Multi-layer golf ball

Abstract

The present invention relates to a golf ball that provides improved playing characteristics by providing a cushioning interface between a center and subsequent layers. The ball can include a center, a soft intermediate layer, and a cover, although various constructions and modifications are possible. The intermediate layer can include an elastomeric latex or solution that will dry to form a soft film on the surface of the center. Such a soft rubber interlayer can serve as a cushioning interface to help improve durability and softness of the ball upon club impact. In another embodiment, the thin intermediate layer includes a responsive viscoelastic composition that exhibits an increase in viscosity under shear forces.

What is claimed is:  
     
         1 . A multi-layer golf ball comprising: 
 a core comprising: 
 a center;  
 a intermediate layer formed around the center, the intermediate layer being less than about 0.01 inches thick and having a flexural modulus of less than about 10,000 psi;  
 a mantle comprising at least one layer, the layer comprising a resilient polymer component, wherein the mantle is disposed concentrically adjacent the intermediate layer; and  
   at least one cover layer disposed concentrically around the mantle;    wherein the intermediate layer comprises low ammonia natural latex and/or pre-vulcanized natural latex, elastomer adhesives, urethane dispersions, aqueous and non-aqueous adhesives, synthetic latexes, alkyd resins, acrylic and latex copolymers, polyurethane coatings, or mixtures thereof.    
     
     
         2 . The ball of    claim 1   , wherein the intermediate layer thickness is about 0.0005 inches to 0.01 inches.  
     
     
         3 . The ball of    claim 2   , wherein the intermediate layer thickness is about 0.0008 inches to 0.002 inches.  
     
     
         4 . The ball of    claim 1   , wherein the intermediate layer has a Shore A hardness less than about 90.  
     
     
         5 . The ball of    claim 4   , wherein the intermediate layer has a Shore A hardness less than about 70.  
     
     
         6 . The ball of    claim 1   , wherein the intermediate layer has a flexural modulus less than about 3,000 psi.  
     
     
         7 . The ball of    claim 1   , wherein the center has an outer diameter of about 0.5 inches to 1.35 inches.  
     
     
         8 . The ball of    claim 7   , wherein the center has an outer diameter of about 0.75 inches to 1.25 inches.  
     
     
         9 . The ball of    claim 1   , wherein a combination of the center, the soft elastic intermediate layer, and the mantle has an outer diameter of about 1.45 inches to 1.6 inches.  
     
     
         10 . The ball of    claim 9   , wherein a combination of the center, the soft elastic intermediate layer, and the mantle has an outer diameter of about 1.5 inches to 1.58 inches.  
     
     
         11 . The ball of    claim 1   , wherein the center is solid, or filled with a liquid, a gel, a foam, or a gas.  
     
     
         12 . The ball of    claim 1   , wherein the mantle layer comprises a reinforcing polymer component.  
     
     
         13 . The ball of    claim 1   , wherein the resilient polymer component of the mantle layer comprises polybutadiene, natural rubber, polyisoprene, styrene-butadiene, or styrene-propylene-diene rubber.  
     
     
         14 . The ball of    claim 1   , wherein the center is a solid center, wherein the solid center comprises a resilient polymer component.  
     
     
         15 . The ball of    claim 14   , wherein the solid center comprises polybutadiene, natural rubber, polyisoprene, styrene-butadiene, or styrene-propylene-diene rubber.  
     
     
         16 . The ball of    claim 13   , wherein the resilient polymer component comprises 1,4-cis-polybutadiene having a molecular weight average of about 50,000 to 1,000,000.  
     
     
         17 . The ball of    claim 13   , wherein the amount of resilient polymer component is between about 60 to 99 weight percent of the total weight of polymer components.  
     
     
         18 . The ball of    claim 13   , further comprising at least one of a filler, a free-radical initiator, or a crosslinking agent.  
     
     
         19 . The ball of    claim 13   , wherein the mantle layer has a flexural modulus of greater than about 3.5 MPa.  
     
     
         20 . The ball of    claim 1   , wherein the soft intermediate layer is comprised of a natural or a synthetic latex material.  
     
     
         21 . The ball of    claim 1   , wherein the intermediate layer is comprised of additives, fillers, thickeners, or a combination thereof.  
     
     
         22 . The ball of    claim 1   , wherein the filler is zinc oxide and is present in an amount of about 0.5 to 20 weight percent.  
     
     
         23 . A golf ball comprising: 
 a solid center having a first hardness;    an intermediate layer formed over the solid center having a second hardness less than the first;    an outer layer formed over the intermediate layer having a third hardness greater than the first hardness;    a cover.    
     
     
         24 . The ball of    claim 23   , wherein the first hardness is from about 20 to 40 Shore D.  
     
     
         25 . The ball of    claim 23   , wherein the second hardness is less than about 20 Shore D.  
     
     
         26 . The ball of    claim 23   , wherein the third hardness is greater than about 50 Shore D.  
     
     
         27 . A multi-layer golf ball comprising: 
 a core having at least one layer;    a cover disposed concentrically about the core and having at least one layer; and    an intermediate layer formed of a responsive viscoelastic composition disposed between the core and the at least one cover layer.    
     
     
         28 . The golf ball of    claim 27   , wherein the intermediate layer is less than about 0.01 inches thick.  
     
     
         29 . The golf ball of    claim 27   , wherein the intermediate layer is from about 0.0005 to 0.01 inches thick.  
     
     
         30 . The golf ball of    claim 27   , wherein the intermediate layer is from about 0.0008 to 0.002 inches thick.  
     
     
         31 . The golf ball of    claim 27   , wherein the intermediate layer is from about 0.01 to 0.1 inches thick.  
     
     
         32 . The golf ball of    claim 27   , wherein the intermediate layer is from about 0.01 to 0.03 inches thick.  
     
     
         33 . The golf ball of    claim 27   , wherein the intermediate layer is disposed between two cover layers.  
     
     
         34 . The golf ball of    claim 27   , wherein the intermediate layer is disposed between the core and a second intermediate layer.  
     
     
         35 . The golf ball of    claim 27   , wherein the intermediate layer has a plasticity of about 20 mils to 150 mils.  
     
     
         36 . The golf ball of    claim 27   , wherein the intermediate layer has a plasticity of about 60 mils to 120 mils.  
     
     
         37 . The golf ball of    claim 27   , wherein the intermediate layer comprises a solid, semi-solid, gel, or gel-like material.  
     
     
         38 . The golf ball of    claim 37   , wherein the material comprises at least one of polydimethyl siloxane, dimethyl cyclosiloxane, a hydroxy-terminated polydimethyl siloxane, polyvinyl alcohol, an acrylic plastisol, an acrylic organosol, a hydrocarbon-based gel, a sulfonate ionomer, butyl rubber ionomer, an ionized crosslinked polyacrylamide gel, a microporous fast-response gel, a thermoplastic elastomer gel, or a blend thereof.  
     
     
         39 . The golf ball of    claim 27   , wherein the intermediate layer material has a hardness of less than about 90 Shore A.  
     
     
         40 . The golf ball of    claim 27   , wherein the intermediate layer material has a hardness of less than about 70 Shore A.  
     
     
         41 . The golf ball of    claim 27   , wherein the cover has a thickness of about 0.02 to 0.1 inches.