Interpenetrating polymer networks using blocked polyurethane/polyurea prepolymers for golf ball layers
View Patent ↗The present invention is directed to a method of forming a golf ball that contains an interpenetrating polymer network, or IPN, which includes at least two polymeric systems, in one or more of the layers. The first polymeric system may include a polyurethane-based or polyurea-based system having blocked isocyanate groups and the second polymeric system may include an epoxy-based or acrylic-based system, wherein the two systems are polymerized or cured simultaneously or sequentially to form an IPN.
1. A method of forming a portion of a golf ball comprising the steps of:
providing a first polymeric precursor formed from the reaction product of a half-blocked intermediate and an amine-terminated component, wherein the half-blocked intermediate is the reaction product of an isocyanate having terminal isocyanate groups and a first curing agent comprising a blocked, delayed action curative;
providing a second polymeric precursor comprising an acrylate resin;
adding a second curing agent to the second polymeric precursor to form a second polymeric system;
combining the first polymeric precursor and second polymeric system in a vessel;
elevating the temperature in the vessel to an amount sufficient to unblock the first curing agent to provide a first polymeric system resulting in an interpenetrating polymer network (“IPN”) comprising the first and second polymeric systems; and
forming the IPN into the portion of the golf ball.
2. The method of claim 1 , wherein the step of adding occurs prior to the steps of combining and elevating.
3. The method of claim 1 , wherein the first curing agent comprises a diamine.
4. The method of claim 1 , wherein the blocked, delayed action curative comprises a salt complex.
5. The method of claim 1 , wherein the blocked, delayed action curative comprises a complex of methylene dianiline and sodium chloride.
6. The method of claim 1 , wherein the step of elevating comprises elevating the temperature in the vessel to about 185° F. to about 325° F.
7. The method of claim 6 , wherein the step of elevating comprises elevating the temperature in the vessel to about 195° F. to about 315° F.
8. The method of claim 7 , wherein the step of elevating comprises elevating the temperature in the vessel to about 205° F. to about 305° F.
9. The method of claim 1 , wherein the second curing agent is selected from the group consisting of benzoyl peroxide, t-amyl peroxide, and mixtures thereof.
10. A method of forming a portion of a golf ball comprising the steps of:
providing a first polymeric precursor comprising the reaction product of a half-blocked intermediate and an amine-terminated component, wherein the half-blocked intermediate is the reaction product of an isocyanate and a first curing agent comprising a blocked, delayed action curative comprising a salt complex;
providing a second polymeric precursor comprising an acrylate resin;
adding a second curing agent to the second polymeric precursor to form a second polymeric system;
combining the first polymeric precursor and second polymeric system in a vessel;
elevating the temperature in the vessel to about 175° F. to about 350° F. to provide a first polymeric system resulting in an interpenetrating polymer network (“IPN”) comprising the first and second polymeric systems; and
forming the IPN into the portion of the golf ball.
11. The method of claim 10 , wherein the step of adding occurs prior to the steps of combining and elevating.
12. The method of claim 10 , wherein the step of providing a first polymeric precursor further comprises the step of forming a blocked, delayed action curative by:
dispersing sodium chloride in dioctyl phthalate; and
complexing the sodium chloride with methylene dianiline.
13. A method of forming a portion of a golf ball comprising the steps of:
providing a half-blocked intermediate that is the reaction product of an isocyanate and a curative comprising a salt complex having a deblocking temperature ranging from 212° F. to 302° F.;
reacting the half-blocked intermediate with an amine-terminated component to form a first polymeric precursor;
providing a second polymeric precursor comprising an acrylate resin;
adding a second curing agent to the second polymeric precursor to form a second polymeric system;
combining the first polymeric precursor and second polymeric system in a vessel;
elevating the temperature in the vessel to the deblocking temperature to provide a first polymeric system resulting in an interpenetrating polymer network (“IPN”) comprising the first and second polymeric systems; and
forming the IPN into the portion of the golf ball.
14. The method of claim 13 , wherein the curative comprises a complex of methylene dianiline and sodium chloride dispersed in dioctyl phthalate.
15. The method of claim 13 , wherein the step of adding a second curing agent comprises adding an initiator selected from the group consisting of benzoyl peroxide, t-amyl peroxide, and mixtures thereof.