Multi-layer golf ball

• US 6,905,423 B2
• Filed: 07/15/2002
• Issued: 06/14/2005
• Est. Priority Date: 02/03/1999
• Status: Expired due to Fees

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Morgan, William E., Sullivan, Michael J., Harris, Kevin M.
• Primary Examiner(s): Vidovich, Gregory
• Assistant Examiner(s): HUNTER, ALVIN A
• Application Number:
  US10/194,291
• Publication Number:
  US 20020187859A1
• Time in Patent Office: 1,065 Days
• Field of Search: 473351-377
• US Class Current: 473/376
• CPC Class Codes: A63B 37/0003 Golf balls
• 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 37/0052 Liquid cores
• CPC Class Codes: A63B 37/0054 Substantially rigid, e.g. metal
• CPC Class Codes: A63B 37/0056 Hollow; Gas-filled
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0076 Multi-piece balls, i.e. having two or more intermediate layers
• CPC Class Codes: A63B 37/0092 Hardness distribution amongst different ball layers

Abstract

The present invention relates to a golf ball that provides improved playing characteristics by providing a cushioning interface between a center and subsequent layers. The ball can include a center, a soft intermediate layer, and a cover, although various constructions and modifications are possible. The intermediate layer can include an elastomeric latex or solution that will dry to form a soft film on the surface of the center. Such a soft rubber interlayer can serve as a cushioning interface to help improve durability and softness of the ball upon club impact. In another embodiment, the thin intermediate layer includes a responsive viscoelastic composition that exhibits an increase in viscosity under shear forces.

Claims

1. A multi-layer golf ball comprising:

a core comprising;

a center;

an intermediate layer formed around the center, the intermediate layer having a thickness of about 0.0008 inches to 0.002 inches and a flexural modulus of less than about 10,000 psi;

a mantle comprising at least one layer, the layer comprising a resilient polymer component, wherein the mantle is disposed concentrically adjacent the intermediate layer; and

at least one cover layer disposed concentrically around the mantle;

wherein the intermediate layer comprises low ammonia natural latex and/or pre-vulcanized natural latex, elastomer adhesives, urethane dispersions, aqueous and non-aqueous adhesives, synthetic latexes, alkyd resins, acrylic and latex copolymers, polyurethane coatings, or mixtures thereof.

2. The ball of claim 1, wherein the intermediate layer has a Shore A hardness less than about 90.

3. The ball of claim 2, wherein the intermediate layer has a Shore A hardness less than about 70.

4. The ball of claim 1, wherein the intermediate layer has a flexural modulus less than about 3,000 psi.

5. The ball of claim 1, wherein the center has an outer diameter of about 0.5 inches to 1.35 inches.

6. The ball of claim 5, wherein the center has an outer diameter of about 0.75 inches to 1.25 inches.

7. The ball of claim 1, wherein a combination of the center, the soft elastic intermediate layer, and the mantle has an outer diameter of about 1.45 inches to 1.6 inches.

8. The ball of claim 7, wherein a combination of the center, the soft elastic intermediate layer, and the mantle has an outer diameter of about 1.5 inches to 1.58 inches.

9. The ball of claim 1, wherein the center is solid, or filled with a liquid, a gel, a foam, or a gas.

10. The ball of claim 1, wherein the mantle layer comprises a reinforcing polymer component.

11. The ball of claim 1, wherein the resilient polymer component of the mantle layer comprises polybutadiene, natural rubber, polyisoprene, styrene-butadiene, or styrene-propylene-diene rubber.

12. The ball of claim 11, wherein the resilient polymer component comprises 1,4-cis-polybutadiene having a molecular weight average of about 50,000 to 1,000,000.

13. The ball of claim 11, wherein the amount of resilient polymer component is between about 60 to 99 weight percent of the total weight of polymer components.

14. The ball of claim 11, further comprising at least one of a filler, a free radical initiator, or a crosslinking agent.

15. The ball of claim 11, wherein the mantle layer has a flexural modulus of greater than about 3.5 MPa.

16. The ball of claim 1, wherein the center is a solid center, wherein the solid center comprises a resilient polymer component.

17. The ball of claim 16, wherein the solid center comprises polybutadiene, natural rubber, polyisoprene, styrene-butadiene, or styrene-propylene-diene rubber.

18. The ball of claim 1, wherein the intermediate layer is comprised of a natural or a synthetic latex material.

19. The ball of claim 1, wherein the intermediate layer is comprised of additives, fillers, thickeners, or a combination thereof.

20. The ball of claim 1, wherein the filler is zinc oxide and is present in an amount of about 0.5 to 20 weight percent.

21. A multi-layer golf ball comprising:

a core comprising;

a center;

an intermediate layer formed around the center, the intermediate layer being less than about 0.01 inches thick and having a Shore A hardness less than about 70 and a flexural modulus of less than about 10,000 psi;

a mantle comprising at least one layer, the layer comprising a resilient polymer component, wherein the mantle is disposed concentrically adjacent the intermediate layer; and

at least one cover layer disposed concentrically around the mantle;

wherein the intermediate layer comprises low ammonia natural latex and/or pre-vulcanized natural latex, elastomer adhesives, urethane dispersions, aqueous and non-aqueous adhesives, synthetic latexes, alkyd resins, acrylic and latex copolymers, polyurethane coatings, or mixtures thereof, and

wherein the resilient polymer component of the mantle layer comprises polybutadiene, natural rubber, polyisoprene, styrene-butadiene, or styrene-propylene-diene rubber.

22. The ball of claim 21, wherein the intermediate layer thickness is about 0.0005 inches to 0.01 inches.

23. The ball of claim 22, wherein the intermediate layer thickness is about 0.0008 inches to 0.002 inches.

24. The ball of claim 21, wherein the intermediate layer has a flexural modulus less than about 3,000 psi.

25. The ball of claim 21, wherein the center has an outer diameter of about 0.5 inches to 1.35 inches.

26. The ball of claim 25, wherein the center has an outer diameter of about 0.75 inches to 1.25 inches.

27. The ball of claim 21, wherein a combination of the center, the soft elastic intermediate layer, and the mantle has an outer diameter of about 1.45 inches to 1.6 inches.

28. The ball of claim 27, wherein a combination of the center, the soft elastic intermediate layer, and the mantle has an outer diameter of about 1.5 inches to 1.58 inches.

29. The ball of claim 21, wherein the center is solid, or filled with a liquid, a gel, a foam, or a gas.

30. The ball of claim 21, wherein the mantle layer comprises a reinforcing polymer component.

31. The ball of claim 21, wherein the center is a solid center, wherein the solid center comprises a resilient polymer component.

32. The ball of claim 31, wherein the solid center comprises polybutadiene, natural rubber, polyisoprene, styrene-butadiene, or styrene-propylene-diene rubber.

33. The ball of claim 21, wherein the resilient polymer component comprises 1,4-cis-polybutadiene having a molecular weight average of about 50,000 to 1,000,000.

34. The ball of claim 21, wherein the amount of resilient polymer component is between about 60 to 99 weight percent of the total weight of polymer components.

35. The ball of claim 21, further comprising at least one of a filler, a free radical initiator, or a crosslinking agent.

36. The ball of claim 21, wherein the mantle layer has a flexural modulus of greater than about 3.5 MPa.

37. The ball of claim 21, wherein the intermediate layer is comprised of a natural or a synthetic latex material.

38. The ball of claim 21, wherein the intermediate layer is comprised of additives, fillers, thickeners, or a combination thereof.

39. The ball of claim 21, wherein the filler is zinc oxide and is present in an amount of about 0.5 to 20 weight percent.