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Multi-layer golf ball providing improved speedRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Natural Rubber Compositions Having Nonreactive Materials (dnrm) Other Than: Carbon, Silicon Dioxide, Glass Titanium Dioxide, Water, Hydrocarbon, Halohydrocarbon, Ethylenically Unsaturated Reactant Admixed With A Preformed Reaction Product Derived From: (a) At Least One Polycarboxylic Acid, Ester, Or Anhydride; (b) At Least One Polyhydroxy Compound; And (c) At Least One Fatty Acid Glycerol Ester, Or A Fatty Acid Or Salt Derived From A Naturally Occurring Glyceride, Tall Oil, Or A Tall Oil Fatty AcidMulti-layer golf ball providing improved speed description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20050261424, Multi-layer golf ball providing improved speed. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001] The invention relates to a process and to an apparatus for preparing polymer dispersions. [0002] As a general rule, emulsion polymerizations are performed by dispersing one or more polymerizable monomers in a liquid which as far as possible is inert in the reaction--usually water, in which soaps or detergents are present as dispersing assistants. Polymerization takes place mostly in the monomer-containing micelles formed, by means of initiator radicals. High molecular masses can be obtained since monomer is able to penetrate continuously into the micelles. The mechanism is normally that of a free-radical polymerization, the reaction products can frequently be processed further directly as dispersions (for example, in the production of paints and adhesives). Known reactants are alkyl (meth)acrylates, vinyl esters of carboxylic acids, vinyl aromatic compounds, nitriles, vinyl halides, vinyl ethers, hydrocarbons having from 2 to 8 carbon atoms and one or two olefinic double bonds (butadiene, isoprene, chloroprene) or hydroxyl-containing monomers. The particle size and particle size distribution may frequently be controlled by using seed (particles) supplied beforehand or generated in situ. Typical process conditions on the industrial scale are reaction times of between 2 and 12 hours at temperatures in the range between 40.degree. C. and 100.degree. C. [0003] DE 23 32 637 A describes an emulsion polymerization wherein butadiene is reacted with comonomers such as styrene, acrylonitrile (AN) or esters of acrylic or methacrylic acid in the presence of customary emulsifying assistants such as higher fatty acids, higher alkyl (acryloyl)sulfonates, adducts of alkylene oxides with long-chain fatty alcohols, and free-radical initiators such as alkali metal persulfates at temperatures of more than 115.degree. C. An advantage over the prior art with temperatures of less than 80.degree. C. is said to be the higher polymerization rate. However, the performance properties of products of this kind prepared at very high temperatures are often adversely affected in respect, for example, of the molecular mass distribution, the particle size distribution, and, associated therewith, for example, the adhesive bonding strength. [0004] Nevertheless, conducting the reaction at relatively high temperatures, i.e., more than 80.degree. C., in particular more than 85.degree. C.--is a measure which is important for industrial plants, since the reaction times can be reduced significantly. Accordingly, an industrial process can be conducted with lower cycle times, thereby saving on capital investment costs for a greater number of plants. An important problem area to be solved in this context is that of heat dissipation, in order for example to prevent instances of local overheating in exothermic reactions, which may often lead to unwanted side reactions, nonuniform molecular mass distributions or particle sizes. [0005] EP-A 0 486 262 discloses the preparation of emulsion copolymers in which energy balance monitoring is used to control the supply of the comonomers and the temperature. For temperature control use is made, inter alia, of an external heat exchanger. No details can be inferred regarding the quality of the products or the construction of the pumps or heat exchangers. [0006] EP 0 608 567 A discloses the use of a Hydrostar pump in the suspension polymerization of VC to homopolymer or copolymers in a tank having a stirrer and an external heat exchanger. The reaction mixture is passed through said pump at an angle of 90.degree., the interior having a conically shaped hub with a blade which moves in spiral rotation. Stirring energy and circulation energy must be adjusted in a specific relationship to one another. A comparable pump is also used in the solution known from EP 0 526 741 B1. [0007] In a process for preparing emulsion polymers according to DE 44 42 577 A, the energy released in the exothermic reaction is partly dissipated by distillative removal of a water/monomer mixer from a reaction vessel under reduced pressure. Although this procedure does lead to a reduction in the polymerization time, it is still unsuitable for industrial plants, particularly since the breadth of use hardly ensures, for example, its application for low-boiling (co)monomers or those which are gaseous under standard conditions, such as those of the butadiene type, for example. [0008] EP-A-835 518 describes a process for preparing homopolymers and