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07/26/07 - USPTO Class 473 |  18 views | #20070173348 | Prev - Next | About this Page  473 rss/xml feed  monitor keywords

Compositions for golf equipment

USPTO Application #: 20070173348
Title: Compositions for golf equipment
Abstract: The present invention is directed to golf balls having at least one layer formed from a polyurea composition. The polyurea is formed by combining an aliphatic polyarea prepolymer, a diamine curative, and a cyclic carbonate diluent. Golf balls of the present invention include one-piece, two-piece, multi-layer, and wound golf balls. The composition may be present in any one or more of a core layer, a cover layer, or an intermediate layer. (end of abstract)



Agent: Acushnet Company - Fairhaven, MA, US
Inventors: Murali Rajagopalan, Manjari Kuntimaddi, Shenshen Wu, Shawn Ricci, Kevin Harris
USPTO Applicaton #: 20070173348 - Class: 473351000 (USPTO)

Related Patent Categories: Games Using Tangible Projectile, Golf, Ball

Compositions for golf equipment description/claims


The Patent Description & Claims data below is from USPTO Patent Application 20070173348, Compositions for golf equipment.

Brief Patent Description - Full Patent Description - Patent Application Claims
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CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/162,544, filed Sep. 14, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 10/859,557, filed Jun. 2, 2004, now U.S. Pat. No. 7,105,628, the entire disclosures of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention is directed to polyurea compositions formed by combining an aliphatic polyurea prepolymer, a diamine curative, a cyclic amidine delayed action catalyst, and a cyclic carbonate diluent. The present invention is also directed to the use of such compositions in golf equipment.

BACKGROUND OF THE INVENTION

[0003] Polyureas are known to be potentially useful materials for golf ball covers. However, polyurea compositions can be difficult to process during golf ball manufacturing. For example, when a polyurea prepolymer is reacted with a diamine curative in a typical castable molding process, the viscosity of the composition is significantly enhanced. The enhanced viscosity can cause drooling at the nozzle, which leads to the production of substandard balls, and necessitates changing of the nozzle more frequently.

[0004] Thus, a desire remains for polyurea compositions with improved processability suitable for forming golf ball layers. The present invention describes such compositions and the use thereof in a variety of golf ball layers.

SUMMARY OF THE INVENTION

[0005] In one embodiment, the present invention provides a golf ball having at least one layer formed from a polyurea composition. The composition comprises the product formed by combining an aliphatic polyurea prepolymer, a diamine curative, and a cyclic carbonate diluent. The cyclic carbonate diluent has a formula selected from the group consisting of:

[0006] where x is 1 to 9; n is 1 to 40; and each R group is independently selected from hydrogen, linear and branched C.sub.1-C.sub.20 hydrocarbon groups, linear and branched C.sub.1-C.sub.20 hydroxylalkyl groups, linear and branched alkoxyalkylenes and polyalkoxyalkylenes, linear and branched C.sub.1-C.sub.20 haloalkyl groups, linear and branched --C.sub.mH.sub.2m+1 where m is 1 to 8, linear and branched --C.sub.mH.sub.2mOH where m is 1 to 8, linear and branched --(CH.sub.2).sub.mH where m is 1 to 2, linear and branched --(CH.sub.2).sub.mOH where m is 1 to 2, and linear and branched alkoxy groups and aryloxy groups.

[0007] In another embodiment, the present invention provides a golf ball comprising a solid rubber core, a cover layer formed from a polyurea composition, and an ionomer-based intermediate layer disposed between the core and the cover layer. The polyurea composition of the cover layer comprises the product formed by combining an aliphatic polyurea prepolymer, a diamine curative, and a propylene carbonate.

DETAILED DESCRIPTION OF THE INVENTION

[0008] The present disclosure relates to golf equipment such as golf balls, golf clubs (drivers, putters, woods, irons, and wedges, including heads and shafts thereof), golf shoes, golf gloves, golf bags, or the like that comprise novel polyurethane, polyurea, and/or poly(urethane-co-urea) compositions. The components of the compositions can be saturated, i.e., substantially free of double or triple carbon-carbon bonds or aromatic groups, to produce light stable compositions. Components that are unsaturated or partially saturated can also be used.

[0009] The golf ball can comprise at least one castable thermoplastic or thermoset material formed from a composition comprising at least one hydroxy-terminated polyamide. The hydroxy-terminated polyamide can be a reaction product of at least one polyamine polyamide or polyamine and at least one cyclic ester or hydroxy acid, or a reaction product of polyacid polyamide and at least one aminoalcohol or polyol amine. The hydroxy-terminated polyamide can be polyol polycaprolactam. The composition can further comprise at least one reactant chosen from isocyanates and curatives, or at least one isocyanate-containing prepolymer where the hydroxy-terminated polyamide is used to cure the prepolymer. The hydroxy-terminated polyamide can have a weight average molecular weight of 200-5,000. The material can at least in part form at least one portion of the golf ball chosen from inner center, core, inner core layer, intermediate core layer, outer core layer, intermediate layer, cover, inner cover layer, intermediate cover layer, outer cover layer, discontinuous layer, wound layer, foamed layer, lattice network layer, web or net, adhesion or coupling layer, barrier layer, layer of uniformed or non-uniformed thickness, layer having a plurality of discrete elements, and layer filled with liquid, gel, powder, and/or gas. For example, the golf ball can comprise a core comprising at least a first portion, and a cover comprising at least a second portion, wherein the material is disposed in at least one of the first and second portions, and/or between the core and the cover. The material can at least in part form at least one cover layer having a thickness of 0.125 inch or less and a Shore D hardness of 20-80.

