JP2002102387A - Crosslinked foam or core as packing material in inner layer of multicomponent golf ball - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide such a golf ball which exhibits a high initial velocity or coefficient of repulsion(COR), can be flied at a relatively long distance in a normal play, can be easily and inexpensively manufactured and exhibits desirable click and feel characteristics. SOLUTION: This golf ball has a core, at least one cover layer which is arranged around the core and a mantle layer which is a mantle layer arranged around the core and between the core and the cover layer and has a polymer matrix material and the plurality of foam granules dispersed in this polymer material. The granules have an average diameter of about 0.001 to about 0.200 inch.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present application was filed on February 20, 1998.
No. 09 / 027,482, filed on Mar. 28, 1997, which is a continuation-in-part application that claims priority to US patent application Ser. Provisional Application No. 60 / 042,430, filed March 28, 1997; and 1
U.S. Ser. No. 08/98, filed Sep. 16, 996;
Claim priority of 714,661.

[0002] This application is also a continuation-in-part application claiming priority of US Ser. No. 08 / 815,556 filed Mar. 12, 1997.

[0003] The present invention relates generally to golf balls, and more particularly to multi-component golf balls. In particular, the invention relates to golf balls having a core, at least one cover layer, and one or more inner mantle layers, which are located between the core and the cover layer. Relatively small foam granules are disposed throughout one or more mantle layers, the core, or both. The multi-component golf ball of the present invention has such a configuration, and uses such foam granules to provide distance and durability characteristics close to those of a conventional two-piece ball, while at the same time, a conventional three-piece ball , Ie, the "click and feel" of a "wound" ball.

[0004]

BACKGROUND OF THE INVENTION Conventional golf balls can be categorized into two general types or groups: two-piece balls or wound balls (also known as three-piece balls). Differences in play characteristics resulting from these different types of configurations can be very significant.

A ball having a two-piece configuration is generally
Most popular for the average distraction golfer,
Because they provide good durability balls, they also provide maximum distance. Two-piece balls use a single solid core, usually made of crosslinked rubber, which is covered by a cover material. Typically, the solid core is made from polybutadiene, which is chemically cross-linked using zinc diacrylate (ZDA) and / or a similar cross-linking agent, and with a tough cut proof blend cover. Covered.
The cover is generally a material such as SURLYN®, which is a trademark for ionomer resins manufactured by DuPont. The combination of the core and cover material provides a "hard" ball, which is virtually unbreakable by the golfer. Further, such a combination gives the ball a high initial velocity, resulting in improved distance. Because these materials are very rigid, two-piece balls provide a hard "feel" when struck with a club. Similarly, due to their hardness, these balls have a relatively low spin rate, which makes them difficult to control, especially on shorter approach shots. However, two-piece balls will likely continue to gain in popularity as golf ball manufacturers continue to improve the spin and feel characteristics of the two-piece ball.

However, at present, wound balls are still the preferred ball for more advanced players,
It is due to its excellent spin and feel properties. Wound balls typically have either solid rubber or a liquid central core around which many yards of stretched elastic threads or yarns are wound. The wound core can then be used with a durable cover material (eg, SU
RLYN®) or similar material or a softer cover (eg, Balata). Wound balls are generally softer and provide better spin, which can give a skilled golfer more control over the ball's distance. However, wound high spin balls typically have a shorter distance as compared to two-piece balls. Furthermore, wound balls generally require longer time to manufacture and are more expensive to produce than two-piece balls, as a result of their complex construction.

As a result, there is a need for an improved ball that provides the "click and feel" of a wound ball, while also providing the relatively easy manufacture, durability and distance of a two-piece ball.

Several patents have been issued directed at modifying the properties of conventional two-piece balls by modifying the typical single-layer core and single-cover layer structure to provide a multi-layer core. The developments disclosed in prior art patents are:
Various golf ball properties have been addressed.

