Golf balls containing impact modified non-ionic thermoplastic polycarbonate/polyester copolymers or blends
View Patent ↗The present invention is directed a golf ball that uses impact modified non-ionic engineered thermoplastic polycarbonate/polyester copolymer or blend, for example polycarbonate/poly(butylene terephthalate) (PC/PBT) impact modified by blending with functionalized thermoplastic block co-polymers like maleic anhydride grafted styrene-butadiene-styrene and its hydrogenated derivatives. The impact modified thermoplastic polycarbonate/polyester are used as intermediate layers to produce golf balls having lower flexural modulus and improved durability.
1. A golf ball comprising:
a central core having at least one core layer;
an outer cover layer having at least one cover layer; and
an intermediate layer disposed between the central core and the outer cover layer;
wherein the intermediate layer has a flexural modulus of less than 100,000 psi and comprises an impact modified non-ionic thermoplastic polycarbonate/polyester copolymer or blend comprising an aliphatic component selected from the group consisting of a block copolyester of poly(1,4-butylene terephthalate) and an aliphatic polyester, a blend of copolyester of poly(1,4-butylene terephthalate) and an aliphatic polyester and a poly(ethylene terephthalate) resin, block terpolymers derived from aliphatic polyester, polysiloxane and polycarbonate, a polycarbonate/polyester copolymer derived from caprolactone-based polyols, a blend of polycarbonate/polyester derived from caprolactone-based polyols, a polycarbonate/polyester copolymer derived from cyclohexanediol and cyclohexanedimethanol, a blend of polycarbonate/polyester derived from cyclohexanediol and cyclohexanedimethanol a polycarbonate/polyester copolymer derived from caprolactone-based polyols, cyclohexanediol and cyclohexanedimethanol, and a blend of polycarbonate/polyester derived from caprolactone-based polyols, cyclohexanediol and cyclohexanedimethanol.
2. The golf ball of claim 1 , wherein the intermediate layer has a flexural modulus of 80,000 psi or less.
3. The golf ball of claim 2 , wherein the intermediate layer has a flexural modulus of 50,000 psi to 70,000 psi.
4. The golf ball of claim 1 , wherein the intermediate layer has a thickness of 0.125 to 0.035 inch.
5. The golf ball of claim 1 , wherein the intermediate layer has a specific gravity of 1.100 or less.
6. The golf ball of claim 1 , wherein the non-ionic thermoplastic polycarbonate/polyester copolymer or blend comprises an aromatic component.
7. The golf ball of claim 6 , wherein the aromatic component is a member selected from the group consisting of a polycarbonate/poly(butylene terephthalate), a block copolyester of poly(1,4-butylene terephthalate) and an aromatic polyester, a blend of copolyester of poly(1,4-butylene terephthalate) and an aromatic polyester and a poly(ethylene terephthalate) resin, a block poly(carbonate-co-ester) copolymer derived from an aromatic dihydroxy compound and a carbonic acid diester, a block copolyestercarbonate derived from at least one dihydroxy-substituted aromatic hydrocarbon moiety and at least one aromatic dicarboxylic acid moiety, a blend of polycarbonate-polyester derived from a polyester resin, an aromatic polycarbonate and a phosphonium sulfonate, a block terpolymer derived from aromatic polyester, polysiloxane and polycarbonate, a blend of a linear aromatic polycarbonate with a polycarbonate/polyester copolymer, a blend of aromatic polycarbonate homopolymer derived from bisphenol A with a polyester/polycarbonate copolymer derived from a dicarboxylic acid and bisphenol A, a blend of brominated polycarbonate and a metal sulfonate polyester copolymer, and a blend of brominated polycarbonate and a polyester copolymer.
8. The golf ball of claim 1 , wherein the impact modified thermoplastic polycarbonate/polyester copolymer or blend further comprises an impact modifying compound, wherein the impact modifying compound is present in an amount from 10 wt % to 70 wt %.
9. The golf ball of claim 8 , wherein the impact modifying compound is present in an amount from 30 wt % to 50 wt %.
10. The golf ball of claim 8 , wherein the impact modifying compound comprises a functionalized thermoplastic block copolymer.
11. The golf ball of claim 10 , wherein the functionalized thermoplastic block copolymer comprises styrene-butadiene-styrene.
12. The golf ball of claim 11 , wherein the functionalized thermoplastic block copolymer further comprises maleic anhydride or glycidyl methacrylate.
13. The golf ball of claim 12 , wherein the maleic anhydride or glycidyl methacrylate is present from 1% to 5% by weight.
14. The golf ball of claim 13 , wherein the maleic anhydride or glycidyl methacrylate is present at 2% by weight.
15. The golf ball of claim 1 , wherein the central core has a coefficient of restitution of 0.81 to 0.83.
16. The golf ball of claim 15 , wherein the central core has a coefficient of restitution of 0.825 to 0.83.
17. The golf ball of claim 1 , wherein the at least one core layer and the intermediate layer are treated with an amine terminated silane solution.
18. The golf ball of claim 17 , wherein the amine terminated silane solution comprises a member selected from the group consisting of N-2-(aminoethyl)-3-aminoproplyltrimethoxy silane, 4-amino-3,3-dimethylbutyltrimethoxysilane, 3-aminopropyltriethoxysilane, 2-(3,4-epoxycyclohexyl)-ethyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, octyltriethoxysilane, and a combination thereof.
19. A golf ball comprising:
a central core having at least one core layer;
an outer cover layer having at least one cover layer; and
an intermediate layer disposed between the central core and the outer cover layer;
wherein the intermediate layer has a flexural modulus of less than 100,000 psi and comprises an impact modified non-ionic thermoplastic polycarbonate/polyester copolymer or blend comprising a siloxane component selected from the group consisting of a block terpolymer of siloxane polyester-carbonate, a block polysiloxane-polycarbonate copolymer, a block terpolymer derived from aromatic polyester, polysiloxane and polycarbonate, a block terpolymers derived from aliphatic polyester, polysiloxane and polycarbonate, a blend of a silicone polycarbonate block copolymer with a polycarbonate, a blend of silicone-polyester copolymer having a silicone block and a polyester block, and a blend of silicone-polycarbonate block copolymer and polyphenylene ether resin and polyester resin.
20. A golf ball comprising:
a central core having at least one core layer;
an outer cover layer having at least one cover layer; and
an intermediate layer disposed between the central core and the outer cover layer;
wherein the intermediate layer comprises an impact modified non-ionic thermoplastic polycarbonate/polyester copolymer or blend, and has a flexural modulus of less than 100,000 psi;
and wherein the impact modified thermoplastic polycarbonate/polyester copolymer or blend further comprises an impact modifying compound present in an amount from 30 wt % to 50 wt % and comprising a functionalized thermoplastic block copolymer comprising styrene-butadiene-styrene functionalized with, maleic anhydride, or glycidyl methacrylate.