[0010] Golf equipment can be formed from a variety of compositions. Balata, a natural or synthetic trans-polyisoprene rubber, has been used to form golf ball covers. Olefinic ionomer resins have also been used as cover materials. Chemically, olefinic ionomer resins are copolymers of olefin (such as ethylene) and .alpha.,.beta.-ethylenically unsaturated carboxylic acid (such as acrylic acid or methacrylic acid) that have 10% to 100% of the carboxylic acid groups neutralized by cations (such as metal cations). Examples of commercially available olefinic ionomer resins include, but are not limited to, SURLYN.RTM. from Du Pont de Nemours and Company, and ESCOR.RTM. and IOTEK.RTM. from ExxonMobil.

[0011] Polyurethanes are useful materials for golf ball covers. Polyurethane covers can be polyurethane prepolymers cured with curing agents having at least one active hydrogen groups (such as amines and/or polyols), wherein the prepolymers are formed of hydroxy-terminated telechelics with polyisocyanates. Polyureas formed of polyurea prepolymers and curatives are relatively new choices for golf ball materials. Polyurethanes and polyureas can be thermoset or thermoplastic, depending at least in part on the curing agent used. Unsaturated components (such as aromatic diisocyanate, aromatic polyol, and/or aromatic polyamine) used in a polyurethane or polyurea composition are at least in part responsible for the composition's susceptibility to discoloration and degradation upon exposure to thermal and actinic radiation, such as ultraviolet (UV) light. Substituting the unsaturated components with partially unsaturated or saturated components can enhance light stability of the composition. Highly light-stable compositions may include only substantially saturated components. As used herein, the term "saturated" or "substantially saturated" means that the compound or material of interest is fully saturated (i.e., contains no double bonds, triple bonds, or aromatic ring structures), or that the extent of unsaturation is negligible, e.g., as shown by a bromine number in accordance with ASTM E234-98 of less than 10, such as less than 5. The compositions of the disclosure may also include at least one light stabilizer to improve light stability, especially when unsaturated (e.g., aromatic) components are used.

[0012] Moisture absorption is another mechanism through which desirable physical properties in the composition are compromised. This can be remedied, for example, by incorporating at least one moisture vapor barrier layer in the golf ball. Alternatively, the use of waterlmoisture-resistant compositions in golf ball components leads to a golf ball with improved shelf-life and/or use-life. Conventional polyurethane and polyurea golf ball covers can be prone to absorption of moisture. Incorporation of hydrophobic backbones into the compositions can reduce moisture absorption and water/moisture permeability, as reflected in reduced water vapor transmission rate (WVTR).

[0013] As used herein, the terms "araliphatic," "aryl aliphatic," or "aromatic aliphatic" all refer to compounds that contain one or more aromatic moieties and one or more aliphatic moieties, where the reactable functional groups such as, without limitation, isocyanate groups, amine groups, and hydroxyl groups are directly linked to the aliphatic moieties and not directly bonded to the aromatic moieties. Illustrative examples of araliphatic compounds are o-, m-, and p-tetramethylxylene diisocyanate (TMXDI).

[0014] The subscript letters such as m, n, x, y, and z used herein within the generic structures are understood by one of ordinary skill in the art as the degree of polymerization (i.e., the number of consecutively repeating units). In the case of molecularly uniformed products, these numbers are commonly integers, if not zero. In the case of molecularly non-uniformed products, these numbers are averaged numbers not limited to integers, if not zero, and are understood to be the average degree of polymerization.

[0015] Any numeric references to amounts, unless otherwise specified, are "by weight." The term "equivalent weight" is a calculated value based on the relative amounts of the various ingredients used in making the specified material and is based on the solids of the specified material. The relative amounts are those that result in the theoretical weight in grams of the material, like a polymer, produced from the ingredients and give a theoretical number of the particular functional group that is present in the resulting polymer.

[0016] As used herein, the term "polymer" is used to refer to oligomers, adducts, homopolymers, random copolymers, pseudo-copolymers, statistical copolymers, alternating copolymers, periodic copolymer, bipolymers, terpolymers, quaterpolymers, other forms of copolymers, substituted derivatives thereof, and mixtures thereof. These polymers can be linear, branched, block, graft, monodisperse, polydisperse, regular, irregular, tactic, isotactic, syndiotactic, stereoregular, atactic, stereoblock, single-strand, double-strand, star, comb, dendritic, and/or ionomeric.

[0017] As used herein, the term "telechelic" is used to refer to polymers having at least two terminal reactive end-groups and capable of entering into further polymerization through these reactive end-groups. Reactive end-groups disclosed herein include, without limitation, amine groups, hydroxyl groups, isocyanate groups, carboxylic acid groups, thiol groups, and combinations thereof.

[0018] Other than in the operating examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, times and temperatures of reaction, ratios of amounts, values for molecular weight (whether number average molecular weight ("M.sub.n") or weight average molecular weight ("M.sub.w"), and others in the following portion of the specification may be read as if prefaced by the word "about" even though the term "about" may not expressly appear with the value, amount or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0019] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

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