Multi-layer golf ball Number:7,520,823 from the United States Patent and Trademark Office (PTO) owispatent A golf ball comprises a molded core, one or more ionomer mantles, and a thermoset polyurethane cover. The core is a high cis-polybutadiene crosslinked with zinc diacrylate and may also comprise a halogenated thiophenol and metal thiosulfate. One or more of the ionomer mantles comprises an ionomer neutralized to 80% or greater.<H layer, Multi, Multi, layer, gol, 7520823.html, Patent, pto, 7520823

Title: Multi-layer golf ball

Abstract: A golf ball comprises a molded core, one or more ionomer mantles, and a thermoset polyurethane cover. The core is a high cis-polybutadiene crosslinked with zinc diacrylate and may also comprise a halogenated thiophenol and metal thiosulfate. One or more of the ionomer mantles comprises an ionomer neutralized to 80% or greater.

Patent Number: 7,520,823 Issued on 04/21/2009 to Kennedy, III, et al.

Inventors: Kennedy, III; Thomas J. (Wilbraham, MA), Binette; Mark L. (Ludlow, MA), Simonds; Vincent J. (Brimfield, MA), Tzivanis; Michael J. (Chicopee, MA), Melanson; David M. (Northampton, MA)
Assignee: Callaway Golf Company (Carlsbad, CA)

Appl. No.: 11/927,413

Filed: October 29, 2007

Related U.S. Patent Documents


Application Number	Filing Date	Patent Number	Issue Date
11245757	Oct., 2005	7306529

Current U.S. Class: 473/374

Current International Class: A63B 37/06 (20060101)

Field of Search: 473/373,374,368,367

References Cited [Referenced By]

U.S. Patent Documents


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Primary Examiner: Trimiew; Raeann
Attorney, Agent or Firm: Catania; Michael A. Lo; Elaine H.

Parent Case Text

CROSS REFERENCES TO RELATED APPLICATIONS

The Present Application is a Continuation Application of U.S. patent application Ser. No. 11/245,757, filed on Oct. 7, 2005.

Claims

The invention claimed is:

1. A golf ball, comprising: a molded core comprising a high cis-polybutadiene having a Mooney viscosity of from about 20 to about 70 and an Instron compression of greater than 0.0880, wherein the core further comprises pentachlorothiophenol in an amount of 0.2 to 1.0 parts by weight per one hundred parts by weight of cis-polybutiadene and disodium hexamethylene thiosulfate dehydrate in an amount of 0.5 to 1.5 parts by weight per one hundred parts by weight of cis-polybutiadene, wherein the core has a COR of from about 0.600 to about 0.850, and the core has a diameter ranging from 1.40 inches to 1.60 inches; a mantle comprising a 100% neutralized ionomer and an oleic acid, the mantle having a Shore D hardness of from about 30 to about 85; and and a cover composed of a high flexural modulus material having a Shore D hardness ranging from 60 to 75 and a thickness ranging from 0.010 inch to 0.090 inch; wherein the golf ball has a diameter of at least 1.68 inches.

2. A golf ball, comprising: a molded core comprising a high cis-polybutadiene having a Mooney viscosity of from about 20 to about 70 and an Instron compression of greater than 0.0880, wherein the core further comprises pentachlorothiophenol in an amount of 0.2 to 1.0 parts by weight per one hundred parts by weight of cis-polybutiadene and disodium hexamethylene thiosulfate dehydrate in an amount of 0.5 to 1.5 parts by weight per one hundred parts by weight of cis-polybutiadene, wherein the core has a COR of from about 0.600 to about 0.850, and the core has a diameter ranging from 1.40 inches to 1.60 inches; a mantle comprising an ionomer neutralized to 80% or more and an oleic acid, the mantle having a Shore D hardness of from about 30 to about 85; and and a cover composed of a material having a Shore D hardness ranging from 60 to 75 and a thickness ranging from 0.010 inch to 0.090 inch.

Description

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure relates, in various embodiments, to multi-layer golf balls. The golf balls exhibit enhanced combinations of compression, resilience, and durability properties. Methods of preparing such golf balls are also disclosed.

2. Description of the Related Art

For many years, golf balls have been categorized into three different groups. These groups are, namely, one-piece or unitary balls, wound balls, and multi-piece solid balls.

