US 2016/0101325 A1Published application

Golf ball cores having foam center and thermoset outer layers with hardness gradients

AssigneeAcushnet Company

InventorsMichael J. Sullivan, Mark L. Binette, Brian Comeau, Douglas S. Goguen, Michael Michalewich, Shawn Ricci

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Abstract

Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core assembly preferably has a positive hardness gradient extending across the entire assembly. The core structure and resulting ball have relatively good resiliency.

Claims15

Dependent claims

A golf ball, comprising:

i) a core assembly, the core assembly comprising an inner core layer comprising a foamed composition, the inner core layer having a diameter in the range of about 0.100 to about 1.100 inches, an outer surface specific gravity (SGskin of inner core) and a center specific gravity (SGcenter of inner core), the (SGskin of inner core) being greater than the (SGcenter of inner core) to provide a positive density gradient, 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;
ii) an intermediate core layer comprising a first thermoset material, the intermediate layer being disposed about the inner core and having a thickness in the range of about 0.050 to about 0.400 inches, a specific gravity (SGintermediate), and an outer surface hardness (Houter surface of IC) and an inner surface hardness (Hinner surface of IC), the Houter surface of IC being the same or less than the Hinner surface of IC to provide a zero or negative hardness gradient;
and
iii) an outer core layer comprising a second thermoset material, the outer core layer being disposed about the intermediate core layer and having a thickness in the range of about 0.100 to about 0.750 inches, a specific gravity (SGouter), and an outer surface hardness (Houter surface of OC) and an inner surface hardness (Hinner surface of OC), the Houter surface of OC being greater than the Hinner surface of OC to provide a positive hardness gradient, and
iv) a cover, the cover comprising at least one polymeric layer;
wherein the SGouter, is greater than the SGinner, and the SGintermediate is greater than the SGinner, and the center hardness of the inner core (Hinner core center) is in the range of about 10 Shore C to about 60 Shore C and the outer surface hardness of the outer core layer (Houter surface of OC) is in the range of about 40 Shore C to about 90 Shore C to provide a positive hardness gradient across the core assembly.

3 more elements

A golf ball, comprising:

i) a core assembly, the core assembly comprising an inner core layer comprising a foamed composition, the inner core layer having a diameter in the range of about 0.100 to about 1.100 inches, an outer surface specific gravity (SGskin of inner core) and a center specific gravity (SGcenter of inner core), the (SGskin of inner core) being greater than the (SGcenter of inner core) to provide a positive density gradient, 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;
ii) an intermediate core layer comprising a first thermoset material, the intermediate layer being disposed about the inner core and having a thickness in the range of about 0.050 to about 0.400 inches, a specific gravity (SGintermediate) and an outer surface hardness (Houter surface of IC) and an inner surface hardness (Hinner surface of IC), the Houter surface of IC being greater than the Hinner surface of IC to provide a positive hardness gradient;
and
iii) an outer core layer comprising a second thermoset material, the outer core layer being disposed about the intermediate core layer and having a thickness in the range of about 0.100 to about 0.750 inches, a specific gravity (SGouter), and an outer surface hardness (Houter surface of OC) and an inner surface hardness (Hinner surface of OC), the Houter surface of OC being greater than the Hinner surface of OC to provide a positive hardness gradient;
and
iv) a cover, the cover comprising at least one polymeric layer;
wherein the SGinner, is greater than the SGinner, and the SGintermediate is greater than the SGinner, and the center hardness of the inner core (Hinner core center) is in the range of about 10 Shore C to about 60 Shore C and the outer surface hardness of the outer core layer (Houter surface of OC) is in the range of about 40 Shore C to about 96 Shore C to provide a positive hardness gradient across the core assembly.

4 more elements

A golf ball, comprising:

i) a core assembly, the core assembly comprising an inner core layer comprising a foamed composition, the inner core layer having a diameter in the range of about 0.100 to about 1.100 inches, an outer surface specific gravity (SGskin of inner core) and a center specific gravity (SGcenter of inner core), the (SGskin of inner core) being greater than the (SGcenter of inner core) to provide a positive density gradient, 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;
ii) an intermediate core layer comprising a first thermoset material, the intermediate layer being disposed about the inner core and having a thickness in the range of about 0.050 to about 0.400 inches, a specific gravity (SGintermediate), and an outer surface hardness (Houter surface of IC) and an inner surface hardness (Hinner surface of IC), the Houter surface of IC being greater than the Hinner surface of IC to provide a positive hardness gradient;
and
iii) an outer core layer comprising a second thermoset material, the outer core layer being disposed about the intermediate core layer and having a thickness in the range of about 0.100 to about 0.750 inches, a specific gravity (SGouter), and an outer surface hardness (Houter surface of OC) and an inner surface hardness (Hinner surface of OC), the Houter surface of OC being the same or less than the Hinner surface of OC to provide a zero or negative hardness gradient,
iv) a cover, the cover comprising at least one polymeric layer;
wherein the SGouter, is greater than the SGinner, and the SGintermediate is greater than the SGinner, and the center hardness of the inner core (Hinner core center) is in the range of about 10 Shore C to about 60 Shore C and the outer surface hardness of the outer core layer (Houter surface of OC) is in the range of about 40 Shore C to about 90 Shore C to provide a positive hardness gradient across the core assembly.

3 more elements

Dependencies are inferred from the claim text.

Facts

Application: 14/972,217Filed 17 Dec 2015
Priority: 11 Apr 2013
Published: 14 Apr 2016
Term ends: Not estimatedThe source records don’t support an estimate.

Classification31 codes

A63B 37/0076
With a specified number of layers: multi-piece balls, i.e. having two or more intermediate layers
A63B 37/0024
Covers: materials other than ionomers or polyurethane
A63B 37/0027
Materials other than ionomers or polyurethane: polyurea
A63B 37/0039
Intermediate layers, e.g. inner cover, outer core, mantle: characterised by the material

Family

Application13/860,717Continuation in part · filed 11 Apr 2013
Application13/929,956Continuation · filed 28 Jun 2013
Application14/683,471Continuation · filed 10 Apr 2015
Application14/972,217Continuation
Application13/929,956Continuation in part
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From the US filing history. Foreign family members aren’t listed.