Multi-core, multi-layer cover golf ball

Abstract

The present invention is directed to a golf ball comprising a multi-layer core component. The multi-layer core comprises an interior center component formed from a thermoset material, a thermoplastic material, or combinations thereof. The multi-layer core also comprises a core layer disposed about the center component, formed from a thermoset material, a thermoplastic material, or combinations thereof. The present invention golf ball may further comprise an outer core layer that surrounds the multi-layer core. The resulting multi-layered golf ball of the present invention provides for enhanced distance without sacrificing playability or durability when compared to known golf balls.

What is claimed is:  
     
         1 . A golf ball comprising: 
 a multi-layer core comprising a center component and a core layer disposed about said center component;    wherein said center component comprises a thermoset material and said core layer comprises a thermoset material; and,    a cover layer disposed about said multi-layer core;    wherein said cover layer includes at least one of (i) a multi-layer cover comprising an inner cover layer having a Shore D hardness of 65 or greater and an outer cover layer having a Shore D hardness of 65 or less, said inner cover layer being harder than said outer cover layer, (ii) a multi-layer cover comprising an inner cover layer having a Shore D hardness of 65 or less and an outer cover layer of 65 or greater, wherein said inner cover layer is softer than said outer cover layer, (iii) a single non-ionomeric outer cover layer having a Shore D hardness of from about 40 to 80, and (iv) a single ionomeric outer cover layer having a Shore D hardness of at least 56.    
     
     
         2 . The golf ball of  claim 1  wherein the outer cover layer is selected from multi-layer cover (i) or multi-layer cover (ii).  
     
     
         3 . The golf ball of  claim 1  wherein said thermoset material comprises a material selected from the group consisting of (i) a diene-containing polymer, (ii) a metallocene catalyzed polyolefin that is cross-linked, (iii) a polyurethane, (iv) a silicone, (v) a polyamide, (vi) a polyurea, and (vii) combinations thereof; and said thermoplastic material comprises a material selected from the group consisting of (i) an ionomer, (ii) a polyurethane, (iii) an elastomer, (iv) a polyetheramide, (v) a polyetherester, (vi) a metallocene catalyzed polyolefin, (vii) a styrene butadiene block copolymer, and (viii) combinations thereof.  
     
     
         4 . The golf ball of  claim 1  wherein said core layer comprises more than one layer.  
     
     
         5 . The golf ball of  claim 1  wherein said center component thermoset material comprises a polybutadiene rubber.  
     
     
         6 . The golf ball of  claim 5  wherein said thermoset polybutadiene rubber further comprises zinc diacrylate (ZDA).  
     
     
         7 . The golf ball of  claim 1  wherein said core layer thermoset material comprises polybutadiene rubber.  
     
     
         8 . The golf ball of  claim 7  wherein said polybutadiene rubber further comprises zinc diacrylate (ZDA).  
     
     
         9 . The golf ball of  claim 1  wherein said center component of said multi-layer core has an outer diameter of from about 1.340 inches to about 1.400 inches, and said core layer of said multi-layer core has an thickness of from about 0.020 to about 0.100 inches.  
     
     
         10 . The golf ball of  claim 1  wherein said center component of said multi-layer core is softer relative to said core layer.  
     
     
         11 . The golf ball of  claim 10  wherein said core layer ha s a Shore D hardness of at least 60.  
     
     
         12 . The golf ball according to  claim 1  wherein each layer in the multi-layer cover (i) and multi-layer cover (ii) is independently formed from a thermoplastic resin, a thermoset resin, or a blend thereof.  
     
     
         13 . The golf ball according to  claim 2  wherein the multi-layer cover (i) or multi-layer cover (ii) comprises at least one ionomeric material.  
     
     
         14 . A golf ball comprising: 
 a multi-layer core comprising a center component and a core layer disposed about said center component;    wherein said center component comprises a polybutadiene thermoset material and said core layer comprises a polybutadiene thermoset material; and,    a cover layer disposed about said multi-layer core;    wherein said cover layer includes at least one of (i) a multi-layer cover comprising an inner cover layer having a Shore D hardness of 65 or greater and an outer cover layer having a Shore D hardness of 65 or less, said inner cover layer being harder than said outer cover layer, (ii) a multi-layer cover comprising an inner cover layer having a Shore D hardness of 65 or less and an outer cover layer of 65 or greater, wherein said inner cover layer is softer than said outer cover layer, and (iii) a single non-ionomeric outer cover layer having a Shore D hardness of from about 40 to 80, and (iv) a single ionomeric outer cover layer having a Shore D hardness of at least 56.    
     
     
         15 . The golf ball according to  claim 14  wherein the cover layer is selected from multi-layer cover (i) or multi-layer cover (ii).  
     
     
         16 . The golf ball of  claim 14  wherein said thermoset material further comprises zinc diacrylate (ZDA).  
     
     
         17 . The golf ball of  claim 14  wherein said core layer comprises more than one layer.  
     
     
         18 . The golf ball of  claim 14  wherein said center component of said dual core comprise is softer relative to said core layer.  
     
     
         19 . The golf ball of  claim 11  wherein said core layer has a Shore D hardness of at least 60.  
     
     
         20 . A golf ball comprising: 
 a multi-layer core comprising a center component and a core layer disposed about said center component;    wherein said center component comprises a polybutadiene/ZDA thermoset material and said core layer comprises a polybutadiene/ZDA thermoset material; and,    a multi-layer, ionomeric cover layer disposed about said dual core;    wherein said cover layer includes at least one of (i) a multi-layer cover comprising an inner cover layer having a Shore D hardness of 65 or greater and an outer cover layer having a Shore D hardness of 65 or less, said inner cover layer being harder than said outer cover layer, and (ii) a multi-layer cover comprising an inner cover layer having a Shore D hardness of 65 or less and an outer cover layer of 65 or greater, wherein said inner cover layer is softer than said outer cover layer.