US-12616877-B2 - Golf ball components incorporating reclaimed resources and golf balls formed therefrom

Abstract

Reclaimed resources obtained from a thermal process used to combust golf ball waste and, more specifically, inorganic reclaimed resources that include at least one metal component, compositions including such reclaimed resources, golf ball components made from such compositions, and golf balls including such golf ball components.

Inventors

• Derek A. Ladd

Assignees

• ACUSHNET COMPANY

Dates

Publication Date

20260505

Application Date

20221222

Claims (18)

1. 1 . A golf ball, comprising: a dual core comprising an outer core layer disposed over an inner core layer, wherein at least one of the outer core layer or the inner core layer is formed of a composition, the composition comprising: a base rubber; and about 2 to 15 percent organic-free ash residue by weight of the composition, wherein the ash residue comprises about 5 percent to about 30 percent by weight of metal compounds, and wherein the metal compounds comprise (1) zinc, barium, and titanium, (2) zinc, barium, and limestone, or (3) zinc, titanium, and limestone; and a cover layer surrounding the dual core, wherein the cover layer comprises an ionomer, polyurethane, polyurea, polyurethane-urea hybrid, or copolymers and blends thereof.
2. 2 . The golf ball of claim 1 , wherein the metal compounds comprise zinc, barium, and limestone or zinc, titanium, and limestone.
3. 3 . The golf ball of claim 1 , wherein the metal compounds comprise zinc, barium, and limestone.
4. 4 . The golf ball of claim 1 , wherein the ash residue is present in the composition in an amount of about 5 to 10 percent by weight of the composition.
5. 5 . The golf ball of claim 1 , wherein the composition further comprises an organic peroxide, a cross-linking co-agent, a radical scavenger, or a combination thereof.
6. 6 . The golf ball of claim 5 , wherein the co-agent comprises a zinc salt of an acrylate, diacrylate, methacrylate, or dimethacrylate.
7. 7 . The golf ball of claim 1 , wherein the outer core layer is formed of the composition.
8. 8 . The golf ball of claim 1 , wherein the base rubber comprises polybutadiene.
9. 9 . The golf ball of claim 1 , wherein the at least one metal compound is present in the ash residue in an amount of about 10 to about 25 percent by weight of the ash residue.
10. 10 . The golf ball of claim 1 , wherein the ash residue is golf ball waste ash residue.
11. 11 . A golf ball, comprising: a core formed of a composition, the composition comprising: a base rubber; and organic-free ash residue present in the composition in an amount of about 1 to 20 percent by weight of the composition, wherein the ash residue metal comprises barium, and wherein the barium is present in the ash residue in an amount of about 12 to 20 percent by weight of the ash residue; a cover layer; and a layer disposed between the core and the cover, wherein the layer and cover each comprises an ionomer, polyurethane, polyurea, polyurethane-urea hybrid, or copolymers and blends thereof.
12. 12 . The golf ball of claim 11 , wherein the ash residue further comprises limestone.
13. 13 . The golf ball of claim 11 , wherein the ash residue further comprises zinc, titanium, or a combination thereof.
14. 14 . The golf ball of claim 11 , wherein the ash residue is present in the composition in an amount of about 2 to 15 percent by weight of the composition.
15. 15 . A golf ball, comprising: a core formed of a composition, the composition comprising: a base rubber comprising polybutadiene, butyl rubber, or a combination thereof; and organic-free ash residue present in the composition in an amount of about 7 to 18 percent by weight of the composition, wherein at least one metal compound is present in an amount of about 10 percent to about 25 percent based on the total weight of the ash residue, and wherein the at least one metal compound comprises barium, limestone, or a combination thereof; and a cover layer.
16. 16 . The golf ball of claim 15 , further comprising a layer disposed between the core and the cover, wherein the layer and cover each comprises an ionomer, polyurethane, polyurea, polyurethane-urea hybrid, or copolymers and blends thereof.
17. 17 . The golf ball of claim 15 , wherein the at least one metal compound is present in the ash residue in an amount of about 13 to 15 percent by weight of the ash residue.
18. 18 . The golf ball of claim 15 , wherein the at least one metal compound is present in the ash residue in an amount of about 12 to 20 percent by weight of the ash residue.

