# US 10,441,854 B2 · Golf balls having a foam center with regions of different hardness

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- Number: US 10,441,854 B2
- Document ID: US10441854B2
- Status: Granted
- Kind: B2
- Application number: 15/944,993
- Filed: 2018-04-04
- Published: 2018-08-09
- Granted: 2019-10-15
- Earliest claimed: 2016-03-16
- Assignees: Acushnet Company
- Applicants: Acushnet Company
- Inventors: Mark L. Binette; Michael J. Sullivan; Douglas S. Goguen; Brian Comeau; Michael Michalewich; Shawn Ricci; John D. Farrell
- Web page: https://patentgrep.com/patent/US10441854B2

## CPC

- A63B 37/0094: {Rebound resilience}
- A63B 37/0031: {Hardness}
- A63B 37/0039: {characterised by the material}
- A63B 37/0044: {Hardness gradient}
- A63B 37/0045: {Thickness}
- A63B 37/0047: {Density; Specific gravity}
- A63B 37/0051: {Materials other than polybutadienes; Constructional details}
- A63B 37/0058: {Polyurethane}
- A63B 37/0061: {Coefficient of restitution}
- A63B 37/00621: {Centre hardness}
- A63B 37/00622: {Surface hardness}
- A63B 37/0063: {Hardness gradient}
- A63B 37/0064: {Diameter}
- A63B 37/0065: {Deflection or compression}
- A63B 37/0066: {Density; Specific gravity}
- A63B 37/0075: {Three piece balls, i.e. cover, intermediate layer and core}
- A63B 37/0076: {Multi-piece balls, i.e. having two or more intermediate layers}
- A63B 37/0084: {Initial velocity}
- A63B 37/0091: {Density distribution amongst the different ball layers}
- A63B 37/0092: {Hardness distribution amongst different ball layers}
- A63B 37/0096: {Spin rate}
- A63B 45/00: Apparatus or methods for manufacturing balls (working of plastics or substances in a plastic state B29)
- C08G 18/10: Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
- C08G 18/42: Polycondensates having carboxylic or carbonic ester groups in the main chain
- C08G 18/44: Polycarbonates
- C08G 18/48: Polyethers
- C08G 18/6204: {Polymers of olefins (unsaturated polymers of conjugated dienes C08G18/69)}
- C08G 2101/00: Manufacture of cellular products
- C08G 2110/0083: prepared using water as the sole blowing agent
- A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

## Abstract

Golf balls having a multi-layered core made of a foamed composition are provided. The core preferably has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition is used to form the foam center. The foam inner core preferably includes a fully-foamed center region and a partially or completely-collapsed foam outer region. The hardness of the fully-foamed region is different than the hardness of the collapsed foam region. Non-foamed thermoset or thermoplastic materials such as polybutadiene rubbers or ethylene acid copolymer ionomer may be used to form the outer core layer. The ball further includes a cover that may be multi-layered. The foam cores have good resiliency.

## Claims

### Claim 1

A golf ball, comprising:
i) an inner core comprising a foam composition having a geometric center, an outer region, and outer surface, wherein the foam composition is foamed in the center and at least partially-collapsed in the outer region, the inner core having a diameter in the range of about 0.100 to about 1.100 inches and an outer surface hardness (Hinner core surface) and a center hardness (Hinner core center), the Hinner core surface being greater than the Hinner core center to provide a positive hardness gradient in the inner core;
ii) an outer core layer comprising a non-foamed thermoset or thermoplastic composition, the outer core layer being disposed about the inner core layer and having a thickness in the range of about 0.100 to about 0.750 inches, and an outer surface hardness (Houter surface of OC), wherein the (Houter surface of OC) is greater than the (Hinner core center) to provide a positive hardness gradient across the core assembly; and
iii) a cover layer comprising a thermoset or thermoplastic material, the cover layer having a thickness in the range of about 0.010 to about 0.080 inches, wherein an intermediate layer is disposed between the cover layer and outer core layer.

### Claim 2 (depends on 1)

The golf ball of claim 1, wherein the cover layer comprises a material selected from the group consisting of polyurethanes, polyureas, and hybrids, copolymers, and blends thereof.

### Claim 3 (depends on 1)

The golf ball of claim 1, wherein the cover layer comprises an ethylene acid copolymer ionomer material.

### Claim 4 (depends on 1)

The golf ball of claim 1, wherein the cover has a material hardness in the range of about 70 to about 92 Shore C.

### Claim 5 (depends on 1)

The golf ball of claim 1, wherein the inner core comprises a foamed polyurethane composition.

### Claim 6 (depends on 1)

The golf ball of claim 1, wherein the inner core comprises a foamed ethylene vinyl acetate composition.

### Claim 7 (depends on 1)

The golf ball of claim 1, wherein the outer core layer comprises a thermoset polybutadiene rubber composition.

### Claim 8 (depends on 1)

The golf ball of claim 1, wherein the Hinner core center is in the range of about 10 to about 55 Shore C and the Hinner core surface is in the range of about 15 to about 60 Shore C to provide a positive hardness gradient.

### Claim 9 (depends on 1)

The golf ball of claim 1, wherein the inner core further has a midpoint hardness in the outer region (Hmidpoint inner core outer region) and the Hinner core surface is greater than the Hmidpoint inner core outer region and the Hmidpoint inner core outer region is greater than the Hinner core center.

### Claim 10 (depends on 1)

The golf ball of claim 1, wherein the outer core layer has an outer surface hardness (Houter surface of OC) and a midpoint hardness (Hmidpoint of OC), the Houter surface of OC being greater than the (Hmidpoint of OC), to provide a positive hardness gradient.

### Claim 11 (depends on 10)

The golf ball of claim 10, wherein the Hmidpoint of OC is in the range of about 45 to about 90 Shore C and the Houter surface of OC is in the range of about 50 to about 98 Shore C.