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

• US 9,750,985 B2
• Filed: 08/01/2016
• Issued: 09/05/2017
• 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:
  US15/225,063
• Publication Number:
  US 20160339304A1
• Time in Patent Office: 400 Days
• Field of Search: 473376
• 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 six-piece ball having a three-layered core and three-layered cover is formed. Preferably, the inner core is made of a thermoset rubber composition, the intermediate core layer is made of a thermoplastic 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 five-piece ball having a two-layered core and three-layered cover 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 intermediate core layer formed from a thermoplastic composition having a material hardness (H_{intermediate core material}) of 83 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 intermediate core layer has a thickness in the range of 0.015 to 0.070 inches.

3. The golf ball of claim 1, wherein the H_{intermediate core material} is at least 87 Shore C.

4. The golf ball of claim 1, wherein the intermediate core layer has a surface hardness (H_{intermediate core surface}) and the outer core layer has a surface hardness (H_{outer core surface}), and the H_{intermediate core surface} is greater than H_{outer core surface}.

5. The golf ball of claim 1, wherein the H_{intermediate core material} is at least 87 Shore C and H_{outer core material} is at least 45 Shore D.

6. 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 intermediate core layer formed from a thermoplastic composition having a material hardness (H_{intermediate core material}) of 83 Shore C or greater, the intermediate core layer having a thickness of 0.015 to 0.070 inches;

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 (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.

7. The golf ball of claim 6, wherein the H_{intermediate core material} is at least 87 Shore C.

8. The golf ball of claim 6, wherein the intermediate core layer has a surface hardness (H_{intermediate core surface}) and the outer core layer has a surface hardness (H_{outer core surface}), and the H_{intermediate core surface} is greater than H_{outer core surface}.

9. The golf ball of claim 6, wherein the H_{intermediate core material} is at least 87 Shore C and H_{outer core material} is at least 45 Shore D.