Multi-Block Copolymer Golf Ball Catalyst via Chain Shuttling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional block copolymers used in golf ball compositions lack a balance of desirable properties such as light stability, heat resistance, and flexibility due to narrow molecular weight distribution and poor crystallinity.
Innovation Solution
A multi-block copolymer is produced using a catalyst composition that combines a first and second olefin polymerization catalyst with a chain shuttling agent, allowing for the formation of polymers with varied chemical and physical properties, including broad molecular weight distribution and enhanced crystallinity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional block copolymers are used to provide flexibility, then the polymer lacks light stability and heat resistance
Solution Approach 1:
The patent divides the polymer into distinct blocks: saturated polyethylene blocks provide flexibility and elasticity, while saturated polypropylene blocks provide light stability and heat resistance. This segmentation allows each block to contribute its specific properties without compromising the others.
Solution Approach 2:
The invention creates a composite polymer structure combining saturated polyethylene and saturated polypropylene blocks into a single multi-block copolymer. This composite approach integrates the beneficial properties of both polymers: flexibility from polyethylene and stability from polypropylene.
2Manufacturing precision
If metallocene-catalyzed polymers are used to achieve narrow molecular weight distribution, then processability and heat resistance deteriorate
Solution Approach 1:
The patent employs dynamic chain shuttling between two metallocene catalysts during polymerization, allowing the system to adapt and produce a broad molecular weight distribution. This dynamic process enables better processability while maintaining controlled polymer architecture through the shuttling mechanism.
3Manufacturing precision
If metallocene-catalyzed polymers are used to achieve narrow molecular weight distribution, then crystallinity is reduced
Solution Approach 1:
The patent segments the polymer into crystalline polypropylene blocks and amorphous polyethylene blocks. The crystalline blocks maintain high crystallinity and stability, while the amorphous blocks provide flexibility. This segmentation resolves the contradiction between narrow molecular weight distribution and crystallinity.
4Adaptability or versatility
If conventional block copolymers are used to provide flexibility, then UV stability deteriorates
Solution Approach 1:
The patent applies local quality by making specific blocks saturated (polypropylene) to resist UV degradation, while other blocks (polyethylene) remain unsaturated to provide flexibility. Each block has locally optimized properties for its specific function.
Solution Approach 2:
The invention creates a composite structure where saturated polypropylene blocks act as UV-stable components embedded within the flexible polyethylene matrix, providing localized protection against UV degradation while maintaining overall flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting multi-block copolymers exhibit improved light stability, heat resistance, and flexibility, making them suitable for various golf ball layers, including cores, covers, and intermediate layers.
Implementation Method 1
contacting ethylene under addition polymerization conditions with a catalyst composition
Implementation Method 2
At least one of the first or second polymerization catalyst is capable of forming a branched polymer by means of chain walking or reincorporation of in situ formed olefinic polymer chains
Implementation Method 3
The catalyst composition comprises the admixture or reaction product resulting from combining (A) a first olefin polymerization catalyst, (B) a second olefin polymerization catalyst
Implementation Method 4
The catalyst composition comprises the admixture or reaction product resulting from combining (A) a first olefin polymerization catalyst, (B) a second olefin polymerization catalyst capable of preparing polymers differing in chemical or physical properties from the polymer prepared by the first olefin polymerization catalyst under equivalent polymerization conditions, and (C) a chain shuttling agent
Implementation Method 5
Conventional block copolymers, however, contain unsaturated butadiene, and are thus not UV-stable unless the butadiene is hydrogenated to produce a more light stable polymer
Implementation Method 6
a first olefin polymerization catalyst, (B) a second olefin polymerization catalyst capable of preparing polymers differing in chemical or physical properties
Data Source
AI summary
The present invention is directed to golf balls having at least one layer which comprises a polymer produced by a process wherein one or more monomers are contacted with a composition comprising the admixture or reaction product resulting from combining (A) a first olefin polymerization catalyst, (B) a second olefin polymerization catalyst capable of preparing polymers differing in chemical or physical properties from the polymer prepared by the first olefin polymerization catalyst under equivalent polymerization conditions, and (C) a chain shuttling agent. Golf balls of the present invention include one-piece, two-piece, and multi-layer golf balls. In two-piece and multi-layer golf balls of the present invention, the polymer may be present in a core layer, a cover layer, an intermediate layer (in the case of multi-layer balls), or a combination thereof.