Golf ball which includes fast-chemical-reaction-produced component and method of making same

Abstract

Disclosed herein is a golf ball comprising fast-chemical-reaction-produced component, such as a component which comprises a reaction injection molded polyurethane material. A process of making a golf ball by forming at least one core and/or cover component of the ball by mixing two or more reactants that react and form a reaction product with a flex modulus of 5-310 kpsi in a reaction time of about 5 minutes or less, the component having a thickness of at least 0.01 inches and a demold time of 10 minutes or less is disclosed. In one preferred form of the invention, excess polyurethane from forming golf ball covers is recycled by using it to form golf ball cores.

1 . A process for forming a layer of a golf ball, the process comprising: 
 heating an isocyanate reactant to a temperature ranging from 100° F. to 150° F.;    heating a polyol reactant to a temperature ranging from 100° F. to 150° F.;    impinging the isocyanate reactant against the polyol reactant in an impingement mix head under a pressure ranging from 1500 psi to 3000 psi to form a mixture material;    injecting the mixture material into a mold cavity to form a layer of a golf ball.    
     
     
         2 . The process according to  claim 1  further comprising mixing the mixing material in an aftermixer prior to injecting the mixture material into a mold cavity.  
     
     
         3 . The process according to  claim 1  wherein the layer is composed of a polyurethane material.  
     
     
         4 . The process according to  claim 1  wherein the layer is composed of a polyurea material.  
     
     
         5 . The process according to  claim 1  wherein the layer is formed in a reaction time of five minutes or less.  
     
     
         6 . The process according to  claim 1  wherein the layer is formed in a reaction time of three minutes or less.  
     
     
         7 . The process according to  claim 1  wherein the layer is a cover of a golf ball.  
     
     
         8 . The process according to  claim 1  wherein the layer is a core of a golf ball.  
     
     
         9 . The process according to  claim 1  wherein the layer is a mantle layer of a golf ball.  
     
     
         10 . A process for forming a layer of a golf ball, the process comprising: 
 heating a isocyanate reactant within an isocyanate tank to a temperature ranging from 100° F. to 120° F.;    heating a second liquid reactant within a second tank to a temperature ranging from 100° F. to 120° F.;    feeding the isocyanate reactant from the isocyanate tank to a recirculation mix head;    feeding the second reactant from the second tank to the recirculation mix head;    impinging the isocyanate reactant against the second reactant in a recirculation mix head under a pressure ranging from 1500 psi to 3000 psi to form a mixture material;    mixing mixture material in an aftermixer;    injecting the mixture material into a mold cavity to form a layer of a golf ball.    
     
     
         11 . The process according to  claim 10  wherein the layer is formed in a reaction time of five minutes or less.  
     
     
         12 . The process according to  claim 10  wherein the layer is formed in a reaction time of three minutes or less.  
     
     
         13 . The process according to  claim 10  wherein the layer is a cover of a golf ball.  
     
     
         14 . The process according to  claim 10  wherein the layer is a core of a golf ball.  
     
     
         15 . The process according to  claim 10  wherein the layer is a mantle layer of a golf ball.  
     
     
         16 . A process for forming a layer of a golf ball, the process comprising: 
 heating a first reactant within a first tank to a temperature ranging from 100° F. to 120° F.;    heating a second liquid reactant within a second tank to a temperature ranging from 100° F. to 120° F.;    feeding the first reactant from the first tank to a recirculation mix head;    feeding the second reactant from the second tank to the recirculation mix head;    impinging the first reactant against the second reactant in a recirculation mix head under a pressure ranging from 1500 psi to 3000 psi to form a mixture material;    mixing mixture material in an aftermixer;    injecting the mixture material into a mold cavity to form a layer of a golf ball, the layer composed of a polyurethane material.