Compositions incorporating ethylene acid (E/X) ionomers and non-ionomeric softening polymers for golf ball constructions and methods relating thereto
View Patent ↗A golf ball comprising a core and a cover disposed about the core; wherein at least one of the core and the cover comprises a tri-blend composition of the non-E/X/Y type (TBC) formed from a blend of an ethylene acid (E/X) ionomer, a non-ionomeric softening copolymer (NISC) and a low viscosity component (LVC). A portion of the TBC comprising the ethylene acid (E/X) ionomer and the NISC has a Melt Flow Index MF 1 and a CoR 1 and the TBC has a Melt Flow Index MF 2 and a CoR 2 such that MF 2 >MF 1 and CoR 1 and CoR 2 differ by less than about 0.1. In one embodiment, the TBC has a composition property relationship ΔCoR/ΔMFI≦˜10, wherein ΔCoR is the amount by which CoR 1 and CoR 2 differ, and ΔMFI=(MFI 2 −MFI 1 ). In one embodiment, the TBC comprises a phase-separated blend. The invention is also directed to a method of making the golf ball.
1. A golf ball comprising a core and a cover disposed about the core;
wherein at least one of the core and the cover comprises a tri-blend composition of a non-E/X/Y type (TBC), formed from a blend of an ethylene acid (E/X) ionomer, a non-ionomeric softening copolymer (NISC) and a low viscosity component (LVC);
wherein a portion of the TBC comprising the ethylene acid (E/X) ionomer and the NISC has a Melt Flow Index MF 1 and a CoR 1 and the TBC has a Melt Flow Index MF 2 and a CoR 2 such that MF 2 >MF 1 and CoR 1 and CoR 2 differ by less than about 0.1; and
wherein an E/X ionomer and NISC portion of the blend comprises the E/X ionomer in an amount of from about 30% to about 85% of the portion.
2. The golf ball of claim 1 , wherein the E/X ionomer is formed from ethylene and an α,β-ethylenically unsaturated carboxylic acid.
3. The golf ball of claim 2 , wherein the α,β-ethylenically unsaturated carboxylic acid comprises at least one of acrylic acid and methacrylic acid.
4. The golf ball of claim 1 , wherein the E/X ionomer and NISC portion of the blend comprises the E/X ionomer in an amount of from about 30% to about 75% of the portion.
5. The golf ball of claim 1 , wherein the E/X ionomer and NISC portion of the blend comprises the E/X ionomer in an amount of from about 30% to about 60% of the portion.
6. The golf ball of claim 1 , wherein the portion has a Melt Flow Index of less than about 3 g/10 mins.
7. The golf ball of claim 1 , wherein the portion has a Melt Flow Index of less than about 2 g/10 mins.
8. The golf ball of claim 1 , wherein the portion has a Melt Flow Index of less than about 1 g/10 mins.
9. The golf ball of claim 1 , wherein the NISC comprises at least one of ethylene butyne, ethylene hexane and ethylene alkyl acrylate.
10. The golf ball of claim 1 , wherein the LVC comprises at least one of a polyethylene homopolymer, a high-density oxidized polyethylene homopolymer, a polypropylene homopolymer, an ethylene-acrylic acid copolymer, oxidized ethylene-vinyl acetate copolymer, polyethylene copolymers, ethylene maleic anhydride copolymers, and propylene maleic anhydride copolymers.
11. The golf ball of claim 1 , wherein the blend has a Melt Flow Index that is greater than the Melt Flow Index of the portion.
12. The golf ball of claim 11 , wherein the blend has a Melt Flow Index that is greater than the Melt Flow Index of the portion by up to about 0.03 g/10 mins or greater.
13. The golf ball of claim 11 , wherein the blend has a Melt Flow Index that is greater than the Melt Flow Index of the portion by at least about 0.11 g/10 mins.
14. The golf ball of claim 11 , wherein the blend has a Melt Flow Index that is greater than the Melt Flow Index of the portion by about 0.66 g/10 mins or greater.
15. The golf ball of claim 11 , wherein the blend has a Melt Flow Index that is greater than the Melt Flow Index of the portion by at least about 1.68 g/10 mins.
16. The golf ball of claim 1 , wherein the blend has an Atti compression of from about −75 to about 200.
17. The golf ball of claim 1 , wherein the TBC has a composition property relationship ΔCoR/ΔMFI≦˜10, wherein ΔCoR is the amount by which CoR 1 and CoR 2 differ, and ΔMFI=(MFI 2 −MFI 1 ).
18. A golf ball comprising a core and a cover disposed about the core;
wherein at least one of the core and the cover comprises a tri-blend composition of a non-E/X/Y type (TBC), formed from a blend of an ethylene acid (E/X) ionomer, a non-ionomeric softening copolymer (NISC) and a low viscosity component (LVC);
wherein a portion of the TBC comprising the ethylene acid (E/X) ionomer and the NISC has a Melt Flow Index MF 1 and a CoR 1 and the TBC has a Melt Flow Index MF 2 and a CoR 2 such that MF 2 >MF 1 and CoR 1 and CoR 2 differ by less than about 0.1; and
wherein the NISC is grafted.
19. The golf ball of claim 18 , wherein the portion has a Melt Flow Index of less than about 3 g/10 mins.
20. The golf ball of claim 18 , wherein the NISC comprises at least one of ethylene butyne, ethylene hexane and ethylene alkyl acrylate.
