# US 2019/0168078 A1 · Golf balls having a foam inner core with thermal barrier

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- Number: US 2019/0168078 A1
- Document ID: US20190168078A1
- Status: Published application
- Kind: A1
- Application number: 16/257,145
- Filed: 2019-01-25
- Published: 2019-06-06
- Earliest claimed: 2016-04-28
- Assignees: Acushnet Company
- Applicants: Acushnet Company
- Inventors: Michael J. Sullivan; Mark L. Binette; Douglas S. Goguen; Brian Comeau; Michael Michalewich; Shawn Ricci; John D. Farrell
- Web page: https://patentgrep.com/patent/US20190168078A1

## CPC

- A63B 37/0063: {Hardness gradient}
- A63B 37/0004: {Surface depressions or protrusions}
- A63B 37/004: {Physical properties}
- 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 37/0064: {Diameter}
- A63B 37/0066: {Density; Specific gravity}
- A63B 37/0076: {Multi-piece balls, i.e. having two or more intermediate layers}
- A63B 37/0091: {Density distribution amongst the different ball layers}
- A63B 37/0092: {Hardness distribution amongst different ball layers}
- A63B 45/00: Apparatus or methods for manufacturing balls (working of plastics or substances in a plastic state B29)
- A63B 37/0039: {characterised by the material}
- A63B 2037/065: {Foam}
- A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H)

## Abstract

Golf balls having a multi-layered core made of a foamed composition are provided. The core assembly preferably includes a foam inner core (center) and surrounding outer core layer. Preferably, a polyurethane foam composition is used to form the foam center. The core layers have different hardness gradients and specific gravity values. The foamed inner core assembly includes a geometric center, outer surface (skin), and thermal barrier layer that helps protect the foamed center region from the negative effects of high temperatures used during the ball-manufacturing process. Non-foamed thermoset materials such as polybutadiene rubber may be used to form the thermal barrier layer. The foam cores have good resiliency, thermal stability, and durability over a wide temperature range. The ball further includes a cover that may be multi-layered.

## Claims

### Claim 1

A golf ball, comprising a core assembly and a cover, the core assembly comprising:
i) an inner core comprising a foam composition having a geometric center, outer surface, and thermal barrier layer, wherein the inner core layer has 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 the same as or less than the Hinner core center to provide a zero or negative hardness gradient in the inner core; and
ii) an outer core 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.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 2)

The golf ball of claim 2, wherein the foamed polyurethane composition is prepared by adding water to a mixture of polyisocyanate, polyol, and curing agent compounds, surfactant, and catalyst, the water being added in a sufficient amount to cause the mixture to foam.

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 1)

The golf ball of claim 1, wherein the thermal barrier layer comprises at least one thermoset rubber material selected from the group consisting of polybutadiene, ethylene-propylene rubber, ethylene-propylene-diene rubber, polyisoprene, styrene-butadiene rubber, polyalkenamers, butyl rubber, halobutyl rubber, polystyrene elastomers, copolymers of isobutylene and p-alkylstyrene, halogenated copolymers of isobutylene and p-alkylstyrene, copolymers of butadiene with acrylonitrile, polychloroprene, alkyl acrylate rubber, chlorinated isoprene rubber, acrylonitrile chlorinated isoprene rubber, and mixtures thereof

### Claim 6 (depends on 5)

The golf ball of claim 5, wherein the thermal barrier layer comprises a thermoset polybutadiene rubber composition.

### Claim 7 (depends on 1)

The golf ball of claim 1, wherein the thermal barrier layer has a thickness in the range of about 0.002 to about 0.800 inches.

### Claim 8 (depends on 1)

The golf ball of claim 1, wherein the thermal barrier layer has a midpoint hardness (Hmidpoint of thermal barrier layer), and Hmidpoint of thermal barrier layer is greater than the Hinner core surface and the Hinner core surface is less than the Hinner core center.

### Claim 9 (depends on 1)

The golf ball of claim 1, wherein the Hinner core center is in the range of about 15 to about 55 Shore C and the Hinner core surface is in the range of about 10 to about 50 Shore C.

### 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 40 to about 87 Shore C and the Houter surface of OC is in the range of about 48 to about 95 Shore C.

### Claim 12 (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 less than the (Hmidpoint of OC), to provide a negative hardness gradient.

### Claim 13 (depends on 12)

The golf ball of claim 12, wherein the Hmidpoint of OC is in the range of about 46 to about 96 Shore C and the Houter surface of OC is in the range of about 40 to about 90 Shore C.

### Claim 14 (depends on 1)

The golf ball of claim 1, wherein the inner core has an outer surface specific gravity (SGinner core surface) and a center specific gravity (SGinner core center), the SGinner core surface being greater than the SGinner core center.

### Claim 15 (depends on 14)

The golf ball of claim 14, wherein the thermal barrier layer has a midpoint specific gravity (SGmidpoint of thermal barrier layer), and wherein the SGmidpoint of thermal barrier layer is greater than the SGinner core surface and the SGinner core surface is greater than the SGinner core center.