Castable golf ball components using acrylate functional resins

1. A golf ball comprising a core and a cover, wherein the cover is cast from a castable reactive acrylate functional composition consisting essentially of:

a saturated polyurethane backbone;

at least one acrylate functional component reacted with the saturated polyurethane backbone; and

at least one free radical initiator.

2. The golf ball of claim 1 , wherein the at least one acrylate functional component is selected from the group consisting of monofunctional, difunctional, trifunctional, tetrafunctional, and pentafunctional monomers and oligomers, and combinations thereof.

3. The golf ball of claim 1 , wherein the at least one acrylate functional component has a viscosity of about 100 cP or greater.

4. The golf ball of claim 1 , wherein the at least one free radical initiator comprises at least one peroxide.

5. The golf ball of claim 1 , wherein the at least one free radical initiator comprises at least one azo compound.

6. The golf ball of claim 4 , wherein the at least one free radical initiator is selected from the group consisting of di-t-amyl peroxide, tert-amyl peroxy-2-ethylhexyl carbonate, t-amyl peroxyacetate, ethyl 3,3-D (t-amylperoxy) butyrate, 2,2-di-(t-amylperoxy) propane, t-amyl perbenzoate, di(2-t-butyl-peroxyisopropyl)benzene peroxide, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, dicumyl peroxide, di-t-butyl peroxide, 2,5-di-(t-butylperoxy)-2,5-dimethyl hexane, n-butyl-4,4-bis(t-butylperoxy)valerate, lauryl peroxide, benzoyl peroxide, t-butyl hydroperoxide, and mixtures thereof.

7. The golf ball of claim 1 , further comprising an intermediate layer.

8. The golf ball of claim 7 , wherein the intermediate layer comprises an ionomeric material.

9. The golf ball of claim 1 , wherein the golf ball further comprises at least one top coat disposed about the cover.

10. The golf ball of claim 9 , wherein the cover has a thickness of about 50 μm or greater.

11. The golf ball of claim 10 , wherein the cover has a thickness of about 0.2 inches to about 0.035 inches.

12. A golf ball comprising at least one cover layer formed from an acrylate functional composition consisting essentially of:

a polyurethane backbone formed from the reaction of at least one isocyanate and at least one polyol;

at least one unsaturated acrylate functional segment reacted with the polyurethane backbone; and

at least one free radical initiator.

13. The golf ball of claim 12 , wherein the at least one unsaturated acrylate functional segment comprises hydroxy-terminated acrylates, amine-terminated acrylates, or mixtures thereof.

14. The golf ball of claim 13 , wherein the at least one acrylate functional segment comprises hydroxy-terminated acrylate, hydroxy-terminated methacrylate, hydroxy-terminated methyl methacrylate, hydroxy-terminated ethyl acrylate, hydroxy-terminated ethyl methacrylate, hydroxy-terminated butyl acrylate, hydroxy-terminated butyl methacrylate, hydroxy-terminated glycidyl acrylate, hydroxy-terminated glycidal methacrylate, or mixtures thereof.

15. The golf ball of claim 12 , wherein the at least one free radical initiator comprises at least one peroxide.

16. The golf ball of claim 15 , wherein the at least one free radical initiator comprises di-t-amyl peroxide, di(2-t-butyl-peroxyisopropyl)benzene peroxide, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, dicumyl peroxide, di-t-butyl peroxide, 2,5-di-(t-butylperoxy)-2,5-dimethyl hexane, n-butyl-4,4-bis(t-butylperoxy)valerate, lauryl peroxide, benzoyl peroxide, t-butyl hydroperoxide, or mixtures thereof.

17. The golf ball of claim 15 , wherein the at least one free radical initiator is selected from the group consisting of di-t-amyl peroxide, tert-amyl peroxy-2-ethylhexyl carbonate, t-amyl peroxyacetate, ethyl 3,3-D (t-amylperoxy) butyrate, 2,2-di-(t-amylperoxy) propane, t-amyl perbenzoate, and mixtures thereof.

18. The golf ball of claim 12 , wherein the at least one unsaturated acrylate functional segment comprises epoxy acrylates, epoxy methacrylates, acrylate half esters, methacrylate half esters, polybutadiene acrylates, urea acrylates, and combinations thereof.

19. A golf ball comprising a core, an inner cover, and an outer cover, wherein at least one of the inner cover or outer cover is formed from an acrylate functional composition consisting essentially of:

a polyurethane backbone formed from the reaction of at least one isocyanate and at least one hydroxy-terminated compound;

at least one unsaturated acrylate functional segment reacted with the polyurethane backbone; and

at least one free radical initiator.

20. The golf ball of claim 19 , wherein the at least one unsaturated acrylate functional segment comprises hydroxy-terminated acrylate, hydroxy-terminated methacrylate, hydroxy-terminated methyl methacrylate, hydroxy-terminated ethyl acrylate, hydroxy-terminated ethyl methacrylate, hydroxy-terminated butyl acrylate, hydroxy-terminated butyl methacrylate, hydroxy-terminated glycidyl acrylate, hydroxy-terminated glycidal methacrylate, or mixtures thereof.

21. The golf ball of claim 19 , wherein the at least one unsaturated acrylate functional segment comprises hydroxy-terminated acrylates, amine-terminated acrylates, or mixtures thereof.

22. The golf ball of claim 19 , wherein the polyurethane backbone comprises linkages having the general formula:

or a mixture thereof, wherein x is the chain length, i.e., about 1 or greater, and wherein R and R 1 are straight chain or branched hydrocarbon chains having about 1 to about 20 carbons, and wherein the linkages form greater than about 10 percent of the polyurea backbone.

23. The golf ball of claim 19 , wherein the acrylate functional composition is present in the outer cover layer.

24. The golf ball of claim 19 , wherein the at least one free radical initiator is selected from the group consisting of di-t-amyl peroxide, tert-amyl peroxy-2-ethylhexyl carbonate, t-amyl peroxyacetate, ethyl 3,3-D (t-amylperoxy) butyrate, 2,2-di-(t-amylperoxy) propane, t-amyl perbenzoate, and mixtures thereof.