Foam-core golf balls

• US 9,056,226 B2
• Filed: 04/07/2014
• Issued: 06/16/2015
• Est. Priority Date: 05/29/2002
• Status: Expired due to Fees

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Sullivan, Michael J., Ladd, Derek A., Hebert, Edmund A.
• Primary Examiner(s): Gorden, Raeann
• Application Number:
  US14/246,361
• Publication Number:
  US 20140364251A1
• Time in Patent Office: 435 Days
• Field of Search: 473/373, 473/374
• US Class Current: 1/1
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0039 characterised by the material
• CPC Class Codes: A63B 37/0041 Coefficient of restitution
• CPC Class Codes: A63B 37/0045 Thickness
• CPC Class Codes: A63B 37/0047 Density; Specific gravity
• CPC Class Codes: A63B 37/0058 Polyurethane
• CPC Class Codes: A63B 37/0061 Coefficient of restitution
• CPC Class Codes: A63B 37/0064 Diameter
• 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

Abstract

A golf ball with a controlled moment of inertia and controlled spin rate is disclosed. The golf ball comprises a subassembly and a cover, the subassembly comprising an inner core and an intermediate layer, wherein the subassembly has a diameter of from about 1.45 inches to about 1.66 inches, the inner core has a diameter of less than about 0.75 inches, and the intermediate layer comprises a foamed polyurethane composition. The inner core has a specific gravity of higher than about 1.15, the intermediate layer has its specific gravity reduced to less than about 1.05, and the subassembly has its specific gravity reduced up to about 8% such that the coefficient of restitution of the subassembly is controlled by or is substantially the same as the coefficient of restitution of the intermediate layer, and the golf ball has its coefficient of restitution reduced by less than about 6%.

Claims

1. A golf ball comprising a subassembly and a cover, the subassembly comprising an inner core and an intermediate layer, wherein the subassembly has a diameter of from about 1.45 inches to about 1.66 inches, the inner core has a diameter of less than about 0.75 inches and a specific gravity of higher than about 1.15, the intermediate layer comprises a foamed polyurethane composition and has its specific gravity reduced to less than about 1.05, and the subassembly has its specific gravity reduced up to about 8% such that the coefficient of restitution of the subassembly is controlled by or is substantially the same as the coefficient of restitution of the intermediate layer and the golf ball has its coefficient of restitution reduced by less than about 6%.

2. The golf ball of claim 1, wherein the intermediate layer comprises an outer core.

3. The golf ball of claim 1, wherein the intermediate layer comprises an inner cover.

4. The golf ball of claim 1, wherein the intermediate layer comprises a mantle layer.

5. The golf ball of claim 1, wherein the foamed polyurethane composition comprises a microcellular polyurethane elastomers, closed-cell polyurethane rigid foams, flexible polyurethane foam compositions, semiflexible polyurethane foam compositions, polyurethane flexible integrally-skinning compositions, polyurethane integral rigid foams, thermoplastic polyurethane elastomers (TPUs), closed-cell polyurethane rigid foams, and combinations thereof.

6. The golf ball of claim 1, wherein the foamed polyurethane composition comprises a physical foaming agent selected from the group comprising freons (CFCs), halogenated hydrocarbons, water, aliphatic hydrocarbons, gases, and solid blowing agents.

7. The golf ball of claim 1, wherein the foamed polyurethane composition comprises at least one of activated carbon, calcium carbonate, diatomaceous earth, and silicates saturated with carbon dioxide.

8. The golf ball of claim 1, wherein the foamed polyurethane composition comprises at least one foaming/blowing agent selected from the group comprising ammonium carbonate, carbonates of alkalai metals, azo and diazo compounds, nitroso compounds, sulfonylhydrazides, azides of organic acids, triazines, tri- and tetrazole derivatives, sulfonyl semicarbazides, urea derivatives, guanidine derivatives, mixtures of acids and metals, mixtures of organic acids and inorganic carbonates, mixtures of nitriles and ammonium salts, and hydrolytic decomposition of urea.

9. The golf ball of claim 1, wherein the foamed polyurethane comprises from about 1% to about 3% expandable microspheres.