Multi-layer golf ball construction

Abstract

Disclosed herein is a six piece golf ball having a core, an inner mantle layer, an intermediate mantle layer, an outer mantle layer, an inner cover layer, and an outer cover layer.

We claim: 
     
         1 . A six piece golf ball consisting essentially of;
 I a core having a center and an outer surface and having a diameter of from about 0.50 to about 1.62 in, a PGA compression of less than or equal to 40, a flex modulus of less than or equal to 15 kpsi, and a Shore D hardness as measured at said outer surface of less than or equal to 60;   II an inner mantle layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 45, a flex modulus of from about 2 to about 30 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 25;   III an intermediate mantle layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 50, a flex modulus of from about 2 to about 40 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 25;   IV an outer mantle layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 25, a flex modulus of from about 10 to about 50 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 25;   V an inner cover layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 55, a flex modulus of from about 40 to about 85 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 50; and   VI an outer cover layer having a thickness of from about 0.015 to about 0.100 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 95, a flex modulus of from about 2 to about 35 kpsi and a Shore D hardness as measured on the ball of from about 30 to about 75.   
     
     
         2 . The six piece golf ball of  claim 1  wherein;
 I said core has a diameter of from about 0.70 to about 1.50 in, a PGA compression of less than or equal to 30, a flex modulus of less than or equal to 12 kpsi, and a Shore D hardness as measured at said outer surface of less than or equal to 55; 
 II said inner mantle layer has a thickness of from about 0.020 to about 0.200 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 35, a flex modulus of from about 2 to about 25 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 30; 
 III said intermediate mantle layer has a thickness of from about 0.020 to about 0.200 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 35, a flex modulus of from about 5 to about 37 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 30; 
 IV said outer mantle layer has a thickness of from about 0.020 to about 0.200 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 30, a flex modulus of from about 15 to about 45 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 40; 
 V said inner cover layer has a thickness of from about 0.020 to about 0.200 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 60, a flex modulus of from about 45 to about 80 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 55; and 
 VI said outer cover layer has a thickness of from about 0.020 to about 0.080 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 90, a flex modulus of from about 4 to about 25 kpsi and a Shore D hardness as measured on the ball of from about 38 to about 68. 
 
     
     
         3 . The six piece golf ball of  claim 1  wherein;
 I said core has a diameter of from about 0.80 to about 1.45 in, a PGA compression of less than or equal to 30, a flex modulus of less than or equal to 10 kpsi, and a Shore D hardness as measured at said outer surface of less than or equal to 50; 
 II said inner mantle layer has a thickness of from about 0.030 to about 0.100 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 35, a flex modulus of from about 5 to about 15 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 40; 
 III said intermediate mantle layer has a thickness of from about 0.030 to about 0.100 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 40, a flex modulus of from about 8 to about 34 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 40; 
 IV said outer mantle layer has a thickness of from about 0.030 to about 0.100 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 35, a flex modulus of from about 15 to about 45 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 45; 
 V said inner cover layer has a thickness of from about 0.030 to about 0.100 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 65, a flex modulus of from about 50 to about 75 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 60; and 
 VI said outer cover layer has a thickness of from about 0.025 to about 0.060 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 90, a flex modulus of from about 5 to about 20 kpsi and a Shore D hardness as measured on the ball of from about 40 to about 65. 
 
     
     
         4 . The six piece golf ball of  claim 3  wherein;
 I said core comprises polybutadiene, and a peptizer selected from the group consisting of an organic sulfur compound, a metal salt of an organic sulfur compound, a non-metal salt of an organic sulfur compound, and any and all combinations thereof; 
 II said inner mantle layer comprises a polyalkenamer having a trans-content of from about 40 to about 95 wt %, a cis-content of from about 5 to about 60, wt %, and a melting point of greater than about 15° C. or a modified unimodal or modified bimodal ionomer; 
 III said intermediate mantle layer comprises a polyalkenamer having a trans-content of from about 40 to about 95 wt %, a cis-content of from about 5 to about 60, wt %, and a melting point of greater than about 15° C. or a modified unimodal or modified bimodal ionomer; 
 IV said outer mantle layer comprises a polymer selected from the group consisting of;
 a) a polyalkenamer having a trans-content of from about 40 to about 95 wt %, a cis-content of from about 5 to about 60, wt %, and a melting point of greater than about 15° C.; 
 b) a modified unimodal ionomer; 
 c) a modified bimodal ionomer; and 
 d) all combinations of a), b) and c) 
 
 V said inner cover layer comprises an ionomer; and 
 VI said outer cover layer comprises a polymer selected from the group consisting of
 a) a thermoset polyurethane; 
 b) a thermoplastic polyurethane; 
 c) a thermoset polyurea; 
 d) a thermoplastic polyurea; 
 e) a multicomponent blend composition (“MCBC”), the MCBC comprising (A) a block copolymer; and (B) one or more acidic polymers; and (C) one or more basic metal salts present in an amount to neutralize at greater than or equal to about 30 percent of the acid groups of Component (B); and 
 f) any and all combinations thereof. 
 
 
     
     
         5 . The golf ball of  claim 4  having a frequency of less than or equal to 3250 Hz, and a sound pressure level, S, of less than or equal to 89.5 dB. 
     
     
         6 . The golf ball of  claim 1  wherein each successive layer starting from the core and moving [progressively outward to inner cover layer has a flexural modulus that is greater by at least 3 kpsi relative to the immediately adjacent inner layer. 
     
     
         7 . The golf ball of  claim 1  having a flexural modulus (FM) gradient relationship such that FM(core)<FM(inner mantle)<FM(intermediate mantle)<FM(outer mantle)<FM(inner cover)>FM(outer cover). 
     
     
         8 . The golf ball of  claim 1  having a material Shore D hardness (H) gradient relationship of: H(core)<H(inner mantle)<H(intermediate mantle)<H(outer mantle)<H(inner cover)>H (outer cover). 
     
     
         9 . The golf ball of  claim 8  wherein the Shore D of each successive mantle layer through the inner cover layer increases by 2 or more Shore D hardness units. 
     
     
         10 . A six piece golf ball consisting essentially of;
 I) a core having a center and an outer surface and having a diameter of from about 0.50 to about 1.62 in, a PGA compression of less than or equal to 30, a flex modulus of less than or equal to 15 kpsi, and a Shore D hardness as measured at said outer surface of less than or equal to 60;   II) an inner mantle layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 35, a flex modulus of from about 2 to about 25 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 25;   III) an intermediate mantle layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 35, a flex modulus of from about 2 to about 30 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 25;   IV) an outer mantle layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 25, a flex modulus of from about 10 to about 50 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 25;   V) an inner cover layer having a thickness of from about 0.010 to about 0.400 inches, a PGA compression as measured on the golf ball precursor of greater than or equal to 60, a flex modulus of from about 50 to about 80 kpsi and a Shore D hardness as measured on the ball of greater than or equal to 55; and   VI) an outer cover layer having a thickness of from about 0.015 to about 0.100 inches, a PGA compression as measured on the golf ball precursor of less than or equal to 90, a flex modulus of from about 2 to about 30 kpsi and a Shore D hardness as measured on the ball of from about 30 to about 75.