Several patents have been disclosed for improving the flight distance of a ball. For example, US Pat.
No. 167 relates to a three-piece solid golf ball, which has improved rebound characteristics to increase the ball's flight distance. The golf ball has a central portion, and an outer layer formed of a rubber composition, preferably having a base rubber of polybutadiene, wherein the outer layer further has a specific gravity higher than the specific gravity of the inner layer. Gravity fill as given to
r) (for example, tungsten or tungsten carbide). The difference in specific gravity of these layers should be between 0.15 and 0.8 for small balls and between 0.15 and 0.45 for large balls. Preferably, this outer layer is harder than the central part.

[0010] US Patent No. 5,184,828 relates to a solid three-piece golf ball having improved rebound characteristics and carry distance while maintaining adequate spin speed. These properties are obtained by controlling the size and specific gravity and hardness of the inner core and outer layer. The core and mantle layers are made from a rubber compound (eg, polybutadiene) and have a Shore D hardness of 30-62 and 30-56, respectively. The key to obtaining the desired rebound characteristics is
The maximum hardness (42-62) must be located at the interface between the core and the mantle, and this hardness must decrease both inward and outward.

US Pat. No. 4,714,253 also states that
The present invention relates to a three-piece golf ball having an excellent rebound coefficient. This golf ball has 57-
Shore C hardness of 80, but 5 to 10 m from the center
It has a core with a Shore C hardness of 83 or less at a distance between m and an outer layer with a Shore hardness C of 70 to 83.

In addition, there are also numerous patents relating to improving the spin, click or feel of a solid ball while maintaining the distance provided by the solid structure. Various approaches to manipulating the core structure are described in the art. For example, U.S. Pat. No. 5,072,944 discloses a three-piece solid golf ball having a central and outer layer. These are prepared from a rubber composition and preferably have a base rubber of polybutadiene.
The central core is softer than the outer layer, each 25-50
And having a hardness (Shore C) of 70-90,
desirable.

US Pat. No. 4,625,964 teaches that
The invention relates to a solid golf ball having a polybutadiene rubber core having a diameter of not more than mm, a polybutadiene rubber intermediate layer having a specific gravity less than the specific gravity of the core material, and a cover.

US Pat. No. 4,650,193 relates to a solid golf ball having a core with a central portion and an integral outer layer. Preferably, the core is a curable elastomer (e.g., polybutadiene) and is treated with a curing alteration agent that softens the outer layer of the core. By this treatment, a central layer having a hardness (Shore C) greater than 75,
And an outer layer having a hardness (Shore A) of less than 80.

US Pat. No. 4,848,770 discloses a non-wound three-piece golf ball, wherein the ball is filled with a core of a highly filled synthetic rubber or polymer material. Has no synthetic rubber middle mantle, and cover. The core and the intermediate mantle have a hardness of 50-95.

US Pat. No. 5,002,281 relates to a three-piece solid golf ball, the ball comprising 25-7
It has an inner core with a hardness of 0 (Shore C), an outer shell with a hardness of 80-95 (Shore C), and a cover. Further, the specific gravity of the inner core should be greater than 1.0 but less than or equal to the specific gravity of the outer shell, which must be less than 1.3.

US Pat. No. 5,253,871 relates to a golf ball having a three-piece structure,
It has an elastomeric core, an intermediate layer of a thermoplastic material comprising at least 10% of an ether block copolymer, which is preferably blended with an ionomer, and a thermoplastic cover.

In addition, several patents also exist for golf balls having multiple cover layers. For example,
U.S. Pat. No. 4,431,193 relates to a golf ball having a multilayer cover. In this multilayer cover, the inner layer is a hard, high flexural modulus ionomer resin, and the outer layer is a soft, low flexural modulus ionomer resin, wherein either or both layers comprise a foam ionomer resin. obtain.

US Pat. No. 5,314,187 also claims that
For a golf ball having a multilayer cover, where the outer layer is molded over the inner layer and has a blend of balata rubber and an elastomer, and the inner layer is an ionomer resin.

