Golf balls having a multi-layered cover with a thermoplastic inner cover layer

• US 9,409,062 B2
• Filed: 07/16/2015
• Issued: 08/09/2016
• Est. Priority Date: 11/28/2001
• Status: Expired due to Fees

• Current Assignee: Acushnet Company (FILA Holdings Corp.)
• Original Assignee: Acushnet Company (FILA Holdings Corp.)
• Inventors: Sullivan, Michael J.
• Primary Examiner(s): Gorden, Raeann
• Application Number:
  US14/800,753
• Publication Number:
  US 20150314169A1
• Time in Patent Office: 390 Days
• Field of Search: 473/376
• US Class Current: 1/1
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0027 Polyurea
• CPC Class Codes: A63B 37/0031 Hardness
• CPC Class Codes: A63B 37/0039 characterised by the material
• CPC Class Codes: A63B 37/0043 Hardness
• CPC Class Codes: A63B 37/0045 Thickness
• 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 37/0066 Density; Specific gravity
• CPC Class Codes: A63B 37/0076 Multi-piece balls, i.e. having two or more intermediate layers
• CPC Class Codes: A63B 37/0092 Hardness distribution amongst different ball layers

Abstract

Multi-piece golf balls having a multi-layered solid core and multi-layered cover are provided. In one version, a five-piece ball having a two-layered core and three-layered cover is formed. Preferably, the inner core is made of a thermoset rubber composition and the outer core layer is made of a highly neutralized polymer (HNP) composition. The cover includes inner, intermediate, and outer cover layers, wherein the outer cover is made of a composition comprising a polyurethane, polyurea, or copolymer or blend thereof. In a second version, a six-piece ball having inner and intermediate cover layers that also can be made of HNP compositions is produced. The finished balls have high resiliency and rebounding properties.

Claims

1. A golf ball consisting essentially of:

an inner core layer formed from a thermoset rubber composition and having a diameter of 1.2 inches or greater, a center hardness (H_{center material}) of 60 Shore C or greater, and an outer surface hardness (H_{center surface}) of 80 Shore C or greater;

an outer core layer formed from a highly neutralized polymer composition and having a material hardness (H_{outer core material}) of 35 Shore D or greater;

an inner cover layer formed from a thermoplastic composition having a material hardness (H_{inner cover material}) of 95 Shore C or less;

an intermediate cover layer formed from a thermoplastic composition having a material hardness(H_{intermediate cover material}) of 80 Shore C or greater, the H_{intermediate cover material} being greater than the H_{outer core material}; and

an outer cover layer formed from a composition selected from the group consisting of polyurethanes, polyureas, and copolymers and blends thereof.

2. The golf ball of claim 1, wherein the thermoplastic composition of the inner cover layer is a partially neutralized ionomer composition comprising an ethylene acid copolymer having acid groups such that the amount of neutralized acid groups is in the range of 30% to less than 80%.

3. The golf ball of claim 1, wherein the thermoplastic composition of the inner cover layer is an ionomer composition comprising an ethylene acid copolymer having acid groups such that the amount of neutralized acid groups is 80% or greater.

4. The golf ball of claim 1, wherein the thermoplastic composition of the intermediate cover layer is a partially neutralized ionomer composition comprising an ethylene acid copolymer having acid groups such that the amount of neutralized acid groups is in the range of 30% to less than 80%.

5. The golf ball of claim 1, wherein the thermoplastic composition of the intermediate cover layer is an ionomer composition comprising an ethylene acid copolymer having acid groups such that the amount of neutralized acid groups is 80% or greater.

6. The golf ball of claim 1, wherein the H_{intermediate cover material} is greater than the H_{inner cover material}.

7. The golf ball of claim 6, wherein the H_{inner cover material} is 75 Shore C or less.

8. A golf ball consisting essentially of:

an inner core layer formed from a thermoset rubber composition and having a diameter of 1.2 inches or greater, a center hardness (H_{center material}) of 60 Shore C or greater, and an outer surface hardness (H_{center surface}) of 80 Shore C or greater;

an outer core layer formed from a highly neutralized polymer composition and having a material hardness (H_{outer core material}) of 35 Shore D or greater, the inner core and outer core layer forming a core structure having a diameter of 1.40 to 1.55 inches;

an inner cover layer formed from a thermoplastic composition having a material hardness of (H_{inner cover material}) of 95 Shore C or less;

an intermediate cover layer formed from a thermoplastic composition having a material hardness (H_{intermediate cover material}) of 80 Shore C or greater, the H_{intermediate cover material} being greater than the H_{outer core material}, and the intermediate cover layer having a thickness of 0.020 to 0.150 inches; and

an outer cover layer formed from a composition selected from the group consisting of polyurethanes, polyureas, and copolymers and blends thereof.

9. The golf ball of claim 8, wherein the thermoplastic composition, of the intermediate cover layer is a partially neutralize ionomer composition comprising an ethylene acid copolymer having acid groups such that the amount of neutralized acid groups is in the range of 30% to less than 80%.

10. The golf ball of claim 8, wherein the thermoplastic composition of the intermediate cover layer is an ionomer composition comprising an ethylene acid copolymer having acid groups such that the amount of neutralized acid groups is 80% or greater.

11. The golf ball of claim 8, wherein the H_{intermediate cover material} is greater than the H_{inner cover material}.

12. The golf ball of claim 11, wherein the H_{inner cover material} is 75 Shore C or less.