Multilayer golf ball containing at least three core layers, at least one intermediate barrier layer, and at least one cover layer

• US 7,951,015 B2
• Filed: 11/17/2006
• Issued: 05/31/2011
• Est. Priority Date: 10/09/2001
• Status: Expired due to Fees

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Cavallaro, Christopher
• Primary Examiner(s): GORDEN, RAEANN
• Application Number:
  US11/560,926
• Publication Number:
  US 20070129172A1
• Time in Patent Office: 1,656 Days
• Field of Search: 473/376, 473/377, 473/367, 473/368
• US Class Current: 473/376
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0033 Thickness
• CPC Class Codes: A63B 37/004 Physical properties
• CPC Class Codes: A63B 37/0043 Hardness
• CPC Class Codes: A63B 37/0045 Thickness
• CPC Class Codes: A63B 37/0052 Liquid cores
• CPC Class Codes: A63B 37/0063 Hardness gradient
• 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 37/0078 Coefficient of restitution
• CPC Class Codes: A63B 37/0087 Deflection or compression
• 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: C08L 81/04 Polysulfides

Abstract

The present invention is directed to multi-layer golf balls having at least three core layers, at least one cover layer, and at least one intermediate layer between the core and the cover layer that acts as a vapor barrier. Advantageously, the at least three core layers have a hardness gradient that either increases or decreases toward the at least one intermediate vapor barrier layer.

Claims

1. A multilayer golf ball comprising:

a core comprising at least three core layers comprising a center, an inner core layer, and an outer core layer;

at least one cover layer; and

at least one moisture vapor barrier layer comprising a locally curable material selected from the group comprising butyl rubber, polysulfide rubber, a single-pack castable polymer comprising uretdione, a single-pack castable polymer comprising isocyanate and an amine, and a single-pack castable polymer comprising isocyanate and a polyol intermediate between the outer core layer and the at least one cover layer and exhibiting a moisture vapor transmission rate less than that of the cover layer;

wherein the center, the inner core layer, and the outer core layer exhibit a hardness gradient,

wherein the hardness gradient increases toward the at least one intermediate vapor barrier layer, and wherein;

the center hardness is no more than about 50 Shore C;

the inner core hardness is greater than about 50 Shore C;

the outer core hardness is greater than about 65 Shore C;

or

a combination thereof.

2. The multilayer golf ball of claim 1, wherein the thickness of the at least one vapor barrier layer is relatively uniform and is not more than about 0.020 inch.

3. The multilayer golf ball of claim 1, wherein the at least one vapor barrier layer comprises a thermoplastic elastomeric binder and a particulate material that has a low moisture vapor transmission rate.

4. The multilayer golf ball of claim 1, comprising a moment of inertia of less than about 85 kg·

m².

5. The multilayer golf ball of claim 1, comprising a coefficient of restitution of greater than about 0.7.

6. The multilayer golf ball of claim 1, comprising an atti compression of at least about 40.

7. A multilayer golf ball comprising:

a core comprising at least three core layers comprising a center, an inner core layer, and an outer core layer;

at least one cover layer; and

at least one moisture vapor barrier layer comprising a locally curable material selected from the group comprising butyl rubber, polysulfide rubber, single-pack castable polymers comprising uretdione, single-pack castable polymers comprising isocyanate and an amine, and single-pack castable polymers comprising isocyanate and a polyol intermediate between the outer core layer and the at least one cover layer and exhibiting a moisture vapor transmission rate less than that of the cover layer wherein the center, the inner core layer, and the outer core layer exhibit a hardness gradient, wherein;

the center has

a diameter from about 0.5 inch to about 1.6 inches,

a Mooney viscosity greater than about 35,

a deflection under a load of about 100 kg of at least about 1 mm,

a zinc diacrylate content from about 10 to about 40 parts per hundred parts of rubber,

or some combination thereof;

the inner core layer has an outer diameter of not more than about 1.610 inches,

a Mooney viscosity greater than about 35,

a zinc diacrylate content from about 15 to about 45 parts per hundred parts of rubber, or

some combination thereof; and

the outer core layer has

an outer diameter of not more than about 1.660 inches,

a Mooney viscosity greater than about 35,

a zinc diacrylate content from about 15 to about 45 parts per hundred parts of rubber, or

some combination thereof.

8. A multilayer golf ball comprising:

a core comprising at least three core layers comprising a center, an inner core layer, and an outer core layer;

at least one cover layer; and

at least one moisture vapor barrier layer comprising a locally curable material selected from the group comprising butyl rubber, polysulfide rubber, single-pack castable polymers comprising uretdione, single-pack castable polymers comprising isocyanate and an amine, and single-pack castable polymers comprising isocyanate and a polyol intermediate between the outer core layer and the at least one cover layer and exhibiting a moisture vapor transmission rate less than that of the cover layer,

wherein the center, the inner core layer, and the outer core layer exhibit a hardness gradient,

wherein the at least one vapor barrier layer comprises a thermoplastic elastomeric binder and a particulate material that has a low moisture vapor transmission rate,

wherein the thermoplastic elastomeric binder comprises a styrene-diene block copolymer or a styrene-hydrogenated diene block copolymer.

9. A multilayer golf ball comprising:

at least three core layers comprising a center, an inner core layer, and an outer core layer;

at least one cover layer; and

at least one vapor barrier layer comprising a locally curable material selected from the group comprising butyl rubber, polysulfide rubber, single-pack castable polymers comprising uretdione, single-pack castable polymers comprising isocyanate and an amine, and single-pack castable polymers comprising isocyanate and a polyol intermediate between the outer core layer and the at least one cover layer and exhibiting a moisture vapor transmission rate less than that of the cover layer,

wherein the center, the inner core layer, and the outer core layer exhibit a hardness gradient,

wherein the at least one vapor barrier layer comprises a thermoplastic elastomeric binder and a particulate material that has a low moisture vapor transmission rate,

wherein the particulate material comprises an aluminum flake material.

10. The multilayer golf ball of claim 9, wherein the ratio of particulate material to binder material is about 1:

1.