US Pat. No. 4,919,434 relates to a golf ball having a cover, the ball having an inner layer and an outer layer, each of which has a thermoplastic resin. Preferably, these layers include materials that can fuse together.

Prior artisans have attempted to incorporate metal layers or metal filler particles into golf balls to change the physical properties and performance of these balls.
See, for example, Strayer US Pat. No. 3,031,19.
No. 4 relates to the use of a spherical inner metal layer, which is bonded or otherwise adhered to a resilient inner component in the ball. This ball uses a liquid-filled core. Matsuki et al., U.S. Pat.
No. 63,167 discloses a gravity filler.
golf balls, which may be formed from one or more metals disposed within a solid rubber-based core. U.S. Pat. Nos. 4,886,275 and 4,995,613 (both Walker
Discloses a golf ball having a high density metal-containing core. Corley, U.S. Pat.
No. 3,055 relates to a weighted warm-up ball having a metal center.

Prior artisans have also described golf balls having one or more inner layers formed from metal, which feature a hollow center. Davis in U.S. Pat. No. 6,978,816 disclosed a golf ball with a spherical steel shell having a hollow gas filled central portion. K
Empshall has received a number of patents relating to golf balls having a metal inner layer and a hollow interior (eg, 704,748; 704,838; 713,7).
No. 72; and 739, 753). US Patent No. 1,
In 182,604 and 1,182,605, Wadsworth described a golf ball utilizing a concentric spherical shell formed from forged steel. Lewi
US Patent No. 1,568,514 describes several embodiments for golf balls, one of which utilizes a plurality of steel shells disposed within the ball, and Provide a hollow center for the ball.

For incorporation of glass or glassy materials into golf balls, US Patent No. 985,741 to Harvey discloses the use of a glass shell.
Others have described the incorporation of glass microparticles into golf balls (eg, US Pat. No. 4,085,937 to Schenk).

[0024] In contrast, using a polymeric material in the intermediate layer in a golf ball is more common than using, for example, glass or other glassy materials. Kempshall is disclosed in U.S. Patent No. 6,696,887.
No. 701,741 discloses the use of a plastic inner coating layer. Kempsha
II further described the incorporation of a fabric layer in combination with a plastic layer in U.S. Patent Nos. 6,696,891 and 700,656. A number of subsequent approaches to incorporating a plastic inner layer into a golf ball have been patented. A thermoplastic outer core layer is disclosed in US Pat. No. 3,534,96 to Harrison.
No. 5. The inner synthetic polymer layer is Nesbi
No. 4,431,193 to tt. An inner layer of thermoplastic material over the core is described in U.S. Pat. No. 4,919,434 to Saito. The intermediate layer of amide block polyether thermoplastic material is Vie
No. 5,253,871 to Ilaz. Golf balls having a thermoplastic inner shell layer,
No. 5,480,155 to Molitor et al.

Although good in many respects, these patents disclose certain configurations of foams utilized in the present invention and dispersed within a particular type of polymeric material as described herein. The use of shaped materials is not concerned in detail.

Prior artisans have attempted to incorporate various particle and filler materials within the golf ball core and into the intermediate layer. U.S. Pat. No. 3,218,075 to Shakespeare discloses a core of fiberglass particles dispersed within an epoxy matrix. Similarly, US Patent No. 3,671,477 to Nesbitt
Discloses epoxy-based compositions that include an extensive array of fillers. Rubber interlayers containing various metal fillers are disclosed in U.S. Patent No. 4,863,16 to Matsuki et al.
No. 7. Similarly, an inner rubber layer having a filler material is disclosed in U.S. Pat.
No. 48,838. More recently, golf balls having an inner layer of reinforced carbon graphite are disclosed in U.S. Pat. No. 5,273,286 to Sun.

[0027]

However, none of these patents disclose a multilayer having the material and material property requirements disclosed herein to provide the improved golf ball of the present invention. Do not disclose the ball.

