Golf balls having multi-layered cores with heat-activated foam center

Abstract

Multi-layered, golf balls having a core made of a foamed composition are provided. The core preferably has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition comprising secondary blowing agents that are activated by heat is used to form the foam center. Non-foamed thermoset materials such as polybutadiene rubber may be used to form the outer core layer. The core layers have different hardness gradients and specific gravity values. The foam cores have good resiliency, thermal stability, and durability over a wide temperature range. The ball further includes a cover that may be multi-layered.

We claim: 
     
         1 . A golf ball, comprising a core assembly and a cover, the core assembly comprising:
 i) an inner core layer comprising a secondary heat-activated foam composition, the inner core layer having a diameter in the range of about 0.100 to about 1.100 inches and a specific gravity (SG inner ) and a center hardness (H inner core center ); and   ii) an outer core layer comprising a non-foamed thermoset rubber composition, the outer core layer being disposed about the inner core layer and having a thickness in the range of about 0.100 to about 0.750 inches, and a specific gravity (SG outer ) and an outer surface hardness (H outer surface of OC ), wherein the SG outer , is greater than the SG inner , and the H inner core center  is in the range of about 10 to about 60 Shore C and the H outer surface of OC  is in the range of about 65 to about 96 Shore C to provide a positive hardness gradient across the core assembly.   
     
     
         2 . The golf ball of  claim 1 , wherein the secondary heat-activated foam composition comprises primary and secondary chemical blowing agents. 
     
     
         3 . The golf ball of  claim 2 , wherein the primary blowing agent is water and the secondary chemical blowing agent is selected from the group consisting of azo, nitroso, hydrazine, carbazide, and hydrogen carbonate compounds, and mixtures thereof. 
     
     
         4 . The golf ball of  claim 1 , wherein the secondary blowing agent is selected from the group consisting of 4,4′-oxybis(benzenesulfonylhydrazide) and sodium hydrogen carbonate. 
     
     
         5 . The golf ball of  claim 1 , wherein the wherein the secondary heat-activated foam composition further comprises expandable gas-containing microspheres. 
     
     
         6 . The core assembly of  claim 1 , wherein the inner core comprises a foamed polyurethane composition. 
     
     
         7 . The golf ball of  claim 6 , wherein the foamed polyurethane composition is prepared by adding water and a secondary chemical blowing agent to a mixture of polyisocyanate, polyol, and curing agent compounds, surfactant, and catalyst, the water being added in a sufficient amount to cause the mixture to foam. 
     
     
         8 . The golf ball of  claim 1 , wherein the outer core layer comprises at least one thermoset rubber material selected from the group consisting of polybutadiene, ethylene-propylene rubber, ethylene-propylene-diene rubber, polyisoprene, styrene-butadiene rubber, polyalkenamers, butyl rubber, halobutyl rubber, polystyrene elastomers, copolymers of isobutylene and p-alkylstyrene, halogenated copolymers of isobutylene and p-alkylstyrene, copolymers of butadiene with acrylonitrile, polychloroprene, alkyl acrylate rubber, chlorinated isoprene rubber, acrylonitrile chlorinated isoprene rubber, and mixtures thereof 
     
     
         9 . The golf ball of  claim 8 , wherein the outer core layer comprises a thermoset polybutadiene rubber composition. 
     
     
         10 . The golf ball of  claim 1 , wherein the inner core layer has a diameter in the range of about 0.100 to about 0.900 inches and a specific gravity in the range of about 0.25 to about 1.25 g/cc. 
     
     
         11 . The golf ball of  claim 1 , wherein the inner core layer has a diameter in the range of about 0.400 to about 0.800 inches and a specific gravity in the range of about 0.30 to about 0.95 g/cc. 
     
     
         12 . The golf ball of  claim 1 , wherein the outer core layer has a thickness in the range of about 0.250 to about 0.750 inches and a specific gravity in the range of about 0.60 to about 2.90 g/cc. 
     
     
         13 . The golf ball of  claim 1 , wherein the inner core layer has an outer surface hardness (H inner core surface ) and a center hardness (H inner core center ), the H inner core surface  being greater than the H inner core center  to provide a positive hardness gradient; and the outer core layer has an outer surface hardness (H outer surface of OC ) and a midpoint hardness (H midpoint of OC ), the H outer surface of OC  being greater than the (H midpoint of OC ), to provide a positive hardness gradient. 
     
     
         14 . The golf ball of  claim 13 , wherein the H inner core center  is in the range of about 10 to about 48 Shore C and the H inner core surface  is in the range of about 24 to about 55 Shore C. 
     
     
         15 . The golf ball of  claim 13 , wherein the H inner core center  is in the range of about 15 to about 80 Shore A and the H inner core surface  is in the range of about 20 to about 95 Shore A. 
     
     
         16 . The golf ball of  claim 13 , wherein the H midpoint of OC  is in the range of about 40 to about 87 Shore C and the H outer surface of OC  is in the range of about 72 to about 95 Shore C. 
     
     
         17 . The golf ball of  claim 1 , wherein the inner core layer has an outer surface hardness (H inner core surface ) and a center hardness (H inner core center ), the H inner core surface  being the same or less than the H inner core center  to provide a zero or negative hardness gradient; and the outer core layer has an outer surface hardness (H outer surface of OC ) and a midpoint hardness (H midpoint of OC ), the H outer surface of OC  being greater than the (H midpoint of OC ), to provide a positive hardness gradient. 
     
     
         18 . The golf ball of  claim 17 , wherein the H inner core center  is in the range of about 10 to about 60 Shore C and the H inner core surface  is in the range of about 10 to about 55 Shore C. 
     
     
         19 . The golf ball of  claim 17 , wherein the H inner core center  is in the range of about 15 to about 80 Shore A and the H inner core surface  is in the range of about 10 to about 75 Shore A. 
     
     
         20 . The golf ball of  claim 17 , wherein the H midpoint of OC  is in the range of about 45 to about 85 Shore C and the H outer surface of OC  is in the range of about 72 to about 95 Shore C.