Abstract: A cured elastomer golf ball component is made by heating an elastomer compound containing an ethylenically unsaturated elastomer, an ethylenically unsaturated monomer, and first and second free radical initiators to a first crosslinking temperature T1 in a compression mold and partially crosslinking the elastomer, then heating to a second crosslinking temperature T2 and curing the elastomer component of the golf ball. Either: (i) the first initiator has a half-life of about 0.2-5 minutes at T1, the second initiator has a half-life of about 0.2-5 minutes at T2, and T2 is higher T1 by at least about 30° C.; or (ii) the second initiator's one-minute half-life temperature is at least about 30° C. higher than the first initiator's one-minute half-life temperature, T1 is within about 20° C. of the first initiator's one-minute half-life temperature, and T2 is within about 20° C. of the second initiator's one-minute half-life temperature.

Abstract: A cured elastomer golf ball component is made by heating an elastomer compound containing an ethylenically unsaturated elastomer, an ethylenically unsaturated monomer, and first and second free radical initiators to a first crosslinking temperature T1 in a compression mold and partially crosslinking the elastomer, then heating to a second crosslinking temperature T2 and curing the elastomer component of the golf ball. Either: (i) the first initiator has a half-life of about 0.2-5 minutes at T1, the second initiator has a half-life of about 0.2-5 minutes at T2, and T2 is higher T1 by at least about 30° C.; or (ii) the second initiator's one-minute half-life temperature is at least about 30° C. higher than the first initiator's one-minute half-life temperature, T1 is within about 20° C. of the first initiator's one-minute half-life temperature, and T2 is within about 20° C. of the second initiator's one-minute half-life temperature.

Abstract: A method for making a thermoplastic material includes: (a) partially crosslinking an elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked elastomer composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (c) continuously mixing the mixture while further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of crosslinked elastomer composition in the thermoplastic polymer composition. The elastomer composition may include an elastomer compounded with a curing agent and optionally additional components.

Abstract: A method for making a thermoplastic material includes: (a) partially crosslinking an elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked elastomer composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (c) continuously mixing the mixture while further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of crosslinked elastomer composition in the thermoplastic polymer composition. The elastomer composition may include an elastomer compounded with a curing agent and optionally additional components.

Abstract: A golf ball comprises a dynamically crosslinked thermoplastic material prepared by a method including: (a) partially crosslinking a rubber composition of a rubber polymer and two free radical initiators at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked rubber composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature and at which the thermoplastic polymer composition is liquid; and (c) continuously mixing the mixture while further crosslinking the rubber composition to form a thermoplastic material having a dispersed phase of crosslinked rubber composition in the thermoplastic polymer composition.

Abstract: A cured elastomer golf ball component is made by heating an elastomer compound containing an ethylenically unsaturated elastomer, an ethylenically unsaturated monomer, and first and second free radical initiators to a first crosslinking temperature T1 in a compression mold and partially crosslinking the elastomer, then heating to a second crosslinking temperature T2 and curing the elastomer component of the golf ball. Either: (i) the first initiator has a half-life of about 0.2-5 minutes at T1, the second initiator has a half-life of about 0.2-5 minutes at T2, and T2 is higher T1 by at least about 30° C.; or (ii) the second initiator's one-minute half-life temperature is at least about 30° C. higher than the first initiator's one-minute half-life temperature, T1 is within about 20° C. of the first initiator's one-minute half-life temperature, and T2 is within about 20° C. of the second initiator's one-minute half-life temperature.

Abstract: A golf ball includes a core, one or more inlaid portions formed into the core, and a second layer disposed radially outward of both the core and the one or more inlaid portions. The core and the one or more inlaid portions cooperate to define a continuous spherical surface, and the core and the second layer cooperate to surround each of the one or more inlaid portions. The one or more inlaid portions are formed by over-molding the core, and then removing the over-molded material back to at least the outer surface of the core.

Abstract: A method for making a thermoplastic material includes: (a) partially crosslinking an elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked elastomer composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (c) continuously mixing the mixture while further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of crosslinked elastomer composition in the thermoplastic polymer composition. The elastomer composition may include an elastomer compounded with a curing agent and optionally additional components.

Abstract: A method of forming a golf ball includes forming a pair of thermoplastic hemispherical shells from an elastomer compound including an elastomer and first, second, and third free radical initiators, with the elastomer being pre-crosslinked to a first crosslinking density, then positioning a spherical component between the hemispherical shells and compression molding and curing the hemispherical shells to a second crosslinking density around the spherical component. The method uses three different crosslinking temperatures.

Abstract: A method for making a thermoplastic material includes: (a) partially crosslinking an elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked elastomer composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (c) continuously mixing the mixture while further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of crosslinked elastomer composition in the thermoplastic polymer composition. The elastomer composition may include an elastomer compounded with a curing agent and optionally additional components.

Abstract: Scuff-resistant golf ball covers and methods of manufacturing golf balls are described. The cover is made of a thermoplastic polymeric portion including at least one first, high molecular weight copolymer of ethylene/5-12 percent by weight acrylic or methacrylic acid or both/5-40 percent by weight alkyl acrylate or methacrylate or both; optionally at least one second, low molecular weight copolymer of ethylene/3-25 percent by weight acrylic or methacrylic acid or both; and a high molecular weight dipolymer of ethylene/acrylic acid that has a molar fraction of the acrylic acid monomer units within ±about 10% of a molar fraction of the ?,?-ethylenically unsaturated carboxylic acid monomer units of the at least one first copolymer. The acid groups of all acid monomer units are neutralized 30% to about 75% on a molar basis by magnesium cations, calcium cations, zinc cations, or a combination of these cations.