21. The golf ball of claim 18 , wherein the LVC comprises at least one of a polyethylene homopolymer, a high-density oxidized polyethylene homopolymer, a polypropylene homopolymer, an ethylene-acrylic acid copolymer, oxidized ethylene-vinyl acetate copolymer, polyethylene copolymers, ethylene maleic anhydride copolymers, and propylene maleic anhydride copolymers.
22. A golf ball comprising a core and a cover disposed about the core;
wherein at least one of the core and the cover comprises a tri-blend composition of a non-E/X/Y type (TBC), formed from a blend of an ethylene acid (E/X) ionomer, a non-ionomeric softening copolymer (NISC) and a low viscosity component (LVC);
wherein a portion of the TBC comprising the ethylene acid (E/X) ionomer and the NISC has a Melt Flow Index MF 1 and a CoR 1 and the TBC has a Melt Flow Index MF 2 and a CoR 2 such that MF 2 >MF 1 and CoR 1 and CoR 2 differ by less than about 0.1; and
wherein the blend comprises the LVC in an amount of from about 2% to about 40%.
23. The golf ball of claim 22 , wherein the blend comprises the LVC in an amount of from about 5% to about 40%.
24. The golf ball of claim 22 , wherein the blend comprises the LVC in an amount of from about 10% to about 40%.
25. The golf ball of claim 22 , wherein the portion has a Melt Flow Index of less than about 3 g/10 mins.
26. The golf ball of claim 22 , wherein the NISC comprises at least one of ethylene butyne, ethylene hexane and ethylene alkyl acrylate.
27. The golf ball of claim 22 , wherein the LVC comprises at least one of a polyethylene homopolymer, a high-density oxidized polyethylene homopolymer, a polypropylene homopolymer, an ethylene-acrylic acid copolymer, oxidized ethylene-vinyl acetate copolymer, polyethylene copolymers, ethylene maleic anhydride copolymers, and propylene maleic anhydride copolymers.
28. A method of making a golf ball comprising:
providing a core and forming a cover about the core;
wherein at least one of the core and the cover comprises a tri-blend composition of the non-E/X/Y type (TBC) that is formed by blending an ethylene acid ionomer (E/X), a non-ionomeric softening copolymer (NISC) and a low viscosity component (LVC);
wherein a portion of the TBC comprising the ethylene acid (E/X) ionomer and the NISC has a Melt Flow Index MF 1 and a CoR 1 and the TBC has a Melt Flow Index MF 2 and a CoR 2 such that MF 2 >MF 1 and CoR 1 and CoR 2 differ by less than about 0.1; and
wherein the blend comprises the LVC in an amount of from about 2% to about 40%.
29. The method of making a golf ball of claim 28 , wherein the blend comprises the NISC in an amount of from about 15% to about 70%.
30. A method of making a golf ball comprising:
providing a core and forming a cover about the core;
wherein at least one of the core and the cover comprises a tri-blend composition of the non-E/X/Y type (TBC) that is formed by blending an ethylene acid ionomer (E/X), a non-ionomeric softening copolymer (NISC) and a low viscosity component (LVC);
wherein a portion of the TBC comprising the ethylene acid (E/X) ionomer and the NISC has a Melt Flow Index MF 1 and a CoR 1 and the TBC has a Melt Flow Index MF 2 and a CoR 2 such that MF 2 >MF 1 and CoR 1 and CoR 2 differ by less than about 0.1; and
wherein a portion of the blend comprising the E/X ionomer and NISC comprises the E/X ionomer in an amount of from about 30% to about 85% of the portion.
31. The method of making a golf ball of claim 30 , wherein the portion has a Melt Flow Index of less than about 3 g/10 mins.
32. The method of making a golf ball of claim 30 , wherein the blend has a Melt Flow Index that is greater than the Melt Flow Index of the portion.
33. The method of making a golf ball of claim 30 , wherein the blend comprises the NISC in an amount of from about 15% to about 70%.
34. A golf ball comprising a core and a cover disposed about the core;
wherein at least one of the core and the cover comprises a tri-blend composition of the non-E/X/Y type (TBC) formed from a blend of an ethylene acid ionomer (E/X), a non-ionomeric softening copolymer (NISC) and a low viscosity component (LVC); and
wherein the TBC comprises a phase-separated blend; and
wherein the phase-separated blend comprises a continuous phase and a discontinuous phase wherein the average size of the discontinuous phase is less than about 10 microns.
35. The golf ball of claim 34 , wherein the TBC has a composition property relationship CPR=(Atti compression)×(Melt Index) of from about −10,000 to about 10,000.
36. The golf ball of claim 34 , wherein the ethylene acid (E/X) ionomer and NISC portions of the blend, combined, have a CoR 1 and the TBC has a CoR 2 such that CoR 1 -CoR 2 is less than about 0.1.
37. The golf ball of claim 34 , wherein the average size of the discontinuous phase is less than about 5 microns.
38. The golf ball of claim 34 , wherein the E/X ionomer is formed from ethylene and an α,β-ethylenically unsaturated carboxylic acid.
39. The golf ball of claim 34 , wherein the LVC comprises at least one of wherein the LVC comprises at least one of a polyethylene homopolymer, a high-density oxidized polyethylene homopolymer, a polypropylene homopolymer, an ethylene-acrylic acid copolymer, oxidized ethylene-vinyl acetate copolymer, polyethylene copolymers, ethylene maleic anhydride copolymers, and propylene maleic anhydride copolymers.
40. The golf ball of claim 34 , wherein the NISC comprises at least one of ethylene butyne, ethylene hexane and ethylene alkyl acrylate.