A one-piece ball typically is formed from a solid mass of moldable material, such as an elastomer, which has been cured to develop the necessary degree of hardness, durability, etc., desired. The one-piece ball generally possesses the same overall composition between the interior and exterior of the ball. One piece balls are described, for example, in U.S. Pat. Nos. 3,313,545; 3,373,123; and 3,384,612.

A wound ball has frequently been referred to as a "three-piece ball" since it is produced by winding vulcanized rubber thread under tension around a solid or semi-solid center to form a wound core. The wound core is then enclosed in a single or multi-layer covering of tough protective material. Until relatively recently, the wound ball was desired by many skilled, low handicap golfers due to a number of characteristics.

For example, the three-piece wound ball was previously produced utilizing a balata, or balata like, cover which is relatively soft and flexible. Upon impact, it compresses against the surface of the club producing high spin. Consequently, the soft and flexible balata covers along with wound cores provide an experienced golfer with the ability to apply a spin to control the ball in flight in order to produce a draw or a fade or a backspin which causes the ball to "bite" or stop abruptly on contact with the green. Moreover, the balata cover produces a soft "feel" to the low handicap player. Such playability properties of workability, feel, etc., are particularly important in short iron play and low swing speeds and are exploited significantly by highly skilled players.

However, a three-piece wound ball has several disadvantages both from a manufacturing standpoint and a playability standpoint. In this regard, a thread wound ball is relatively difficult to manufacture due to the number of production steps required and the careful control which must be exercised in each stage of manufacture to achieve suitable roundness, velocity, rebound, "click", "feel", and the like.

Additionally, a soft thread wound (three-piece) ball is not well suited for use by the less skilled and/or high handicap golfer who cannot intentionally control the spin of the ball. For example, the unintentional application of side spin by a less skilled golfer produces hooking or slicing. The side spin reduces the golfer's control over the ball as well as reduces travel distance.

Similarly, despite all of the benefits of balata, balata covered balls are easily "cut" and/or damaged if miss-hit. Consequently, golf balls produced with balata or balata containing cover compositions can exhibit a relatively short life span. As a result of this negative property, balata and its synthetic substitute, trans-polyisoprene, and resin blends, have been essentially replaced as the cover materials of choice by golf ball manufacturers by materials comprising ionomeric resins and other elastomers such as polyurethanes.

Multi-piece solid golf balls, on the other hand, include a solid resilient core and a cover having single or multiple layers employing different types of material molded on the core. The core can also include one or more layers. Additionally, one or more intermediate, or mantle, layers can also be included between the core and cover layer(s).

By utilizing different types of materials and different construction combinations, multi-piece solid golf balls have now been designed to match and/or surpass the beneficial properties produced by three-piece wound balls. Additionally, the multi-piece solid golf balls do not possess the manufacturing difficulties, etc., that are associated with the three-piece wound balls.

The one-piece golf ball and the solid core for a multi-piece solid (non-wound) ball frequently are formed from a combination of elastomeric materials such as polybutadiene and other rubbers that are cross-linked. These materials are molded under high pressure and temperature to provide a ball or core of suitable compression and resilience. The cover or cover layers typically contain a substantial quantity of ionomeric resins that impart toughness and cut resistance to the covers. Additional cover materials include synthetic balatas, polyurethanes, and blends of ionomers with polyurethanes, etc.

As a result, a wide variety of multi-piece solid golf balls are now commercially available to suit an individual player's game. In essence, different types of balls have been, and are being, specifically designed to suit various skill levels. Moreover, improved golf balls are continually being produced by golf ball manufacturers with technological advancements in materials and manufacturing processes.

In this regard, the composition of the core or center of a golf ball is important in that it affects several characteristics (i.e., playability, durability, etc.) of the ball. Additionally, it provides resilience to the golf ball, while also providing many desirable properties to both the core and the overall golf ball, including weight, compression, distance, etc. Similarly, the mantle layers affect, among other things, the compression and resilience of the overall golf ball. The composition of the cover layer affects the spin, feel, resilience, and playability properties of the ball.

Due to the continuous importance of improving the properties of a golf ball, it would be beneficial to make a multi-layer golf ball that exhibits improved properties, particularly improved combinations of compression, resilience, and durability.

These and other non-limiting objects and features of the disclosure will be apparent from the following description and from the claims.

