Multi-layer golf ball with a foamed intermediate layer

• US 6,995,191 B2
• Filed: 05/19/2003
• Issued: 02/07/2006
• Est. Priority Date: 05/19/2003
• Status: Expired due to Term

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Cavallaro, Christopher, Sullivan, Michael J, Ladd, Derek A
• Primary Examiner(s): Buttner, David J.
• Application Number:
  US10/440,984
• Publication Number:
  US 20040234775A1
• Time in Patent Office: 995 Days
• Field of Search: 524/322, 524/394, 524/397, 524/398, 524/399, 524/400, 473/355, 473/373, 473/374, 473/376, 521/134
• US Class Current: 521/134
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0039 characterised by the material
• CPC Class Codes: A63B 37/0046 Deflection or compression
• CPC Class Codes: A63B 37/0047 Density; Specific gravity
• CPC Class Codes: A63B 37/0062 Hardness
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0065 Deflection or compression
• CPC Class Codes: A63B 37/0066 Density; Specific gravity
• CPC Class Codes: A63B 37/0076 Multi-piece balls, i.e. having two or more intermediate layers
• CPC Class Codes: A63B 37/0078 Coefficient of restitution
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2038/0084 Foaming
• CPC Class Codes: B32B 2307/536 Hardness
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 7/022 Mechanical properties
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

A golf ball with relatively rigid inner core and soft intermediate layer is disclosed. The rigid inner core maintains the balls'"'"' high coefficient of restitution at high impact speeds, while the soft intermediate layer provides better feel for greenside play. The intermediate layer can be made from a highly neutralized polymer, which can be thermoset or thermoplastic. The highly neutralized polymer is foamed or otherwise has its specific gravity reduced. The intermediate layer can also be made from a castable reactive liquid polymer.

Claims

1. A golf ball comprising a core, an intermediate layer and a cover layer, wherein the intermediate layer comprises a highly neutralized thermoplastic polymer which has its specific gravity reduced to less than 1.05, is neutralized by at least about 80%, and comprises a foamed composition formed from a saponified polymer blended with a metallocene catalyzed polymer, and wherein the core has a compression in the range of between about 40 PGA and about 120 PGA, and wherein the compression of the core is higher than the compression of the core and the encasing intermediate layer.

2. A golf ball comprising a core, an intermediate layer and a cover layer, wherein the intermediate layer comprises a highly neutralized thermoplastic polymer, wherein the highly neutralized thermoplastic polymer has its specific gravity reduced to less than 1.05, and wherein the core has a compression in the range of between about 40 PGA and about 120 PGA and the compression of the core is higher than the compression of the core and the encasing intermediate layer, wherein the highly neutralized polymer comprises a foamed composition formed from a saponified polymer.

3. A golf ball comprising a core, an intermediate layer and a cover layer, wherein the intermediate layer comprises a highly neutralized thermoplastic polymer which has its specific gravity reduced to less than 1.05 and comprises a foamed composition formed from a saponified polymer blended with a metallocene catalyzed polymer, and wherein the core has a compression in the range of between about 40 PGA and about 120 PGA, and wherein the compression of the core is higher than the compression of the core and the encasing intermediate layer.