[0028] In view of the ever-increasing demands of the current golf industry, there is a need for yet another improved golf ball design and configuration. For details,
There is a need for golf balls that exhibit a high initial velocity or coefficient of restitution (COR), can be hit a relatively long distance in regular play, and can be manufactured easily and inexpensively. And there is a further need for golf balls that exhibit desirable "click and feel" characteristics.

[0029]

SUMMARY OF THE INVENTION The golf ball of the present invention comprises a core, at least one cover layer disposed around the core, and a periphery of the core and between the core and the cover layer. A mantle layer provided with a polymer matrix material and a plurality of foam granules dispersed within the polymer matrix material, wherein the granules comprise from about 0.001 inches to about 0.200 inches. A mantle layer having an average diameter;
This solves the above problem.

[0030] In one embodiment, the golf ball of the present invention is characterized in that the granules have a particle size of about 0.0012 inches to about 0.18 inches.
It has an average diameter of up to 0 inches.

In one embodiment, in the golf ball of the present invention, the granules have a specific gravity of about 0.01 to about 0.8.

In one embodiment, in the golf ball of the present invention, the granules have a specific gravity of about 0.1 to about 0.7.

[0033] In one embodiment, the golf ball of the present invention has a structure in which the mantle layer is from about 0.005 inches to about 0.4 inches.
It has a thickness of up to 500 inches.

[0034] In one embodiment, the golf ball of the present invention is characterized in that the mantle layer is from about 0.02 inches to about 0.3 inches.
It has a thickness of up to 00 inches.

In one embodiment, the golf ball of the present invention is characterized in that the mantle layer is from about 0.050 inches to about 0.5 inches.
It has a thickness of up to 250 inches.

In one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the granules of about 5-90% granules to about 10% matrix material.
９５95%.

In one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the granules of about 10-75% of the granules to about 25-75% of the matrix.
It is in the range of 90%.

In one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the granules of about 15 to 50% granules to about 50 to 50% matrix.
It is in the range of 85%.

[0039] In one embodiment, the golf ball of the present invention further comprises a secondary mantle layer disposed around the mantle layer and between the mantle layer and the cover layer.

A golf ball according to a twelfth aspect of the present invention includes a core, a cover layer disposed around the core, an inner mantle surrounding the core, and disposed between the core and the cover layer. A mantle comprising a plurality of foam particles dispersed in a polymer matrix material, the particles comprising an ionomer, a non-ionomer polyolefin, a metallocene catalyzed polymer, polyethylene ethyl or methyl acrylate, a styrene butadiene elastomer, a thermoplastic. Polyester, thermoplastic polyetherester, thermoplastic polyetheramide, polyamide,
An inner mantle layer comprising one or more materials selected from the group consisting of polycarbonates, polyphenylene oxides, thermoplastic or thermoset polyurethanes, silicone elastomers, dynamically vulcanized elastomers, and combinations or blends thereof; Which solves the above-mentioned problem.

According to one embodiment, the golf ball of the present invention is characterized in that the particles have a particle size of about 0.001 inches to about 0.2.
It has an average diameter of up to 00 inches.

According to one embodiment, the golf balls of the present invention have one such particle having an average diameter of from about 0.0012 inches to about 0.180 inches.

According to one embodiment, in the golf ball of the present invention, the particles have a specific gravity of about 0.01 to about 0.8.

According to one embodiment, in the golf ball of the present invention, the particles have a specific gravity of about 0.1 to about 0.7.

According to one embodiment, the golf ball of the present invention has the mantle layer having a thickness from about 0.005 inches to about 0.500 inches.

According to one embodiment, the golf ball of the present invention has a structure in which the mantle is from about 0.02 inches to about 0.2 mm.
It has a thickness of up to 300 inches.

According to one embodiment, the golf ball of the present invention has the mantle having a thickness from about 0.050 inches to about 0.250 inches.

According to one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the particles in the range of about 5-90% granules to about 10-95% matrix material.

According to one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the particles of about 10 to 75% of granules and about 2 to about 2 of matrix.
It is in the range of 5-90%.