copolymers by the method of free-radically initiated aqueous emulsion polymerization, again using an external heat exchanger for cooling. [0009] WO 99/14496 discloses a tubular diaphragm pump which can be used to convey chemical media. [0010] In the conveying of commercially customary polymer dispersions, the impellers of the pumps used to date have tended to block during the polymerization. The cause of this was the formation of polymer in areas of the impellers characterized by poor flow, where, on stiffening and reinforcing ribs, for example, deposits formed which subsequently led to the failure of the pumps within a very short time. With the configurations used to date, it was insignificant whether the impellers were enclosed by a spiral housing or whether they protruded freely from the pump chamber. [0011] Types of pumps used to date to convey media with a tendency toward coagulation have been rotary piston pumps, unchokeable pumps, disk pumps, eccentric screw pumps, and reciprocating diaphragm pumps, and also screw spindle pumps. Impellers equipped with rounded blades for streamlined conveying have also been used, such as are disclosed, for example, in DE 199 40 399 A1. [0012] The polymer dispersions to be prepared may be very sensitive to shearing and may alter their viscosity within wide ranges during the preparation process. The polymer dispersions may tend to form coagulum, thereby imposing specific requirements on the pump that circulates the reaction mixture. The pump should convey with as little shearing as possible, so that coagulum is not formed. Furthermore, the pump must be resistant to a certain degree of fouling. [0013] It is an object of the present invention to specify an industrially practicable preparation process with a broad field of use which in particular permits short reaction times, accepts a broad spectrum of different monomers, including monomers gaseous under standard conditions, and is at least comparable in performance properties with currently prepared products, and which is not critical in terms of the effort of cleaning the plant components as a result of fouling and soiling with dispersions that tend to form coagulum. [0014] We have found that this object is achieved in accordance with the invention by a process for preparing polymers of at least one of the polymerizable monomers from the groups consisting of alkyl (meth)acrylates, vinyl esters of carboxylic acids, vinylaromatic compounds, nitrites, vinyl halides, vinyl ethers, hydrocarbons having 2-8 carbon atoms and one or two olefinic double bonds, and hydroxyl-containing monomers using a free-radical polymerization initiator. The process of the invention comprises preparing the polymer, which forms to at least 85% by weight from one or more of these monomers, in the stages below, in which [0015] a) in a first stage, water, as reaction-inert solvent, dispersing assistants where appropriate, seed where appropriate, and a first portion of monomer(s), where appropriate, are introduced, [0016] b) in a second stage, initiator, and [0017] c) in a third stage, the remainder or full amount of monomer(s) are added directly or in emulsion form in the presence of further water and, where appropriate, further dispersing assistant or other auxiliaries, [0018] it being possible for stages a) and b) or b) and c) in each case to be run through in one stage or b) and c) to be run through in a gradient procedure, and in all or some stages the reaction mixture present is moved for cooling by an external circuit which leads from and back to the reaction vessel and which comprises one or more low-shear-conveying cylinder or tubular diaphragm pumps and at least one heat exchanger, the polymerization temperature being between 40.degree. C. and 120.degree. C. [0019] The use of an extremely low-shear-conveying cylinder or tubular diaphragm pump permits gentle conveying of dispersions with a coagulation tendency during the preparation process without premature failure of the conveying unit by accumulation of deposits on moving components and without notable quality losses in the medium to be conveyed. Complete lining of all those parts of the low-shear-conveying cylinder or tubular diaphragm pump that are in media contact reduces or prevents fouling and formation of coagulum in the interior of the conveying device considerably and, as a result of the relatively long service times, reduces the cleaning effort, thereby having a beneficial effect on plant availability. As well as in a cooling circuit assigned to the polymerization vessel, the low-shear-conveying cylinder or tubular diaphragm pump may also be used to convey dispersions with a tendency toward coagulation further in a preparation plant, with no coagulation of the conveyed medium during conveying, owing to the low-shear conveying principle of the cylinder or tubular diaphragm pump. Within the cooling circuit, the cylinder or tubular diaphragm pump may be positioned at different sites: for example, upstream or downstream of the heat exchanger. Owing to its complete lining with a friction-reducing coating, cleaning of the cylinder or tubular diaphragm pump is very easy to carry out. The pulsations which are established may provide for a significant reduction or prevention of wall deposits in the circuit. [0020] Using the extremely low-shear-conveying cylinder