Methods of making low spin golf ball utilizing a mantle and a cellular or liquid core

• US 6,561,927 B1
• Filed: 11/09/2000
• Issued: 05/13/2003
• Est. Priority Date: 04/28/1993
• Status: Expired due to Fees

• Current Assignee: Callaway Golf Company (Topgolf Callaway Brands Corp.)
• Original Assignee: Spalding Sports Worldwide, Inc. (Berkshire Hathaway Incorporated)
• Inventors: Sullivan, Michael J., Nesbitt, R. Dennis
• Primary Examiner(s): Graham, Mark S.
• Assistant Examiner(s): Gorden, Raeann
• Application Number:
  US09/709,988
• Time in Patent Office: 915 Days
• Field of Search: 473/409, 473/354, 473/373, 473/374, 473/367, 473/368, 473/370, 473/371, 473/372, 473/375, 473/376
• US Class Current: 473/373
• CPC Class Codes: A63B 2037/085 liquid, jellylike
• CPC Class Codes: A63B 2209/08 magnetic
• CPC Class Codes: A63B 37/00 Solid balls; Rigid hollow balls; Marbles heavy throwing balls A63B65/06
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0024 Materials other than ionomers or polyurethane
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0033 Thickness
• CPC Class Codes: A63B 37/0045 Thickness
• CPC Class Codes: A63B 37/0054 Substantially rigid, e.g. metal
• CPC Class Codes: A63B 37/0065 Deflection or compression
• CPC Class Codes: A63B 37/0076 Multi-piece balls, i.e. having two or more intermediate layers
• CPC Class Codes: A63B 37/008 Diameter
• CPC Class Codes: A63B 37/08 Liquid cores; Plastic cores
• CPC Class Codes: A63B 37/12 Special coverings , i.e. outer layer material balls with finger holes A63B37/0001, golf ball covers A63B37/0023
• CPC Class Codes: A63B 43/00 Balls with special arrangements
• CPC Class Codes: A63B 45/00 Apparatus or methods for manufacturing balls working of plastics or substances in a plastic state B29
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 23/025 Copolymer of an unspecified olefin with a monomer other than an olefin
• CPC Class Codes: C08L 23/08 Copolymers of ethene C08L23/16 takes precedence
• CPC Class Codes: C08L 23/0876 Neutralised polymers, i.e. ionomers
• CPC Class Codes: C08L 2666/04 : Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof

Abstract

The present invention is directed to a golf ball comprising a soft core and a hard cover to produce a resulting molded golf ball having a reduced spin rate. The golf ball comprises one or more metal mantle layers and a cellular or liquid core component. The golf ball may also comprise an optional polymeric spherical substrate inwardly disposed relative to the one or more metal mantle layers. The golf ball of the present invention may also utilize an enlarged diameter which serves to further reduce spin rate. The resulting golf ball exhibits properties of reduced spin without sacrificing durability, playability and resilience.

Claims

1. A method for forming a golf ball having a core that includes a cellular center component about which is disposed a metal mantle layer, said method comprising:

providing a spherical cellular center component;

forming a layer of a polymeric material about said cellular center component;

forming a metal mantle layer on said layer of polymeric material to form a core, wherein said metal mantle layer is formed about said polymeric component by an operation selected from the group consisting of electroplating, thermal spray coating, chemical vapor deposition, vacuum coating, sputtering, and ion plating; and

forming a polymeric cover layer on said metal mantle layer to thereby form said golf ball.

2. The method of claim 1 wherein said metal mantle layer is formed on said polymeric layer by electroplating.

3. The method of claim 1 wherein said metal mantle layer is formed on said polymeric layer by a thermal spray coating technique.

4. The method of claim 1 wherein said metal mantle layer is formed on said polymeric layer by chemical vapor deposition.

5. The method of claim 1 wherein said metal mantle layer is formed on said polymeric layer by vacuum coating.

6. The method of claim 1 wherein said metal mantle layer is formed on said polymeric layer by sputtering.

7. The method of claim 1 wherein said metal mantle layer is formed on said polymeric layer by ion plating.

8. The method of claim 1 wherein said polymeric cover layer is formed on said mantle layer by an injection molding operation.

9. The method of claim 1 wherein said polymeric cover layer is formed on said mantle layer by a compression molding operation.

10. A method of forming a golf ball having a core comprising a cellular center component, a polymeric intermediate layer, and a metal mantle layer, said method comprising:

providing a hollow, spherical polymeric component defining an interior cavity;

introducing a flowable cellular material or cellular core material precursor into the interior cavity of said polymeric component;

forming a metal mantle layer about said polymeric component, wherein said metal mantle layer is formed about said polymeric component by an operation selected from the group consisting of electroplating, thermal spray coating, chemical vapor deposition, vacuum coating, sputtering, and ion plating;

forming a polymeric cover layer about said mantle to thereby form said golf ball.

11. The method of claim 10 wherein said introducing step is performed by injecting a cellular core material precursor and a blowing agent into the interior cavity of said polymeric component and foaming said material in the interior cavity of said polymeric component.

12. The method of claim 10 wherein said polymeric cover layer is formed about said metal mantle layer by injection molding.

13. The method of claim 10 wherein said polymeric cover layer is formed about said metal mantle layer by compression molding.

14. A method of forming a golf ball having a liquid core, said method comprising:

providing a hollow, spherical polymeric component defining an interior cavity;

introducing a liquid into the interior cavity of said polymeric component;

forming a metal mantle layer about said polymeric component, wherein said metal mantle layer is formed about said polymeric component by a technique selected from the group consisting of electroplating, thermal spray coating, chemical vapor deposition, vacuum coating, sputtering, and ion plating; and

forming a polymeric cover layer about said mantle to thereby form said golf ball.

15. The method of claim 14 wherein said liquid is selected from the group consisting of water, alcohol, oil, and combinations thereof.

16. The method of claim 14 wherein said polymeric cover is formed about said metal mantle layer by injection molding.

17. The method of claim 14 wherein said polymeric cover is formed about said metal mantle layer by compression molding.