According to one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the particles of about 15-50% granules to about 5% matrix.
It is in the range of 0-85%.

According to one embodiment, the golf ball of the present invention further comprises a secondary mantle layer disposed around the mantle layer and between the mantle layer and the cover layer.

A golf ball according to a twenty-fourth aspect of the present invention includes a core, at least one cover layer disposed around the core, and surrounding the core, disposed between the core and the cover layer. An inner primary mantle layer comprising a matrix material and a plurality of foam granules dispersed within the matrix material, wherein the weight ratio of the granules to the matrix material is about 5% of the granules.
About 90% to about 90% of the matrix material
And the inner primary mantle layer, which solves the above problem.

According to one embodiment, the golf ball of the present invention is characterized in that the granules have a particle size of about 0.001 inch to about 0.2.
It has an average diameter of up to 00 inches.

According to one embodiment, the golf ball of the present invention is characterized in that the granules have a particle size of from about 0.0012 inches to about 0.5 inches.
It has an average diameter of up to 180 inches.

According to one embodiment, in the golf ball of the present invention, the granules have a specific gravity of about 0.01 to about 0.8.

According to one embodiment, in the golf ball of the present invention, the granules have a specific gravity of about 0.1 to about 0.7.

According to one embodiment, the golf ball of the present invention has the primary mantle layer having a thickness from about 0.005 inches to about 0.500 inches.

According to one embodiment, the golf ball of the present invention has the primary mantle having a thickness from about 0.02 inches to about 0.300 inches.

According to one embodiment, the golf ball of the present invention has the primary mantle having a thickness from about 0.050 inches to about 0.250 inches.

According to one embodiment, the golf ball of the present invention has a weight ratio of said matrix material to said granules ranging from about 10 to 95% matrix material to about 5 to 90% granules.

According to one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the granules of about 10 to 75% of the granules to about 2 to about 2 of the matrix.
It is in the range of 5-90%.

According to one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the granules of about 15 to 50% of the granules to about 5 to 50% of the matrix.
It is in the range of 0-85%.

According to one embodiment, the golf ball of the present invention further comprises a secondary mantle layer disposed around the primary mantle layer and between the primary mantle layer and the cover layer.

[0064] A golf ball according to claim 36 of the present invention comprises a core, at least one cover layer disposed around the core, and a plurality of foam granules dispersed in the core, wherein the number of foam granules is about 0. Granules having an average diameter of from 0.001 inches to about 0.200 inches, thereby solving the above problems.

According to one embodiment, the golf balls of the present invention are characterized in that the granules have a particle size of from about 0.0012 inches to about 0.4 inches.
It has an average diameter of up to 180 inches.

According to one embodiment, in the golf ball of the present invention, the granules have a specific gravity of about 0.01 to about 0.8.

According to one embodiment, in the golf ball of the present invention, the granules have a specific gravity of about 0.1 to about 0.7.

According to one embodiment, in the golf ball of the present invention, the core includes a matrix material, and a weight ratio of the matrix material to the granules is about 5 to 5 granules.
The matrix material ranges from about 10 to 95% for 90%.

According to one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the granules of about 10 to 75% of the granules to about 2 to about 2 of the matrix.
It is in the range of 5-90%.

According to one embodiment, the golf ball of the present invention has a weight ratio of the matrix material to the granules of about 15 to 50% of the granules and about 5 to 50% of the matrix.
It is in the range of 0-85%.

A golf ball according to claim 43 of the present invention provides a core including a first matrix material, at least one cover layer disposed around the core, and surrounding the core, the core and the cover. An inner mantle layer disposed between the first mandrel layer and a mantle layer including a second matrix material; and at least one of the first matrix material of the core and the second matrix material of the mantle layer. A plurality of foam particles dispersed in one, comprising an ionomer, a non-ionomer polyolefin, a metallocene catalyzed polymer, polyethylene ethyl or methyl acrylate, a styrene butadiene elastomer, a thermoplastic polyester, a thermoplastic polyetherester, a thermoplastic polyetheramide, Polyamide, polycarbonate, polyphenyleneo Particles comprising one or more materials selected from the group consisting of SIDs, thermoplastic or thermoset polyurethanes, silicone elastomers, dynamically vulcanized elastomers, and combinations or blends thereof. Thereby, the above problem is solved.

