Acushnet Company

John D Farrell

Brian Comeau

Mark L Binette

Douglas S Goguen

Michael J Sullivan

Shawn Ricci

Michael Michalewich

David A Bulpett

Robert Blink

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.

Golf balls having a foam center with regions of different hardness

Low compression, multi-piece golf balls containing a solid core and two or three-layered cover assemblies are provided. Preferably, the ball has a compression of less than 60 and more preferably less than 50. At least one cover layer is made of a plasticized thermoplastic composition. For example, two-layered and three-layered covers may be made. Preferably, the plasticized thermoplastic composition comprises: a) ethylene acid copolymer, b) plasticizer, and c) cation source. A fatty acid ester such as ethyl oleate or butyl oleate is preferably used as the plasticizer. The cover assembly has good impact durability and helps provide the ball with relatively high resiliency at given compressions.

Low compression golf balls having layers made from plasticized thermoplastic materials

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.

Golf balls having a foam inner core with thermal barrier

Low compression multi-piece golf balls having a solid core comprising at least one layer made of a plasticized thermoplastic composition are provided. Preferably, the ball has a compression of less than 60 and more preferably less than 50. The ball includes a cover in addition to the core sub-assembly. For example, two-piece and three-piece golf balls may be made. The plasticized thermoplastic composition preferably comprises: a) ethylene acid copolymer, b) plasticizer, and c) cation source. Preferably, a fatty acid ester such as butyl oleate is used as the plasticizer. In two-layered core constructions, the outer core layer is preferably formed from a thermoset composition such as polybutadiene rubber. The core layers may have different hardness levels. The core structure and resulting ball have relatively good resiliency at given compressions.

Low compression golf balls containing cores made of plasticized thermoplastic compositions

Multi-piece golf balls having a solid core made of a foamed silicone composition and a cover are provided. For example, three-piece, four-piece, and five-piece golf balls containing different core structures can be made. Preferably, a dual-core having has a silicone foam inner core (center) and surrounding silicone foam outer core layer is made. The core layers can have different hardness gradients. The silicone foam center and outer core layer have good thermal stability and durability and provide the ball with good resiliency.

Golf balls having silicone foam center

Disclosed herein are two-layer and three-layer, low compression golf balls including a low compression single- or dual-layer rubber core and a single cover layer.

Low compression golf ball

Golf ball comprising a non-dissolvable layer having a spherical outer surface; and a dissolvable tie layer or dissolvable layer, dispersible in water heated to a heating temperature of about 80&#xb0; C.-90&#xb0; C. or greater, disposed concentrically about the spherical outer surface and being bonded with the first non-dissolvable layer at an interface there between. The dissolvable tie layer/dissolvable layer may be formed from a composition consisting of a 1-50 percent aqueous mono-valent high acid ionomer dispersion, or, from an ionomer resin composition. The ionomer of either composition has an acid level greater than 18%; has more than 45% of acid groups that are neutralized with a monovalent cation; and is formed from an acid copolymer having a starting melt index of greater than 180 g/10 min. @ 190&#xb0; C. with a 2160 g load. The dissolvable tie layer/dissolvable layer may have a thickness of less than about 0.010 inches, and up to about 0.090 inches in some embodiments.

Recyclable golf ball and method of making

Golf ball comprising a first layer having a first spherical outer surface; a thin moisture vapor barrier layer disposed concentrically about the first spherical outer surface and having a thickness of less than about 0.010 inches; and a second layer disposed concentrically about a second spherical outer surface of the thin moisture vapor barrier layer. The thin moisture vapor barrier layer is formed from an ionomer composition consisting of a 1-50 percent aqueous mono-valent high acid ionomer dispersion, with the ionomer: having an acid level greater than 18%; having more than 45% of acid groups that are neutralized with a monovalent cation; and being formed from an acid copolymer having a starting melt index of greater than 180 g/10 min.@190&#xb0; C. with a 2160 g load. The moisture vapor barrier layer has a moisture vapor transmission rate that is lower than that of at least one of the first layer and/or the second layer.

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Providence, RI, United States of America

John D Farrell