Multi-layer golf ball

• US 6,824,476 B2
• Filed: 04/25/2001
• Issued: 11/30/2004
• Est. Priority Date: 06/01/1993
• Status: Expired due to Fees

• Current Assignee: Callaway Golf Company (Topgolf Callaway Brands Corp.)
• Original Assignee: Callaway Golf Company (Topgolf Callaway Brands Corp.)
• Inventors: Keller, Viktor, Tzivanis, Michael John, Sullivan, Michael J., Kennedy, Thomas J. III, Binette, Mark L., Risen, William M. Jr.
• Primary Examiner(s): TRIMIEW, RAEANN
• Application Number:
  US09/842,607
• Publication Number:
  US 20020025862A1
• Time in Patent Office: 1,315 Days
• Field of Search: 473/377, 473/376, 473/378, 473/373, 473/374, 473/371, 473/367, 473/368
• US Class Current: 473/374
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0033 Thickness
• CPC Class Codes: A63B 37/0065 Deflection or compression
• CPC Class Codes: A63B 37/0075 Three piece balls, i.e. cover, intermediate layer and core
• CPC Class Codes: A63B 37/0076 Multi-piece balls, i.e. having two or more intermediate layers
• CPC Class Codes: A63B 37/02 Special cores balls with finger holes A63B37/0001, golf ball cores A63B37/005
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• 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 2666/18 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

A unique set of preferred embodiment golf balls is disclosed as follows. In one aspect, a multi-layer golf ball utilizes a particular blend of ionomers in either or both of the cover layers. Preferably, the blend includes a minor percentage of high acid ionomers with a major percentage of low acid ionomers. In another embodiment, golf balls having relatively thin multi-layer cover assemblies are provided. The thicknesses of these cover layer assemblies range from about 0.015 inches to about 0.045 inches. Also, cover assemblies utilizing one or more thermoplastic polyurethanes are disclosed. The multi-layer core assembly used in the golf balls preferably exhibits a PGA compression of less than 85.

Claims

1. A golf ball comprising:

a multi-layer core assembly including (i) a center core component, and (ii) a solid core layer disposed about said center core component; and

a multi-layer cover assembly including (i) an inner cover layer disposed on said core layer, and (ii) an outer cover layer disposed on said inner cover layer, said outer cover layer defining a plurality of dimples along an outer surface of said outer cover layer,

wherein at least one of said inner cover layer and said outer cover layer comprise a blend of less than 50% of a high acid ionomer and greater than 50% of a low acid ionomer.

2. The golf ball of claim 1 wherein said blend comprises 10% to 40% of said high acid ionomer and 60% to 90% low acid ionomer.

3. The golf ball of claim 2 wherein said blend comprises 20% to 35% of said high acid ionomer and 65% to 80% low acid ionomer.

4. The golf ball of claim 1 wherein said multi-layer cover assembly has a thickness of from 0.015 inches to about 0.045 inches.

5. The golf ball of claim 4 wherein said multi-layer cover assembly has a thickness of from 0.025 inches to about 0.035 inches.

6. The golf ball of claim 5 wherein said multi-layer cover assembly has a thickness of from about 0.030 inches to about 0.035 inches.

7. The golf ball of claim 1 wherein said outer cover layer has a thickness of from about 0.005 inches to about 0.030 inches.

8. The golf ball of claim 7 wherein said outer cover layer has a thickness of from about 0.010 inches to about 0.020 inches.

9. The golf ball of claim 1 wherein said inner cover layer has a thickness of from about 0.005 inches to about 0.030 inches.

10. The golf ball of claim 9 wherein said inner cover layer has a thickness of from about 0.010 inches to about 0.020 inches.

11. A golf ball comprising:

a multi-layer core assembly including (i) a center core component, and (ii) a solid core layer disposed about said center core component; and

a multi-layer cover assembly including (i) an inner cover layer disposed on said core layer, and (ii) an outer cover layer disposed on said inner cover layer,

wherein at least one of said inner cover layer and said outer cover layer comprises a thermoplastic polyurethane,

wherein at least one of said inner cover layer and said outer cover layer includes an ionomer blend that comprises 10% to 40% of a high acid ionomer and 60% to 90% of a low acid ionomer.