According to one embodiment, the golf ball of the present invention has a particle size of about 0.001 inches to about 0.2.
It has an average diameter of up to 00 inches.

According to one embodiment, the golf ball of the present invention has a particle size ranging from about 0.0012 inches to about 0.5 inches.
It has an average diameter of up to 180 inches.

According to one embodiment, in the golf ball of the present invention, the particles have a specific gravity of about 0.01 to about 0.8.

According to one embodiment, in the golf ball of the present invention, the particles have a specific gravity of about 0.1 to about 0.7.

According to one embodiment, the golf ball of the present invention has the mantle layer having a thickness from about 0.005 inches to about 0.500 inches.

According to one embodiment, the golf ball of the present invention has a mantle having a diameter of about 0.02 inches to about 0.2 mm.
It has a thickness of up to 300 inches.

According to one embodiment, the golf ball of the present invention has the mantle having a thickness from about 0.050 inches to about 0.250 inches.

[0079] These and other objects and features of the invention will be apparent from the following summary of the invention, the description of the invention, the drawings and the claims.

In a first aspect, the present invention relates to a golf ball having a core, a cover assembly disposed around the core, and a mantle layer disposed between the core and the cover layer around the core. The mantle layer comprises a polymer matrix material and a plurality of foam granules dispersed within the polymer matrix material. The granules are
It has an average diameter of about 0.001 inches to about 0.200 inches. The cover assembly may include one or more cover layers.

In a still further aspect, the present invention provides a golf ball comprising a core, a cover layer disposed around the core, and an inner mantle layer covering the core and disposed between the core and the cover layer. . The mantle layer comprises a plurality of foam particles dispersed within a polymer matrix material. These particles include one or more materials selected from a particular set of materials. The cover may be of a single-layer or multi-layer configuration.

In a still further aspect, the present invention provides a golf ball comprising a core, a cover layer disposed around the core, and an inner first mantle surrounding the core and disposed between the core and the cover layer. provide. The first mantle comprises a matrix material and a plurality of foam granules dispersed within the matrix material. The weight ratio of granules to matrix material ranges from about 10-95% matrix material to about 5-90% granules. The cover may include one or more cover layers.

In another aspect, the present invention provides a golf ball comprising a core, at least one cover layer disposed around the core, and a plurality of foam granules dispersed within the core. The foam granules have an average diameter of about 0.001 inches to about 0.200 inches.

In a further aspect, the present invention provides a method comprising:
At least one cover layer disposed about the core, an inner mantle layer surrounding the core and disposed between the core and the cover, and a plurality of foam particles dispersed in one or both of the core and mantle layers A golf ball comprising: Foam particles are formed from one or more specific types of materials.

The above and other objects, features and advantages of the present invention will be better understood from the following description taken in conjunction with the accompanying drawings, in which:

It is understood that these figures need not be to scale, and in particular that FIGS. 1, 3 and 4 are schematic in nature.

[0087]

DETAILED DESCRIPTION OF THE INVENTION In a particularly preferred aspect, the present invention provides a golf ball comprising a plurality of foam granules dispersed throughout a polymer matrix material in one or more inner mantle layers and / or a core in a ball. provide. The foam granules are relatively small, and preferably
Dispersed throughout the thermoplastic or thermoset matrix material.

Referring to FIGS. 1 and 2, a preferred embodiment of the golf ball of the present invention is illustrated as a multilayer golf ball 1, which includes a core 2, at least one cover layer 3, and disposed therebetween. It comprises at least one first mantle 4. All of the preferred embodiment golf balls described herein have a concave outer surface. These various components and other aspects of the preferred embodiment golf ball are described in further detail below.

