
pursuant to ASTM D-2240 and/or JIS C (K6301 Type) using a
calibrated, digital durometer, capable of reading to 0.1 hardness
units and set to record the maximum hardness reading for each
measurement. The digital durometer must be attached to, and its
foot made parallel to, the base of an automatic stand having a
travel speed of approximately 25 mm/sec.
[0060] For purposes of the present disclosure, the hardness of a
thermoset composition refers to the surface hardness of a molded
1.55 inch diameter sphere of the composition. Similarly, the
hardness of a thermoset golf ball layer refers to the surface
hardness of a sphere, as measured on the golf ball layer. The
surface hardness of a sphere is obtained from the average of a
number of measurements taken from opposing hemispheres, taking care
to avoid making measurements on the parting line of the sphere or
on surface defects, such as holes or protrusions. Hardness
measurements are made pursuant to ASTM D-2240 and JIS C (K6301
Type) using a calibrated, digital durometer, capable of reading to
0.1 hardness units and set to record the maximum hardness reading
for each measurement. Because of the curved surface, care must be
taken to insure that the sphere is centered under the durometer
indentor before a surface hardness reading is obtained. The digital
durometer must be attached to, and its foot made parallel to, the
base of an automatic stand having a travel speed of approximately
25 mm/sec.
[0061] For purposes of the present disclosure, the compression of a
sphere is determined according to a known procedure, using a
digital Atti compression test device, wherein a piston is used to
compress a sphere against a spring. Conversion from Atti
compression to Riehle (cores), Riehle (balls), 100 kg deflection,
130-10 kg deflection or effective modulus can be carried out
according to the formulas given in Jeff Dalton's Compression by Any
Other Name, Science and Golf IV, Proceedings of the World
Scientific Congress of Golf (Eric Thain ed., Routledge, 2002).
[0062] When numerical lower limits and numerical upper limits are
set forth herein, it is contemplated that any combination of these
values may be used.
[0063] All patents, publications, test procedures, and other
references cited herein, including priority documents, are fully
incorporated by reference to the extent such disclosure is not
inconsistent with this invention and for all jurisdictions in which
such incorporation is permitted.
[0064] While the illustrative embodiments of the invention have
been described with particularity, it will be understood that
various other modifications will be apparent to and can be readily
made by those of ordinary skill in the art without departing from
the spirit and scope of the invention. Accordingly, it is not
intended that the scope of the claims appended hereto be limited to
the examples and descriptions set forth herein, but rather that the
claims be construed as encompassing all of the features of
patentable novelty which reside in the present invention, including
all features which would be treated as equivalents thereof by those
of ordinary skill in the art to which the invention pertains.
* * * * *