Polyurea Golf Ball Cover Two-Step Prepolymer Process

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional prepolymer manufacturing processes for polyurea and polyurethane compositions face challenges such as high concentrations of free isocyanate, compatibility issues with different isocyanate and polyamine compounds, and health and safety risks, particularly with compounds like toluene diisocyanate, which hinder the use of various isocyanate blends and result in environmental and health concerns.

Innovation Solution

A novel method involving the formation of amine-terminated and isocyanate-terminated prepolymers through a two-step process, where isocyanate compound 'A' is reacted with a stoichiometric excess of polyamine to form an amine-terminated prepolymer, which is then reacted with isocyanate compound 'B' to create an isocyanate-terminated prepolymer, followed by chain extension with amine-terminated curing agents, allowing for the use of different isocyanate compounds and improving reaction control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional prepolymer manufacturing processes are used, then polyurea compositions can be produced, but high concentrations of free isocyanate are generated causing health and safety risks

Engineering Contradiction:

Improvepolyurea composition productionVSAvoidfree isocyanate concentration

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The manufacturing process is divided into two separate steps: first forming an amine-terminated prepolymer by reacting isocyanate with polyamine, then reacting this intermediate with additional isocyanate to form the final polyurea. This segmentation allows better control of isocyanate exposure and reduces free isocyanate concentration in the final product.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The amine-terminated prepolymer is formed as an intermediate step before the final polyurea composition is completed. This preliminary action allows the system to control the timing and amount of isocyanate introduction, minimizing harmful free isocyanate concentrations while still achieving the desired final composition.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If different isocyanate and polyamine compounds are used, then composition versatility is improved, but compatibility issues arise between compounds

Engineering Contradiction:

Improveisocyanate blend varietyVSAvoidcompound compatibility

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The amine-terminated prepolymer acts as an intermediary that bridges different isocyanate and polyamine compounds. By forming this stable intermediate first, the system can then introduce additional isocyanates with better control over compatibility, reducing the direct interaction problems between diverse compounds.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The two-step process changes the reaction parameters and intermediate states, allowing different isocyanate and polyamine compounds to be used in a controlled sequence. This parameter control improves compatibility by managing the reactivity and interaction conditions between different chemical compounds.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If stoichiometric excess of polyamine is used in the first step, then amine-terminated prepolymer formation is improved, but reaction control becomes more complex

Engineering Contradiction:

Improveprepolymer formationVSAvoidreaction control

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The reaction is segmented into two controlled steps with distinct stoichiometric ratios. The first step uses excess polyamine to ensure complete isocyanate consumption and form amine-terminated prepolymer. The second step then controls the remaining reaction. This segmentation simplifies the control complexity by breaking it into two manageable stages with different optimization goals.

Inventive Principle:

Principle #1Segmentation

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

This method enables the production of polyurea polymer compositions with enhanced properties like high tensile strength, flex modulus, impact durability, and cut/tear-resistance, while minimizing free isocyanate production and improving safety by allowing the use of diverse isocyanate blends, thus providing a more homogeneous and consistent final polymer composition.

Implementation Method 1

Polyurea compositions contain urea linkages formed by reacting an isocyanate group (—N═C═O) with an amine group (—NH or —NH2)

Methodology Applied

Scientific EffectUrea linkage formation: Chemical Bonding

Implementation Method 2

The chain length of the polyurea prepolymer is extended by reacting the prepolymer with an amine chain extender (curative)

Methodology Applied

Scientific EffectChain extension reaction: Chemical Bonding

Data Source

PatentUS9211444B2Methods for making polyurea polymer and golf balls prepared therefrom

Publication Date: 2015.12.15 ACUSHNET CO

AI summary

Methods for making golf balls having a cover made from a polyurea composition are provided. The golf balls include a rubber core and intermediate layer made from an olefin-based ionomer composition. The methods for making the polyurea composition involve preparing an amine-terminated first polymer by reacting isocyanate compound A with a stoichiometric excess of polyamine. The first prepolymer is reacted with a stoichiometric excess of isocyanate compound B to form an isocyanate-terminated second prepolymer. The second prepolymer is then reacted with a chain extender.