Golf ball having thin intermediate layer

Abstract

A golf ball has a thin intermediate layer, within specified thickness and hardness, situated between a ball core and cover layer. The thin intermediate layer provides for a ball having superior ball spin performance without loss of ball speed. Particular compositions for the intermediate layer, along with methods for spray-coating of a ball core and grinding down of a thick intermediate layer that are particularly suited for making this thin intermediate layer, also are disclosed.

1 . A golf ball comprising a core, a cover layer on the outer surface of the golf ball, and an intermediate layer between the core and the cover layer, wherein the intermediate layer is situated immediately over a solid surface and comprises an elastomeric material comprising an amide block copolymer, and wherein the intermediate layer has a thickness of from about 0.1 to about 1.0 mm and has a Shore A hardness of from about 30 to about 100.  
   
   
       2 . A golf ball as defined in  claim 1 , wherein the intermediate layer has a thickness of from about 0.1 to about 0.77 mm.  
   
   
       3 . A golf ball as defined in  claim 2 , wherein the intermediate layer has a thickness of from about 0.1 to about 0.65 mm.  
   
   
       4 . A golf ball as defined in  claim 3 , wherein the intermediate layer has a thickness of from about 0.1 to about 0.33 mm.  
   
   
       5 . (canceled)  
   
   
       6 . A golf ball as defined in  claim 1 , wherein the intermediate layer has a Shore A hardness of from about 45 to about 100.  
   
   
       7 . A golf ball as defined in  claim 6 , wherein the intermediate layer has a Shore A hardness of from about 60 to about 100.  
   
   
       8 . (canceled)  
   
   
       9 . A golf ball as defined in  claim 1 , wherein the amide block copolymer comprises a polyether amide block copolymer.  
   
   
       10 . A golf ball comprising a core, a cover layer on the outer surface of the golf ball, and an intermediate layer between the core and the cover layer, wherein the intermediate layer is situated immediately over a solid surface and comprises a polyester elastomer or a polyether ester elastomer, and wherein the intermediate layer has a thickness of from about 0.1 to about 1.0 mm and has a Shore A hardness of from about 30 to about 100.  
   
   
       11 . (canceled)  
   
   
       12 . A golf ball comprising a core, a cover layer on the outer surface of the golf ball, and an intermediate layer between the core and the cover layer, wherein the intermediate layer is situated immediately over a solid surface and comprises a polyurethane, and wherein the intermediate layer has a thickness of from about 0.1 to about 1.0 mm and has a Shore A hardness of from about 30 to about 100.  
   
   
       13 . A golf ball comprising a core, a cover layer on the outer surface of the golf ball, and an intermediate layer between the core and the cover layer, wherein the intermediate layer is situated immediately over a solid surface and comprises a polyester/polyolefin blend, and wherein the intermediate layer has a thickness of from about 0.1 to about 1.0 mm and has a Shore A hardness of from about 30 to about 100.  
   
   
       14 . A golf ball comprising a core, a cover layer on the outer surface of the golf ball, and an intermediate layer between the core and the cover layer, wherein the intermediate layer is situated immediately over a solid surface and comprises styrenic copolymer, styrenic terpolymer, or mixtures thereof, and wherein the intermediate layer has a thickness of from about 0.1 to about 1.0 mm and has a Shore A hardness of from about 30 to about 100.  
   
   
       15 . A golf ball as defined in  claim 1 , wherein the core comprises an inner core and a plurality of outer cores encasing the inner core.  
   
   
       16 - 17 . (canceled)  
   
   
       18 . A golf ball as defined in  claim 1 , further comprising a layer of ribber thread situated between the core and the intermediate layer.  
   
   
       19 . A golf ball as defined in  claim 1 , further comprising a plurality of additional intermediate layers situated between the core and the cover layer.  
   
   
       20 - 44 . (canceled)