or tubular diaphragm pump, it is possible to operate a process for preparing homopolymers or copolymers on the industrial scale wherein the polymer is formed to at least 90% by weight, in particular to at least 93% by weight, from one or more of the monomers mentioned and the polymerization temperature is between 50.degree. C. and 100.degree. C., with particular preference between 60.degree. C. and 95.degree. C. and with very particular preference between 70.degree. C. and 95.degree. C. The process of the invention may be carried out alternatively such that in stage a) or in a combination of a) and b) a portion of monomer(s) is introduced already and later in stage c), which can also be run through in a gradient procedure, or in a combination of b) and c), it being possible for b) and c) to be run through both in a single stage and in a gradient procedure, the remainder is added, or the whole amount is added exclusively in stage c), either in one stage or in a gradient procedure or in a combination of stages b) and c) (in one stage or in a gradient procedure). If introduction of monomer(s) takes place in stage a) or in combination of stages a) and b) already, the amount introduced is appropriately between 3 and 30% by weight of the whole amount of monomer(s) to be supplied, preferably from 5 to 25% by weight and from 8 to 20% by weight. Water-insoluble or sparingly water-soluble monomers are appropriately supplied already in emulsion form, i.e., admixed with water and dispersing assistant. [0021] Examples of principal monomers are alkyl (meth)acrylates such as methyl methacrylate, methyl acrylate, n-butyl acrylate, ethyl acrylate and 2-ethylhexyl acrylate. Furthermore, mixtures of the alkyl (meth)acrylates are also suitable. Also suitable are vinyl esters of carboxylic acids having 1-20 carbon atoms such as, for example, vinyl laurate, vinyl stearate, vinyl propionate, Versatic acid vinyl ester, and vinyl acetate. Suitable vinylaromatic compounds include vinyltoluene, .alpha.- and p-methylstyrene, .alpha.-butylstyrene, 4-n-butylstyrene, 4-n-decylstyrene and, preferably, styrene. Examples of nitriles are acrylonitrile and methacrylonitrile. Besides these it is also possible to use the vinyl halides chlorine-, fluorine- or bromine-substituted, ethylenically unsaturated compounds, preferably vinyl chloride and vinylidene chloride. Examples of vinyl ethers include vinyl methyl ether or vinyl isobutyl ether. Preference is given to vinyl ethers of alcohols containing from 1 to 4 carbon atoms. Mention should also be made of hydrocarbons having from 2 to 8 carbon atoms and one or two olefinic double bonds. [0022] Principal monomers are the alkyl (meth)acrylates, especially the C.sub.1-C.sub.8 alkyl (meth)acrylates, vinyl aromatic compounds having up to 20 carbon atoms, especially styrene, and mixtures of the above monomers. Further monomers are, for example, hydroxyl-containing monomers, particularly C.sub.1-C.sub.10 hydroxyalkyl (meth)acrylates, (meth)acrylamide, ethylenically unsaturated acids, especially carboxylic acids such as (meth)acrylic acid or itaconic acid and the anhydrides thereof, dicarboxylic acids and their anhydrides or monoesters; for example, maleic acid, fumaric acid or maleic anhydride. As hydrocarbons having from 2 to 8 carbon atoms and two olefinic double bonds, mention may be made of butadiene, isoprene, and chloroprene. [0023] In emulsion polymerization, it is normal to use ionic and/or nonionic emulsifiers and/or protective colloids and/or stabilizers as surface-active compounds. [0024] Suitable emulsifiers include anionic, cationic, and nonionic emulsifiers. As accompanying surface-active substances it is preferred to use exclusively emulsifiers, whose molecular weights, unlike those of the protective colloids, are usually less than 2000 g per mole. Where mixtures of surface-active substances are used, the individual components must of course be compatible with one another, which in case of doubt can be checked by means of a few preliminary tests. Surface-active substances used preferably comprise anionic and nonionic emulsifiers. Common accompanying emulsifiers are, for example, ethoxylated fatty alcohols (EO units: 3-50, alkyl radical: C.sub.8-C.sub.38), ethoxylated mono-, di- and tri-alkylphenols (EO units: 3-50, alkyl radical: C.sub.4-C.sub.9), alkali metal salts of dialkyl esters of sulfosuccinic acid and also alkali metal and ammonium salts of alkyl sulfates (alkyl radical: C.sub.8-C.sub.12), of ethoxylated alkanols (EO units 4-30, alkyl radical: C.sub.12-C.sub.18), of ethoxylated alkyl phenols (EO units: 3-50, alkyl radical: C.sub.4-C.sub.9), of alkylsulfonic acids (alkyl radical: C.sub.12-C.sub.18), of alkylaryl sulfonic acids (alkyl radical: C.sub.9-C.sub.18), and of sulfonates with ethoxylated fatty alcohols. Further suitable emulsifiers can also be found in Houben-Weyl, Methoden der organischen Chemie, Volume 14/1, Makromolekulare Stoffe, Georg Thieme Verlag, Stuttgart 1961, pages 192 to 208. Continue reading about Multi-layer golf ball providing improved speed... Full patent description for Multi-layer golf ball providing improved speed Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Multi-layer golf ball providing improved speed patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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