BRIEF SUMMARY OF THE INVENTION

Disclosed herein, in various embodiments, are multi-layer golf balls. The embodiments exhibit enhanced combinations of compression, resilience, and durability properties. In particular, the golf balls have such characteristics as excellent feel and distance, low driver spin, high initial velocity, excellent green-side spin, improved adhesion between the layers, and excellent processability. The multi-layer golf balls comprise a core, a mantle layer, and a polyurethane/polyurea cover. Furthermore, the multi-layer golf balls may comprise a core, an inner mantle, an ionomer outer mantle or skin, and a polyurethane/polyurea cover. The golf balls of the present invention may also comprise a multi-layer core, one or more mantle layers mantle, and a polyurethane/polyurea cover.

In exemplary embodiments, the core comprises a high cis-polybutadiene crosslinked with a difunctional acrylate. In further embodiments, the polybutadiene is a mid to high Mooney viscosity polybutadiene or blends thereof. This results in a soft, enhanced velocity core. The polybutadiene preferably has a Mooney viscosity of about 35 or more, including from about 35 to about 70. In other embodiments, the solid core further comprises a peptizer and/or a thiosynergist to further increase the resilience and softness of the core. The peptizer may be a halogenated thiophenol, such as pentachlorothiophenol, or its metal salt. The thiosynergist may be disodium hexamethylene bis(thiosulfate) dehydrate (DHTS). In further embodiments, the core is a soft, high velocity core. It has a compression (Instron) of greater than 0.0880, including greater than 0.0900 and 0.0950.

In exemplary embodiments comprising more than one inner cover layer, either the inner mantle or the outer mantle comprises a highly neutralized ionomer material, such as a highly neutralized ethylene copolymer or terpolymer. In further exemplary embodiments comprising a single mantle layer, the mantle comprises a highly neutralized ionomer material, such as a highly neutralized ethylene copolymer or terpolymer. In further embodiments, the ionomer is neutralized to 80% or more. These thermoplastic materials produce a relatively soft, low compression inner mantle with high resilience. In other embodiments, the ionomer has been modified with a fatty acid, such as stearic acid, oleic acid, or metal stearate/oleate additive. It may also have a starting material that is a terpolymer or a copolymer. In such embodiments, ethylene acrylic acid, or methacrylate, and ethylene acrylates maybe used as the starting material. The inner mantle has a Shore D hardness of from about 30 to about 75, including from about 50 to about 70.

In exemplary embodiments comprising more than one inner layer, either the inner mantle or outer mantle or skin comprises ionomers or ionomer blends. The other mantle or skin has a high flex modulus. Additionally, the ionomer outer mantle or skin adheres well to the inner mantle and the polyurethane/polyurea cover.

In exemplary embodiments, the polyurethane/polyurea cover comprises a thermoset material. The cover can be produced by cast or reaction injection molding (RIM). The cover has a Shore B hardness of from about 20 to about 95 including from about 60 to about 90.

Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a preferred embodiment of a golf ball.

FIG. 2 is a cross-sectional view of an alternative embodiment of a golf ball.

DETAILED DESCRIPTION OF THE INVENTION

Disclosed herein, in various embodiments, are multi-layered golf balls having improved structural configurations and characteristics. The balls exhibit low spin when struck by a driver off the tee and high initial velocity resulting in increased distance. Furthermore, the balls produce high spin around the green when struck with a high lofted club. These are characteristics that are generally desirable to skilled golfers, i.e., low driver spin off the tee, and high spin and enhanced playability green-side. The balls also exhibit excellent processing and durability characteristics.

A more complete understanding of the compositions, products, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the present development, and are, therefore, not intended to indicate relative size and dimensions of the golf balls and/or components thereof.

Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to component of like function.

Referring to FIG. 1, a multi-layer golf ball 10 is illustrated. In this embodiment, golf ball 10 comprises a core 12, an inner mantle 14, an outer mantle or skin 16, and a cover 18. Referring to FIG. 2, the golf ball 10 comprises a core 12, an inner mantle 14 and a cover 18.

The core 12, is preferably a soft, high resilience, molded core comprising a high cis-polybutadiene having a Mooney viscosity of from about 20 to about 70, more preferably from 35 to about 70, and optionally a peptizer such as pentachlorothiophenol or a metallic salt thereof and/or a metal thiosulfate. The molded core has an Instron compression of greater than 0.0880, including an Instron compression of about 0.0900 to about 0.1150 and a resilience of from about 0.760 to about 0.820, including from about 0.770 to about 0.810.

