Golf balls having at least two core layers formed from HNP compositions

• US 7,731,607 B2
• Filed: 05/22/2008
• Issued: 06/08/2010
• Est. Priority Date: 12/15/2005
• Status: Active Grant

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Jones, Douglas E., Sullivan, Michael J., Hebert, Edmund A., Ladd, Derek A.
• Primary Examiner(s): Trimiew; Raeann
• Application Number:
  US12/125,306
• Publication Number:
  US 20080220904A1
• Time in Patent Office: 747 Days
• Field of Search: 473/373, 473/376, 473/374
• US Class Current: 473/376
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0043 Hardness
• CPC Class Codes: A63B 37/0049 Flexural modulus; Bending stiffness
• CPC Class Codes: A63B 37/0051 Materials other than polybutadienes; Constructional details
• CPC Class Codes: A63B 37/00621 Centre hardness
• CPC Class Codes: A63B 37/00622 Surface hardness
• CPC Class Codes: A63B 37/0063 Hardness gradient
• CPC Class Codes: A63B 37/0064 Diameter
• CPC Class Codes: A63B 37/0072 with a specified number of layers
• 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 37/008 Diameter
• CPC Class Codes: A63B 37/0092 Hardness distribution amongst different ball layers
• CPC Class Codes: A63B 37/02 Special cores balls with finger holes A63B37/0001, golf ball cores A63B37/005
• CPC Class Codes: C08L 23/0876 Neutralised polymers, i.e. ionomers

Abstract

The present invention is directed to golf balls consisting of a multi-layer core and a cover. The multi-layer core consists of a center and an outer core layer that are both soft relative to a hard intermediate core layer. The outer core layer is preferably thin relative to the center and the outer core layer. The multi-layer core includes at least one layer formed from a relatively soft HNP composition and at least one layer formed from a relatively hard HNP composition.

Claims

1. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of:

(a) a center having a diameter of from 0.50 inches to 1.50 inches and a center hardness (H) of from 20 Shore C to 70 Shore C;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater and formed from a first HNP composition, the first HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C and formed from a second HNP composition, the second HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

wherein H<

I and S<

I;

wherein the material hardness of the second HNP composition is less than the material hardness of the first HNP composition; and

wherein H<

S, and wherein S−

H=D, where D is an integer from 1 to 22.

2. The golf ball of claim 1, wherein the center has a diameter of from 0.750 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a

thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

3. The golf ball of claim 2, wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.

4. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of:

(a) a center having a diameter of from 0.50 inches to 1.50 inches and a center hardness (H) of from 20 Shore C to 70 Shore C;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater and formed from a first HNP composition, the first HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C and formed from a second HNP composition, the second HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

wherein H<

I, and S<

I;

wherein the material hardness of the second HNP composition is less than the material hardness of the first HNP composition; and

wherein S<

H, and wherein H−

S=D, where D is an integer from 1 to 22.

5. The golf ball of claim 4, wherein the center has a diameter of from 0.750 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

6. The golf ball of claim 5, wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.

7. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of:

(a) a center having a diameter of from 0.50 inches to 1.50 inches, a center hardness (H) of from 20 Shore C to 70 Shore C, and formed from a first HNP composition, the first HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater and formed from a second HNP composition, the second HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C;

wherein H<

I and S<

I;

wherein the material hardness of the first HNP composition is less than the material hardness of the second HNP composition; and

wherein H<

S, and wherein S−

H=D, where D is an integer from 1 to 22.

8. The golf ball of claim 7, wherein the center has a diameter of from 0.750 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

9. The golf ball of claim 8, wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.

10. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of:

(a) a center having a diameter of from 0.50 inches to 1.50 inches, a center hardness (H) of from 20 Shore C to 70 Shore C, and formed from a first HNP composition, the first HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater and formed from a second HNP composition, the second HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C;

wherein H<

I and S<

I;

wherein the material hardness of the first HNP composition is less than the material hardness of the second HNP composition; and

wherein S<

H, and wherein H−

S=D, where D is an integer from 1 to 22.

11. The golf ball of claim 10, wherein the center has a diameter of from 0.750 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

12. The golf ball of claim 11, wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.

13. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of:

(a) a center having a diameter of from 0.50 inches to 1.50 inches, a center hardness (H) of from 20 Shore C to 70 Shore C, and formed from a first HNP composition, the first HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C and formed from a second HNP composition, the second HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer;

wherein H<

I and S<

I;

wherein the material hardness of the first HNP composition is less than the material hardness of the second HNP composition; and

wherein H<

S, and wherein S−

H=D, where D is an integer from 1 to 22.

14. The golf ball of claim 13, wherein the center has a diameter of from 0.750 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

15. The golf ball of claim 14 wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.

16. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of;

(a) a center having a diameter of from 0.50 inches to 1.50 inches, a center hardness (H) of from 20 Shore C to 70 Shore C, and formed from a first HNP composition, the first HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C and formed from a second HNP composition, the second HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer;

wherein H<

I and S<

I;

wherein the material hardness of the first HNP composition is less than the material hardness of the second HNP composition; and

wherein S<

H, and wherein H−

S=D, where D is an integer from 1 to 22.

17. The golf ball of claim 16, wherein the center has a diameter of from 0.750 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

18. The golf ball of claim 17, wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.

19. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of:

(a) a center having a diameter of from 0.50 inches to 1.50 inches, a center hardness (H) of from 20 Shore C to 70 Shore C, and formed from a first HNP composition, the first HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C and formed from a second HNP composition, the second HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

wherein H<

I and S<

I;

wherein the material hardness of the second HNP composition is less than the material hardness of the first HNP composition; and

wherein H<

S, and wherein S−

H=D, where D is an integer from 1 to 22.

20. The golf ball of claim 19, wherein the center has a diameter of from 0.75 0 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

21. The golf ball of claim 20, wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.

22. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.60 inches and consists of:

(a) a center having a diameter of from 0.50 inches to 1.50 inches, a center hardness (H) of from 20 Shore C to 70 Shore C, and formed from a first HNP composition, the first HNP composition having a material hardness of 45 Shore D or greater and comprising a highly neutralized ethylene/(meth)acrylic acid copolymer;

(b) an intermediate core layer having a surface hardness (I) of 40 Shore C or greater; and

(c) an outer core layer having a surface hardness (S) of from 20 Shore C to 70 Shore C and formed from a second HNP composition, the second HNP composition having a material hardness of 55 Shore D or less and comprising a highly neutralized ethylene/(meth)acrylic acid/alkyl (meth)acrylate copolymer;

wherein H<

I and S<

I;

wherein the material hardness of the second HNP composition is less than the material hardness of the first HNP composition; and

wherein S<

H, and wherein H−

S=D, where D is an integer from 1 to 22.

23. The golf ball of claim 22, wherein the center has a diameter of from 0.750 inches to 1.500 inches and the center hardness (H) is from 50 Shore C to 60 Shore C;

the intermediate core layer surface hardness (I) is from 80 Shore C to 90 Shore C; and

the outer core layer has a thickness of from 0.010 inches to 0.150 inches and the outer core layer surface hardness (S) is from 50 Shore C to 60 Shore C.

24. The golf ball of claim 23, wherein the outer core layer has a thickness of from 0.030 inches to 0.070 inches.