Multi-layer golf ball

• US 6,638,185 B2
• Filed: 11/05/2001
• Issued: 10/28/2003
• Est. Priority Date: 06/01/1993
• Status: Expired due to Fees

• Current Assignee: Callaway Golf Company (Topgolf Callaway Brands Corp.)
• Original Assignee: Top-Flite Golf Company (Topgolf Callaway Brands Corp.)
• Inventors: Tzivanis, Michael J., Kennedy, Thomas J. III, Binette, Mark L., Keller, Viktor, Risen, William M. Jr., Nealon, John L.
• Primary Examiner(s): Graham, Mark S.
• Assistant Examiner(s): Gorden, Raeann
• Application Number:
  US09/992,798
• Publication Number:
  US 20030013557A1
• Time in Patent Office: 722 Days
• Field of Search: 473/370, 473/373, 473/374, 473/367, 473/368, 473/378
• US Class Current: 473/374
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0023 Covers
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0032 Hardness gradient
• CPC Class Codes: A63B 37/0033 Thickness
• CPC Class Codes: A63B 37/0037 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0043 Hardness
• CPC Class Codes: A63B 37/0045 Thickness
• CPC Class Codes: A63B 37/0049 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0075 Three piece balls, i.e. cover, intermediate layer and core
• CPC Class Codes: A63B 37/0078 Coefficient of restitution
• CPC Class Codes: A63B 37/0087 Deflection or compression
• CPC Class Codes: A63B 37/02 Special cores balls with finger holes A63B37/0001, golf ball cores A63B37/005
• CPC Class Codes: A63B 37/06 Elastic 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: C08G 18/42 Polycondensates having carboxylic or carbonic ester groups in the main chain
• CPC Class Codes: C08G 2120/00 Compositions for reaction injection moulding processes
• CPC Class Codes: C08L 101/00 Compositions of unspecified macromolecular compounds
• 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 2666/02 : Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/04 : Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 2666/14 : Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C08L 2666/18 : Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 53/00 : Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 69/00 : Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: C08L 75/04 : Polyurethanes

Abstract

Disclosed herein is a multi-layer golf ball having a soft outer cover. The golf ball has an inner cover layer with a Shore D hardness of 60 or more, and an outer cover with a Shore D hardness of 55 or less, and more preferably 50 or less. In a particularly preferred form of the invention, the outer cover comprises one or more polyurethane materials. The golf ball of the invention has exceptionally soft feel and high spin rates on short shots of 80 yards or less and, particularly, 40 yards or less, while maintaining good distance and average spin on full shots.

Claims

1. A golf ball comprising:

a polybutadiene core;

a thermoplastic inner cover layer disposed about the core, the inner cover layer comprising an ionomer resin, wherein said inner cover layer has a Shore D hardness of at least about 65 as measured on the curved surface thereof; and

an outer cover layer disposed on the inner cover layer, the outer cover layer comprising a polyurethane material having a Shore D hardness of from about 10 to about 55;

wherein the golf ball exhibits a coefficient of restitution of at least 0.790.

2. The golf ball according to claim 1, wherein the outer cover layer comprises a polyurethane having a Shore D hardness of from about 30 to about 55.

3. The golf ball according to claim 1, wherein the outer cover layer has a thickness of 0.030 to 0.060 inches.

4. The golf ball according to claim 3, wherein the outer cover layer has a thickness of about 0.030 inches.

5. The golf ball according to claim 1, wherein the outer cover layer comprises a castable polyurethane material.

6. The golf ball according to claim 1, wherein the outer cover layer comprises a polyurethane having a flex modulus of from about 1,000 to about 310,000 psi.

7. The golf ball according to claim 6, wherein the polyurethane has a flex modulus of from about 5 to about 100 kpsi.

8. The golf ball according to claim 7, wherein the polyurethane has a flex modulus of from about 5 to about 20 kpsi.

9. The golf ball according to claim 1, wherein the golf ball exhibits a PGA compression of 90 or less.

10. The golf ball according to claim 1, wherein the golf ball exhibits a coefficient of restitution of at least 0.800.

11. A golf ball comprising:

a core;

an inner cover layer disposed on the core, the inner cover layer having a Shore D hardness of at least 65 as measured on the curved outer surface thereof, and including at least one high acid ionomer resin comprising greater than 16% by weight of an alpha, beta-unsaturated carboxylic acid;

an outer cover layer disposed about the inner cover layer, the outer cover layer comprising a polyurethane material;

wherein the golf ball exhibits a PGA compression of 90 or less, and a coefficient of restitution of at least 0.780.

12. The golf ball according to claim 12, wherein the outer cover layer has a thickness of about 0.030 to about 0.070 inches.

13. The golf ball according to claim 12, wherein the outer cover layer has a thickness of about 0.030 inches to about 0.060 inches.

14. The golf ball according to claim 13, wherein the outer cover layer has a thickness of about 0.030 inches.

15. The golf ball according to claim 12, wherein the ball exhibits a PGA compression of 80 or less.

16. The golf ball according to claim 12, wherein the outer cover layer comprises a castable polyurethane material.

17. The golf ball according to claim 12, wherein the golf ball exhibits a coefficient of restitution of at least 0.800.