Games using tangible projectile – Golf – Ball
Reexamination Certificate
1999-10-01
2001-09-18
Graham, Mark S. (Department: 3711)
Games using tangible projectile
Golf
Ball
C473S371000
Reexamination Certificate
active
06290614
ABSTRACT:
FIELD OF THE INVENTION
The present invention generally relates to golf balls, and more particularly to golf balls which contain a fast-chemical-reaction-produced component, such as that utilized in a core, and intermediate and/or cover layers. Each of the core and/or layers may include one or more different layers.
BACKGROUND OF THE INVENTION
Golf balls utilize, in general, three types of configurations. The first type is a multi-piece wound ball in which a vulcanized rubber thread is wound under tension around a solid or semi-solid core, and thereafter enclosed in a single or multi-layer covering of a tough, protective material.
A second type of a golf ball is a one-piece ball formed from a solid mass of resilient material which has been cured to develop the necessary degree of hardness to provide utility. One-piece molded balls do not have a second enclosing cover.
A third type of ball is a multi-piece, non-wound ball that includes a liquid, gel or solid core of one or more layers and a cover having one or more layers formed over the core.
Conventional golf ball covers have been made of ionomer, balata, and slow-reacting, thermoset polyurethane. When polyurethane covers are made by conventional methods, such as by casting, a substantial amount of time and energy are required, thus resulting in relatively high cost.
It would be useful to develop a golf ball containing a fast-chemical-reaction-produced component, such as at least one core or cover layer, particularly one which contains polyurethane, polyurea, epoxy and/or unsaturated polyester.
SUMMARY OF THE INVENTION
The present invention relates to new and improved golf balls which overcome the above-referenced problems of others. In this regard, the present invention is directed to a golf ball having a polyurethane cover which is formed by a fast chemical reaction.
Another object of the invention is to provide a non-ionomeric golf ball cover which is efficiently produced by injection molding.
Yet another object of the invention is to provide a golf ball which contains polyurethane.
A further object of the invention is to provide a golf ball in which material from recycling polyurethane can be used to result in an efficient manufacturing process.
A further object of the invention is to produce a durable golf ball containing polyurethane, polyurea, epoxy, and/or unsaturated polyesters.
Another object of the invention is to provide a golf ball with a “seamless” cover layer, i.e., a cover layer having generally the same microscopic and molecular structure distribution both in the regions adjacent to the parting line of the mold and at locations which are not adjacent to the parting line, including near the poles.
Yet another object of the invention is to provide a method of making a golf ball of the type described above.
Still another object of the invention is to provide a method of making a multi-piece golf ball, making at least one of a cover component and a core component of the ball by mixing two or more materials that react to form a reaction product with a flex modulus of 1 to 310 kpsi, a setting time of about 30 seconds or less, the component having a thickness of at least 0.01 inches, and a demold or mold release time of 2 minutes or less, including the reaction time. The composition preferably comprises at least one member selected from the group consisting of polyurethanes, polyureas, epoxies and unsaturated polyesters. The reaction product preferably is formed by reaction injection molding. The component preferably has a thickness of at least 0.02 inches.
Another object of the invention is to provide a multi-piece golf ball comprising a reaction injection molded material comprising polyurethane/polyurea. The golf ball cover preferably has a Shore D hardness in the range of 10 to 95, more preferably 30 to 75, and a flex modulus in the range of 1 to 310 kpsi, and more preferably 5 to 100 kpsi and even more preferably 10 to 80 kpsi. Preferably, at least 5% of the polyurethane/polyurea is formed from molecules obtained by recycling a material comprising at least one of polyurethane, polyurea, polyester and polyethylene glycol.
Yet another object of the invention is to provide a process for producing a golf ball including the step of reaction injection molding a polyurethane/polyurea material to form at least one of a core layer and a cover layer of the ball.
A further object of the invention is to provide a process for producing a golf ball comprising the steps of (a) reaction injection molding a polyurethane/polyurea component of the ball, and (b) recycling some of the polyurethane and/or polyurea that is produced in connection with step (a) but that is not incorporated in the golf ball in step (a). The polyurethane/polyurea preferably, but not necessarily, is recycled by glycolysis.
Yet another object of the invention is to provide a process for producing a golf ball comprising (a) forming a core, (b) covering the core, and (c) coating and adding indicia to the covered ball, wherein at least one of steps (a) and (b) comprises reaction injection molding of a polyurethane and/or polyurea material. The golf ball of the invention can include, in the cover, optical brighteners, white pigment, UV stabilizers, antioxidants, etc. The cover and/or core may further include fillers such as TiO
2
, glass, metal, and other fillers described below.
Yet another object of the invention is to provide a golf ball having a cover comprising a blend of polyurethane and ionomer, wherein the ionomer is a partially cation neutralized organic acid polymer, preferably an alpha, beta unsaturated carboxylic acid with 3 or more carbon atoms. The ionomer may be a polyurethane ionomer.
A further object of the invention is to provide a golf ball comprising at least one fast-chemical-reaction-produced layer, the layer having a flex modulus of 1 to 310 kpsi, with a setting time of about 30 seconds or less and a thickness of at least 0.01 inch.
Yet another object of the invention is to provide a golf ball having a core and a cover, the cover comprising polyurethane/polyurea which is formed from reactants, and 5 to 100 weight percent of which are obtained from recycled polyurethane.
Other objects of the invention will become apparent from the specification, drawings and claims.
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Keller Viktor
Kennedy, III Thomas J.
Risen William
Tzivanis Michael John
Gorden Raeann
Graham Mark S.
Spalding Sports Worldwide Inc.
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