Golf ball with deposited layer

Abstract

A golf ball with a deposited layer is disclosed. The deposited layer is not produced by a molding process, such as injection molding or compression molding. Instead, the deposition process is produced by another process, such as thermal spraying or sintering. The deposited layer may include partially fused particulate material. The deposited layer may be added to a golf ball design as one or more supplemental layers. The deposited layer may also be provided in a golf ball design as a substitute for one or more layers. A golf ball may further include a combination of one or more supplemental deposited layers and one or more substituted deposited layers.

1 . A golf ball comprising a deposited layer, wherein the deposited layer is a cover layer and comprises a plurality of partially fused particulates. 
     
     
         2 . The golf ball of  claim 1 , wherein the partially fused particulates comprise a sintering material, wherein the partially fused particulates have been exposed to at least one of heat and pressure. 
     
     
         3 . The golf ball of  claim 1 , wherein the partially fused particulates comprise re-solidified droplets of a solid material which has been thermally sprayed. 
     
     
         4 . A golf ball, comprising:
 a core;   and   a thermally sprayed cover layer, wherein the thermally sprayed layer comprises re-solidified droplets of a solid material.   
     
     
         5 . (canceled) 
     
     
         6 . The golf ball of  claim 4 , wherein at least one pore is located between adjacent re-solidified droplets. 
     
     
         7 . The golf ball of  claim 6 , wherein the thermally sprayed cover layer has a porosity of approximately 1-20% of its volume. 
     
     
         8 . The golf ball of  claim 4 , wherein the solid material comprises a material selected from the group consisting of polyurethane, polyurea, polysiloxane, polyamide partially or fully neutralized ionomers, thermosetting polydiene rubber, such as polybutadiene, polyisoprene, ethylene propylene diene monomer rubber, ethylene propylene rubber, natural rubber, balata, butyl rubber, halobutyl rubber, styrene butadiene rubber, styrene ethylene butadiene styrene rubber, metallocene catalyzed polyolefin, a single site catalyzed polyolefin, polyurethane copolymers, silicone, thermoplastic elastomer, thermoset elastomer, synthetic rubber, thermoplastic vulcanizate, copolymeric ionomer, terpolymeric ionomer, polycarbonate, polyolefin, polyamide, copolymeric polyamide, polyesters, polyvinyl alcohols, acrylonitrile-butadiene-styrene copolymers, polyarylate, polyacrylate, polyphenylene ether, impact-modified polyphenylene ether, high impact polystyrene, diallyl phthalate polymer, metallocene catalyzed polymers, styrene-acrylonitrile (SAN) (including olefin-modified SAN and acrylonitrile-styrene-acrylonitrile), styrene-maleic anhydride (S/MA) polymer, styrenic copolymer, functionalized styrenic copolymer, functionalized styrenic terpolymer, styrenic terpolymer, cellulose polymer, liquid crystal polymer (LCP), ethylene-propylene-diene terpolymer (EPDM), ethylene-vinyl acetate and compositions containing ethylene-vinyl acetate, and mixtures thereof. 
     
     
         9 . A golf ball comprising a deposited layer, wherein the deposited layer comprises particulates of a sintering material fused by applying at least one of heat and pressure to the sintering material so that the deposited layer comprises fused particulates and wherein the deposited layer is a cover layer. 
     
     
         10 . (canceled) 
     
     
         11 . The golf ball of  claim 9 , further comprising a sprayed layer, wherein the sprayed layer is produced by a thermal spraying process, wherein the thermal spraying process includes providing heat to a solid material to form molten or semi-molten droplets so that the sprayed layer comprises re-solidified droplets. 
     
     
         12 . The golf ball of  claim 11 , wherein the sprayed layer is disposed on the deposited layer. 
     
     
         13 . The golf ball of  claim 11 , wherein the deposited layer is disposed on the sprayed layer. 
     
     
         14 . The golf ball of  claim 11 , wherein at least one additional golf ball layer separates the sprayed layer and the deposited layer. 
     
     
         15 . The golf ball of  claim 11 , wherein the sprayed layer comprises a thermoset material, wherein the spraying process cures the thermoset material. 
     
     
         16 . The golf ball of  claim 9 , wherein the sintering material comprises at least one of a metal, an alloy, a ceramic, a plastic, a composite, and combinations thereof. 
     
     
         17 . The golf ball of  claim 9 , wherein the deposited layer comprises a combination of the sintering material and a powdered thermoset material, wherein the powdered thermoset material comprises a rubber composition. 
     
     
         18 . (canceled) 
     
     
         19 . The golf ball of  claim 9 , wherein the deposited layer is formed on an outer surface of an inner cover layer, wherein the deposited layer includes pits on an outer surface of the cover layer, wherein the pits are located at least on one of lands and dimples of the cover layer. 
     
     
         20 . The golf ball of  claim 9 , wherein at least one pore is located between adjacent fused particulates.