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

• US 7,963,862 B2
• Filed: 05/22/2008
• Issued: 06/21/2011
• 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): GORDEN, RAEANN
• Application Number:
  US12/125,320
• Publication Number:
  US 20080220906A1
• Time in Patent Office: 1,125 Days
• Field of Search: 476/373, 476/376, 476/374
• 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 37/0031 Hardness
• CPC Class Codes: A63B 37/0033 Thickness
• 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 37/0064 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 37/00922 whereby hardness of the cover is lower than hardness of the 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 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 small, hard center enclosed by a soft intermediate core layer and an 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 1.62 inches and consists of:

(a) a center having a diameter of from 0.125 inches to 0.750 inches and a surface hardness of 80 Shore C or greater 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 of less than 80 Shore C; and

(c) an outer core layer having a surface hardness of 80 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;

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

2. The golf ball of claim 1, wherein the intermediate core layer is formed from a rubber composition.

3. The golf ball of claim 1, wherein the intermediate core layer is formed from a third HNP composition, the third 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.

4. The golf ball of claim 1, wherein the cover consists of:

an inner cover layer having a surface hardness of 65 Shore D or greater and a thickness of from 0.020 inches to 0.080 inches; and

an outer cover layer having a surface hardness of 60 Shore D or less and a thickness of from 0.015 inches to 0.055 inches.

5. The golf ball of claim 1, wherein the cover consists of:

an inner cover layer formed from a partially or fully neutralized polymer composition and having a surface hardness of 65 Shore D or greater and a thickness of from 0.030 inches to 0.040 inches; and

an outer cover layer formed from a polyurethane or polyurea composition and having a surface hardness of 50 Shore D or less and a thickness of from 0.025 inches to 0.035 inches.

6. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.62 inches and consists of:

(a) a center having a diameter of from 0.125 inches to 0.750 inches and a surface hardness of 80 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;

(b) an intermediate core layer having a surface hardness of less than 80 Shore C; and

(c) an outer core layer having a surface hardness of 80 Shore C or greater 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 the material hardness of the second HNP composition is less than the material hardness of the first HNP composition.

7. The golf ball of claim 6, wherein the intermediate core layer is formed from a rubber composition.

8. The golf ball of claim 6, wherein the intermediate core layer is formed from a third HNP composition, the third 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.

9. The golf ball of claim 6, wherein the cover consists of:

an inner cover layer having a surface hardness of 65 Shore D or greater and a thickness of from 0.020 inches to 0.080 inches; and

an outer cover layer having a surface hardness of 60 Shore D or less and a thickness of from 0.015 inches to 0.055 inches.

10. The golf ball of claim 6, wherein the cover consists of:

an inner cover layer formed from a partially or fully neutralized polymer composition and having a surface hardness of 65 Shore D or greater and a thickness of from 0.030 inches to 0.040 inches; and

an outer cover layer formed from a polyurethane or polyurea composition and having a surface hardness of 50 Shore D or less and a thickness of from 0.025 inches to 0.035 inches.

11. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.62 inches and consists of:

(a) a center having a diameter of from 0.125 inches to 0.750 inches and a surface hardness of 80 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;

(b) an intermediate core layer having a surface hardness of less than 80 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; and

(c) an outer core layer having a surface hardness of 80 Shore C or greater;

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

12. The golf ball of claim 11, wherein the outer core layer is formed from a rubber composition.

13. The golf ball of claim 11, wherein the outer core layer is formed from an HNP composition.

14. The golf ball of claim 11, wherein the cover consists of:

an inner cover layer having a surface hardness of 65 Shore D or greater and a thickness of from 0.020 inches to 0.080 inches; and

an outer cover layer having a surface hardness of 60 Shore D or less and a thickness of from 0.015 inches to 0.055 inches.

15. The golf ball of claim 11, wherein the cover consists of:

an inner cover layer formed from a partially or fully neutralized polymer composition and having a surface hardness of 65 Shore D or greater and a thickness of from 0.030 inches to 0.040 inches; and

an outer cover layer formed from a polyurethane or polyurea composition and having a surface hardness of 50 Shore D or less and a thickness of from 0.025 inches to 0.035 inches.

16. A golf ball comprising a core and a cover, wherein the core has an overall diameter of from 1.40 inches to 1.62 inches and consists of:

(a) a center having a diameter of from 0.125 inches to 0.750 inches and a surface hardness of 80 Shore C or greater;

(b) an intermediate core layer having a surface hardness of less than 80 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; and

(c) an outer core layer having a surface hardness of 80 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;

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

17. The golf ball of claim 16, wherein the center is formed from a rubber composition.

18. The golf ball of claim 16, wherein the center is formed from an HNP composition.

19. The golf ball of claim 16, wherein the cover consists of:

an inner cover layer having a surface hardness of 65 Shore D or greater and a thickness of from 0.020 inches to 0.080 inches; and

an outer cover layer having a surface hardness of 60 Shore D or less and a thickness of from 0.015 inches to 0.055 inches.

20. The golf ball of claim 16, wherein the cover consists of:

an inner cover layer formed from a partially or fully neutralized polymer composition and having a surface hardness of 65 Shore D or greater and a thickness of from 0.030 inches to 0.040 inches; and

an outer cover layer formed from a polyurethane or polyurea composition and having a surface hardness of 50 Shore D or less and a thickness of from 0.025 inches to 0.035 inches.