12. The golf ball of claim 11 wherein said blend comprises 20% to 35% of said high acid ionomer and 65% to 80% low acid ionomer.

13. The golf ball of claim 11 wherein said multi-layer cover assembly has a thickness of from 0.015 inches to about 0.045 inches.

14. The golf ball of claim 13 wherein said multi-layer cover assembly has a thickness of from 0.025 inches to about 0.035 inches.

15. The golf ball of claim 14 wherein said multi-layer cover assembly has a thickness of from about 0.030 inches to about 0.035 inches.

16. The golf ball of claim 11 wherein said outer cover layer has a thickness of from about 0.005 inches to about 0.030 inches.

17. The golf ball of claim 16 wherein said outer cover layer has a thickness of from about 0.010 inches to about 0.020 inches.

18. The golf ball of claim 11 wherein said inner cover layer has a thickness of from about 0.005 inches to about 0.030 inches.

19. The golf ball of claim 18 wherein said inner cover layer has a thickness of from about 0.010 inches to about 0.020 inches.

20. The golf ball of claim 11 wherein said polyurethane is a reaction product of an ethylene acrylic or methylene acrylic acid ionomer and an isocyanate prepolymer.

21. The golf ball of claim 20 wherein said ionomer is neutralized with a member selected from the group consisting of magnesium, zinc, lithium, sodium, and combinations thereof.

22. The golf ball of claim 11 wherein said polyurethane is a reaction product of an ethylene acrylic or methylene acrylic acid ionomer, an isocyanate prepolymer, and an acrylate.

23. The golf ball of claim 22 wherein said ionomer is neutralized with a member selected from the group consisting of magnesium, zinc, lithium, sodium, and combinations thereof.

24. A golf ball comprising:

a multi-layer core assembly including (i) a center core component, and (ii) a solid core layer disposed about said center core component; and

a multi-layer cover assembly formed about said multi-layer core assembly, said multi-layer cover assembly comprising (i) an inner cover layer disposed on said core layer, and (ii) an outer cover layer disposed on said inner cover layer,

wherein said multi-layer core assembly exhibits a PGA compression of less than,

wherein at least one of said inner cover layer and said outer cover layer includes an ionomer blend that comprises 10% to 40% of a high acid ionomer and 60% to 90% of a low acid ionomer.

25. The golf ball of claim 24 wherein said multi-layer core assembly exhibits a PGA compression of less than 80.

26. The golf ball of claim 24 wherein said blend comprises 20% to 35% of said high acid ionomer and 65% to 80% low acid ionomer.

27. The golf ball of claim 24 wherein said multi-layer cover assembly has a thickness of from 0.015 inches to about 0.045 inches.

28. The golf ball of claim 27 wherein said multi-layer cover assembly has a thickness of from 0.025 inches to about 0.035 inches.

29. The golf ball of claim 28 wherein said multi-layer cover assembly has a thickness of from about 0.030 inches to about 0.035 inches.

30. The golf ball of claim 24 wherein said outer cover layer has a thickness of from about 0.005 inches to about 0.030 inches.

31. The golf ball of claim 30 wherein said outer cover layer has a thickness of from about 0.010 inches to about 0.020 inches.

32. The golf ball of claim 24 wherein said inner cover layer has a thickness of from about 0.005 inches to about 0.030 inches.

33. The golf ball of claim 32 wherein said inner cover layer has a thickness of from about 0.010 inches to about 0.020 inches.

34. The golf ball of claim 24 wherein said multi-layer cover assembly includes a polyurethane which is a reaction product of an ethylene acrylic or methylene acrylic acid ionomer and an isocyanate prepolymer.

35. The golf ball of claim 34 wherein said ionomer is neutralized with a member selected from the group consisting-of magnesium, zinc, lithium, sodium, and combinations thereof.

36. The golf ball of claim 24 wherein said multi-layer cover assembly includes a polyurethane which is a reaction product of an ethylene acrylic or methylene acrylic acid ionomer, an isocyanate prepolymer, and an acrylate.

37. The golf ball of claim 36 wherein said ionomer is neutralized with a member selected from the group consisting of magnesium, zinc, lithium, sodium, and combinations thereof.