Reaction injection moldable compositions, methods for making same, and resultant golf articles

Abstract

The invention relates to a method for forming golf equipment, or a portion thereof, preferably for forming one or more layers of a golf ball, including: providing a first reactable component containing an isocyanate-containing compound, and a second reactable component containing at least one polyol, polyamine, or epoxy-containing compound; mixing the reactable components together to form a reactive mixture; and injecting the reactive mixture into a cavity or mold having a desired shape within a time sufficient to avoid substantial polymerization, gelation, or solidification. Alternately, instead of providing an isocyanate-containing reactable component and at least one polyol, polyamine, or epoxy-containing compound, the method may include providing at least two sets of precursor components that can be reacted to form at least two different polymers of an interpenetrating polymer network, at least one polymer being crosslinked, wherein, if any of the at least two component sets include a mixture of precursor components, then that mixture must be sufficiently non-reactive such that the sets of precursor components, when placed in contact with each other, can still form an interpenetrating polymer network.

1 .- 47 . (canceled) 
   
   
       48 . A method for forming a golf ball layer comprising the steps of:
 providing a first reactable component comprising an aliphatic isocyanate-containing compound and a second reactable component comprising at least one of a polyol, polyamine, or epoxy-containing compound, wherein the aliphatic isocyanate-containing compound comprises a reaction product of a polyamine, epoxy-containing compound, or a mixture thereof and at least one aliphatic polyisocyanate;   combining the reactable components together to form a reactive mixture, wherein the reactive mixture has a gelation time of from about 1 second to about 10 seconds after combining, and wherein the first and second reactable components have a viscosity from about 25 cPs to about 5000 cPs at ambient temperature or at a temperature at which the reactable components are combined;   providing a portion of a golf ball;   placing the golf ball portion into a golf ball mold;   injecting the reactive mixture into the golf ball mold within a time that is less than the gelation time; and   curing the reactive mixture to form a golf ball layer around the golf ball portion within the gelation time,   wherein the golf ball layer has a material hardness of up to about 55 Shore D.   
   
   
       49 . The method of  claim 48 , wherein the step of providing a portion of a golf ball comprises providing a center. 
   
   
       50 . The method of  claim 48 , wherein the step of providing a portion of a golf ball comprises providing a center and at least one intermediate layer disposed about the center. 
   
   
       51 . The method of  claim 48 , wherein the golf ball layer is an outer cover layer comprising dimples. 
   
   
       52 . The method of  claim 51 , wherein the step of providing a portion of a golf ball comprises providing a center, an optional intermediate layer disposed about the center, and an inner cover layer disposed about the center or optional intermediate layer. 
   
   
       53 . The method of  claim 52 , wherein the inner cover layer has a material hardness of at least about 55 Shore D. 
   
   
       54 . The method of  claim 48 , wherein the gelation time is about 1 second to about 5 seconds after combining. 
   
   
       55 . The method of  claim 52 , wherein the outer cover layer has a material hardness that is greater than the material hardness of the inner cover layer. 
   
   
       56 . The method of  claim 55 , wherein outer cover layer material hardness is at least about 55 Shore D and the inner cover layer material hardness is up to about 55 Shore D. 
   
   
       57 . The method of  claim 52 , wherein the inner cover layer has a material hardness that is greater than the material hardness of the outer cover layer. 
   
   
       58 . The method of  claim 57 , wherein the inner cover layer material hardness is at least about 55 Shore D and the outer cover layer material hardness is up to about 55 Shore D. 
   
   
       59 . A method for forming a golf ball comprising the steps of:
 providing a first reactable component comprising an aliphatic isocyanate-containing compound and a second reactable component comprising at least one of a polyol, polyamine, or epoxy-containing compound, wherein the aliphatic isocyanate-containing compound comprises a reaction product of a polyamine, epoxy-containing compound, or a mixture thereof and at least one aliphatic polyisocyanate;   combining the reactable components together to form a reactive mixture, wherein the reactive mixture has a gelation time of from about 1 second to about 5 seconds after combining, and wherein the first and second reactable components have a viscosity from about 25 cPs to about 5000 cPs at ambient temperature or at a temperature at which the reactable components are combined;   providing a core of a golf ball, wherein the core comprises a center, an optional intermediate layer disposed about the center, and an inner cover layer disposed about the center or optional intermediate layer, wherein the inner cover layer has a first material hardness;   placing the core into a golf ball mold;   injecting the reactive mixture into the golf ball mold within a time that is less than the gelation time; and   curing the reactive mixture to form a cover around the core within the gelation time,   wherein the cover has a second material hardness.   
   
   
       60 . The method of  claim 59 , wherein the second material hardness is greater than the first material hardness. 
   
   
       61 . The method of  claim 60 , wherein the second material hardness is at least about 55 Shore D and the first material hardness is up to about 55 Shore D. 
   
   
       62 . The method of  claim 59 , wherein the first material hardness is greater than the second material hardness. 
   
   
       63 . The method of  claim 62 , wherein the first material hardness is at least about 55 Shore D and the second material hardness is up to about 55 Shore D.