Abstract: A method for making a thermoplastic material includes: (a) introducing into an extruder an elastomer composition including an ethylenically unsaturated elastomer polymer, a first free radical initiator, and a second free radical initiator; (b) in a first zone of the extruder, heating and partially crosslinking the elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (c) introducing into the extruder in a second zone downstream of the first zone a thermoplastic polymer composition; (d) mixing and heating the thermoplastic polymer composition and the thermoplastic, partially crosslinked elastomer composition to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (e) mixing and further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of the crosslinked elastomer c

Abstract: A method for making a thermoplastic material includes: (a) partially crosslinking an elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked elastomer composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (c) continuously mixing the mixture while further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of crosslinked elastomer composition in the thermoplastic polymer composition. The elastomer composition may include an elastomer compounded with a curing agent and optionally additional components.

Abstract: A method for making a thermoplastic material includes: (a) introducing into an extruder an elastomer composition including an ethylenically unsaturated elastomer polymer, a first free radical initiator, and a second free radical initiator; (b) in a first zone of the extruder, heating and partially crosslinking the elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (c) introducing into the extruder in a second zone downstream of the first zone a thermoplastic polymer composition; (d) mixing and heating the thermoplastic polymer composition and the thermoplastic, partially crosslinked elastomer composition to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (e) mixing and further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of the crosslinked elastomer c

Abstract: A golf ball comprises a dynamically crosslinked thermoplastic material prepared by a method including: (a) partially crosslinking a rubber composition of a rubber polymer and two free radical initiators at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked rubber composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature and at which the thermoplastic polymer composition is liquid; and (c) continuously mixing the mixture while further crosslinking the rubber composition to form a thermoplastic material having a dispersed phase of crosslinked rubber composition in the thermoplastic polymer composition.

Abstract: A method for making a thermoplastic material includes: (a) partially crosslinking an elastomer composition at a first crosslinking temperature to form a thermoplastic, partially crosslinked elastomer composition; (b) mixing a thermoplastic polymer composition with the thermoplastic, partially crosslinked elastomer composition and heating the mixture to a second crosslinking temperature higher than the first crosslinking temperature, wherein the thermoplastic polymer composition is liquid at the second crosslinking temperature; and (c) continuously mixing the mixture while further crosslinking the elastomer composition to form a thermoplastic material having a dispersed phase of crosslinked elastomer composition in the thermoplastic polymer composition. The elastomer composition may include an elastomer compounded with a curing agent and optionally additional components.

Abstract: A cured elastomer golf ball component is made by heating an elastomer compound containing an ethylenically unsaturated elastomer, an ethylenically unsaturated monomer, and first and second free radical initiators to a first crosslinking temperature T1 in a compression mold and partially crosslinking the elastomer, then heating to a second crosslinking temperature T2 and curing the elastomer component of the golf ball. Either: (i) the first initiator has a half-life of about 0.2-5 minutes at T1, the second initiator has a half-life of about 0.2-5 minutes at T2, and T2 is higher T1 by at least about 30° C.; or (ii) the second initiator's one-minute half-life temperature is at least about 30° C. higher than the first initiator's one-minute half-life temperature, T1 is within about 20° C. of the first initiator's one-minute half-life temperature, and T2 is within about 20° C. of the second initiator's one-minute half-life temperature.

Abstract: A cured elastomer is formed by partially crosslinking an elastomer compound containing first and second free radical initiators at a first crosslinking temperature T1, then further crosslinking at a second crosslinking temperature T2. Either: (i) the first free radical initiator's half-life is about 0.2-5 minutes at T1, the second free radical initiator's half-life is about 0.2-5 minutes at T2, and T2 is higher than T1 by at least about 30° C.; or (ii) the second free radical initiator's one-minute half-life temperature is higher than the first free radical initiator's one-minute half-life temperature by at least about 30° C., T1 is within about 20° C. of the first one-minute half-life temperature, and T2 is within about 20° C. of the second one-minute half-life temperature.

Abstract: A method of forming a golf ball includes forming a pair of thermoplastic hemispherical shells from an elastomer compound including an elastomer and first, second, and third free radical initiators, with the elastomer being pre-crosslinked to a first crosslinking density, then positioning a spherical component between the hemispherical shells and compression molding and curing the hemispherical shells to a second crosslinking density around the spherical component. The method uses three different crosslinking temperatures.

Abstract: Novel methods and kits for creating defects in composite materials, as well as an engineered part or structure with one or more designed defects, are disclosed. The disclosed inventions advantageously permit the intentional introduction of one or multiple defects of any desired size and shape, either between the same two chosen laminae or on different layers within a multi-layer composite, having mechanical and thermal properties that are akin to those found for actual defects. One disclosed method involves creating a mask having a cut-out in the size and shape of a desired defect, placing the mask at a location on a first substrate where the defect is desired, applying a release agent, removing the mask, and adding a second substrate over the first substrate with release agent. The first substrate may be a cured lamina or an uncured lamina pre-impregnated with resin having a barricade in the size and shape of the outline of the desired defect.