Description

FIELD OF THE INVENTION The present disclosure relates generally to incorporating reclaimed resources into golf balls. More particularly, golf balls of the present disclosure include at least one component formed from a composition that includes resources that were obtained from a thermal process used to combust golf ball waste. The golf ball components formed with reclaimed resources may require less use of conventional additives since the reclaimed resources incorporated therein may increase reaction time, help the material band together, have more consistent weight, reduce feathering, or any combination thereof. In addition, golf balls formed in accordance with the present disclosure may be more easily discernable in x-ray processes used to identify and separate various product lines and/or ensure concentricity post-production. BACKGROUND OF THE INVENTION Like any other unused piece of sports equipment, golf balls that are no longer being played or playable become solid waste. Likewise, scrap materials from the production of new golf balls or golf balls that are rejected during the production process for one reason or another must be disposed of in some manner. Typically, such golf ball waste ends up being mixed with other municipal solid waste and put in landfills. It would be advantageous to use at least a portion of this waste as feedstock in new golf balls. To date, there is no large scale method for reclaiming the inorganic metals from golf ball waste and using such reclaimed resources as raw material in the production of certain golf ball components. The present disclosure addresses compositions that include such reclaimed resources, golf ball components that include such compositions, and golf balls including such golf ball components. In this regard, the use of reclaimed resources recovered from the reclamation process may reduce the demand and/or cost of certain raw materials that are commonly used in the production of certain golf ball components. SUMMARY OF THE INVENTION The present disclosure is directed to a golf ball that includes: a dual core including an outer core layer disposed over an inner core layer, wherein at least one of the outer core layer or the inner core layer is formed of a composition, the composition including a base rubber; and ash residue including at least one metal compound, wherein the at least one metal compound is present in the ash residue in an amount of about 5 percent to about 30 percent by weight of the ash residue; and a cover layer surrounding the dual core, wherein the cover layer includes an ionomer, polyurethane, polyurea, polyurethane-urea hybrid, or copolymers and blends thereof. In some aspects, the at least one metal compound includes zinc, titanium, barium, limestone, or a combination thereof. In other aspects, the ash residue includes at least two metal compounds selected from zinc, titanium, barium, and limestone. In still other aspects, the ash residue is present in the composition in an amount of about 5 to 10 percent by weight of the composition. In yet other aspects, the composition further includes an organic peroxide, a cross-linking co-agent, a radical scavenger, or a combination thereof. In one embodiment, the co-agent includes a zinc salt of an acrylate, diacrylate, methacrylate, or dimethacrylate. In some embodiments, the outer core layer is formed of the composition. In other embodiments, the base rubber includes polybutadiene. The present disclosure also relates to a golf ball including: a core formed of a composition including: a base rubber and ash residue including at least one metal compound, wherein the ash residue is present in the composition in an amount of about 1 to 20 percent by weight of the composition, and wherein the at least one metal compound is present in the ash residue in an amount of about 10 to 25 percent by weight of the ash residue; a cover layer; and a layer disposed between the core and the cover, wherein the layer and cover each includes an ionomer, polyurethane, polyurea, polyurethane-urea hybrid, or copolymers and blends thereof. In some embodiments, the at least one metal compound includes zinc, titanium, barium, limestone, or a combination thereof. In other embodiments, the ash residue includes zinc, titanium, and barium. In still other embodiments, the ash residue is present in the composition in an amount of about 2 to 15 percent by weight of the composition. The present disclosure also relates to a golf ball including: a core formed of a composition including a base rubber including polybutadiene, butyl rubber, or a combination thereof and ash residue comprising at least one metal compound, wherein the ash residue is present in the composition in an amount of about 7 to 18 percent by weight of the composition, and wherein the at least one metal compound is present comprises zinc, titanium, barium, limestone, or a combination thereof; and a cover layer. In some embodiments, the golf ball also includes a la