Novel Dual Cores for Golf Balls

Abstract

The present invention is directed to a golf ball comprising a dual core component. The dual core comprises an interior center component formed from a thermoset material, a thermoplastic material, or combinations thereof. The dual 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 dual 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.

1 . A golf ball comprising: 
 a dual core including a center component and a core layer disposed about the center component, the center component comprising a thermoset material including a polyurethane, and the core layer comprising a thermoplastic material; and    a cover layer assembly disposed about the dual core, the cover layer assembly including an inner cover layer and an outer cover layer, wherein one of the inner cover layer and the outer cover layer has a Shore D hardness of 65 or greater and the other of the inner cover layer and the outer cover layer has a Shore D hardness of 65 or less, wherein the Shore D hardnesses of the inner cover layer and the outer cover layer are not the same.    
   
   
       2 . The golf ball of  claim 1  wherein at least one of the inner cover layer and the outer cover layer comprises a polyurethane material.  
   
   
       3 . A golf ball comprising: 
 a dual core including a center component and a core layer disposed about the center component, the center component comprising a thermoset material, the thermoset material comprising a material selected from the group consisting of (i) a diene-containing polymer, (ii) a metallocene catalyzed polyolefin that is crosslinked, (iii) a polyurethane, (iv) a silicone, (v) a polyamide, (vi) a polyurea, and (vii) combinations thereof, and the core layer comprising a thermoplastic material, wherein the center component of the dual core has an outer diameter of from about 0.500 inch to about 1.250 inches, and the dual core has an outer diameter of from about 1.25 inches to about 1.600 inches, and further wherein at least one of the core layer and the center component of the dual core comprise an agent that is foamed or otherwise reduced in density; and    a cover layer assembly disposed about the dual core, wherein the cover layer assembly includes at least one of (i) an inner cover layer having a Shore D hardness of 65 or less and an outer cover layer having a Shore D hardness different from that of the inner cover layer, or (ii) a single outer cover layer having a Shore D hardness of from about 40 to 80.    
   
   
       4 . The golf ball of  claim 3 , wherein the 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.  
   
   
       5 . A golf ball comprising: 
 a dual core including a center component and a core layer disposed about the center component, wherein at least one of the core layer and the center component comprises an agent that is foamed or otherwise reduced in density; and    a cover assembly disposed on the dual core, the cover assembly including an inner cover layer and an outer cover layer, the outer cover layer defining a plurality of dimples, at least one of the inner cover layer and the outer cover layer comprising a first ionomer having 16 weight percent acid or less, and at least one of the inner cover layer and the outer cover layer comprising a second ionomer having greater than 16 weight percent acid.    
   
   
       6 . The golf ball of  claim 5 , wherein the inner cover layer comprises the second ionomer having great than 16 weight percent acid.  
   
   
       7 . A golf ball comprising: 
 a core assembly including a center component and at least one core layer disposed about the core component, wherein at least one of the center component and the at least one core layer comprises a density increasing agent, and wherein at least one of the center component and the at least one core layer comprises an agent that is foamed or otherwise reduced in density; and    a cover assembly disposed on the core assembly, the cover assembly including a plurality of cover layers.