The inner mantle 14 preferably comprises a highly neutralized ionomer, i.e., an ionomer neutralized to 80% or more, including from about 90% to about 100%. Optionally, the highly neutralized ionomer is modified with a fatty acid or a salt thereof. Preferably, the ionomer comprises a copolymer or terpolymer of ethylene and ethylene acrylate neutralized to 80% or more. The inner mantle 14 has a Shore D hardness of from about 30 to about 80, including from about 50 to about 75. This layer maybe injection or compression molded. Furthermore, it may undergo any various post-processing steps know to those skilled in the art i.e centerless grinding, treatment with plasma, treatment with an adhesion promoter, etc.

The outer mantle or skin 16 comprises an ionomer resin or blends thereof. The ionomer skin has a flex modulus of from about 1 to about 100 kpsi, including from about 10 to about 75 kpsi. Additionally, the ionomer skin exhibits good adhesive properties with the inner mantle 14 and the cover 18. This layer may be injection or compression molded. Furthermore, it may undergo any various post-processing steps know to those skilled in the art i.e centerless grinding, treatment with plasma, treatment with an adhesion promoter, etc.

In a further exemplary embodiment, according to FIG. 1, the inner mantle 14 comprises an ionomer resin or blends thereof. The ionomer mantle has a flex modulus of from about 1 to about 100 kpsi, including from about 20 to about 75 kpsi. Furthermore, the outer mantle or skin 16 comprises a highly neutralized ionomer, i.e., an ionomer neutralized to 80% or more, including from about 90% to about 100%. Optionally, the highly neutralized ionomer is modified with a fatty acid or a salt thereof. Preferably, the ionomer comprises a copolymer or terpolymer of ethylene and ethylene acrylate neutralized to 80% or more. The outer mantle or skin 16 has a Shore D hardness of from about 30 to about 80, including from about 50 to about 75. Either layer may be injection or compression molded. Furthermore, either layer may undergo any various post-processing steps know to those skilled in the art i.e centerless grinding, treatment with plasma, treatment with an adhesion promoter, etc.

The cover 18 is a thermoset polyurethane/polyurea cover. Preferably the cover is a thermoset polyurethane/polyurea cover as produced by reaction injection molding. The cover preferably has a flex modulus in the range of from about 1 to about 310 kpsi, a Shore B hardness in the range from about 20 to about 95, a thickness in the range from about 0.005'' to about 0.050'', and shows good scuff resistance and good cut resistance.

Two principal properties involved in golf ball performance are resilience and compression. Resilience is determined by the coefficient of restitution (COR), i.e., the constant "e" which is the ratio of the relative velocity of an elastic sphere after direct impact to that before impact. As a result, the coefficient of restitution ("e") can vary from 0 to 1, with 1 being equivalent to a perfectly or completely elastic collision and 0 being equivalent to a perfectly or completely inelastic collision.

Resilience, along with additional factors such as club head speed, angle of trajectory and ball configuration (i.e., dimple pattern) generally determines the distance a ball will travel when hit. Since club head speed and the angle of trajectory are factors not easily controllable by a manufacturer, factors of concern among manufacturers are the COR and the surface configuration of the ball.

The COR in solid core balls is a function of the composition of the molded core and of the cover. In balls containing a wound core (i.e., balls comprising a liquid or solid center, elastic windings, and a cover), the COR is a function of not only the composition of the center and the cover, but also the composition and tension of the elastomeric windings.

The COR is the ratio of the outgoing velocity to the incoming velocity. In the examples of this application, the COR of a golf ball was measured by propelling a ball horizontally at a speed of 125.+-.1 feet per second (fps) against a generally vertical, hard, flat steel plate and measuring the ball's incoming and outgoing velocity electronically. Speeds were measured with a pair of Ohler Mark 55 ballistic screens, which provide a timing pulse when an object passes through them. The screens are separated by 36 inches and are located 25.25 inches and 61.25 inches from the rebound wall. The ball speed was measured by timing the pulses from screen 1 to screen 2 on the way into the rebound wall (as the average speed of the ball over 36 inches), and then the exit speed was timed from screen 2 to screen 1 over the same distance. The rebound wall was tilted 2 degrees from a vertical plane to allow the ball to rebound slightly downward in order to miss the edge of the cannon that fired it.

As indicated above, the incoming speed should be 125.+-.1 fps. Furthermore, the correlation between COR and forward or incoming speed has been studied and a correction has been made over the .+-.1 fps range so that the COR is reported as if the ball had an incoming speed of exactly 125.0 fps.

The COR must b