(Mantle and Foam Granules) The golf ball of the preferred embodiment comprises at least one inner mantle layer comprising a plurality of foam particles or granules dispersed throughout a polymer matrix material. As used herein, the term "foam granule" refers to a plurality of cells having the properties and properties described herein and defined throughout, or at least substantially throughout, the granule. Or a granule or particle having a structure characterized by a chamber. These cells or chambers are, for example, about 0.00001
It can range in size to have an average internal length of inches to about 0.0001 inches. Preferably, the structure of the foam granules resembles that of a foam. All, some, or none of the cells or chambers may be connected to adjacent cells or chambers. All or a portion of the cell or chamber may be filled with air, one or more other gases, or matrix material, or none. It should be understood that the term foam granules does not imply or imply that the granules utilized in the present invention must be formed according to a foaming process. That is,
Foam granules can be made by other methods, such as leaching or erosion strategies.

The at least one inner mantle layer is referred to herein as a first mantle. FIG. 3 shows a first embodiment of a first mantle 4 comprising foam granules 6 dispersed in a polymer matrix 5.

Preferred foam granules are from about 0.001 to
About 0.200 inches, most preferably about 0.0012
The average diameter ranges from inches to about 0.180 inches. Preferably, the foam granules are from about 0.01 to about 0.5.
8, most preferably having a specific gravity of about 0.1 to about 0.7.

The matrices and granules may include ionomers, non-ionomer polyolefins, metallocene catalyzed polymers, polyethylene ethyl or methyl acrylate, styrene butadiene elastomers, thermoplastic polyesters, thermoplastic polyetheresters, thermoplastic polyetheramides, polyamides, Polycarbonate, polyphenylene oxide, thermoplastic or thermoset polyurethane, silicone elastomer, dynamically vulcanized
d) may be formed from a wide array of materials such as, but not limited to, elastomers, or combinations or blends described above. Further examples of suitable materials for the primary mantle are given below.

[0093] In all preferred embodiments described herein, the granules dispersed within (typically throughout the mantle layer and / or core) one or more mantle layers and / or cores of the golf ball. Significantly, is formed from a material or composition that is different from the material or composition of the matrix that makes up the mantle layer (s) and / or core. It is known in the prior art to form cells or foam-like regions in a layer of material having a constant composition throughout the layer. The golf balls of the preferred embodiments are readily distinguishable in that they are based, at least in part, on incorporation of foam granules having a composition different from the composition of the matrix throughout which they are dispersed.

[0094] Foam granules can be prepared according to a wide variety of methods known in the art. Preferably, the granules are prepared by known foaming techniques. Conventional blowing agents may be used. Once foamed and fully cured to a rigid solid shape, the material is granulated such that the foamed material is preferably processed into fine particles having an average diameter as described above. ) Undergo a sizing operation like a process.

As noted above, foam granules are:
Either an open cell foam structure, a closed cell foam structure, or a hybrid structure containing both open and closed cells may be utilized.

A comprehensive description of foamed plastics and their manufacture can be found in KirkOthmer Enc.
Cyclopedia of Chemical Tec
hnology 「Foamed Plastic
s ", Volume 11, Fourth Edition, pp. 730-783;
This is incorporated herein by reference.

Preferably, the foam granules are crosslinked. Crosslinking of the granules can be performed before, during or after incorporation of the granules into the polymer matrix described in more detail herein.

The preferred total thickness of the primary mantle layer is:
From about 0.010 inches to about 0.500 inches, more preferably from about 0.020 inches to about 0.300 inches, and most preferably from about 0.050 inches to about 0.250 inches.

Preferably, the granulate and matrix material comprises about 10% to 95% matrix, versus about 5% to 90%.
They are combined together in a specific weight ratio, such as granules. More preferably, the granulate and matrix material comprises about 2
5% -90% matrix versus about 10% -75% granules,
And most preferably, they are combined in a weight ratio of about 50% to 85% matrix to about 15% to 50% granules.

In addition to the primary mantle layer described above, comprising foam granules dispersed in a matrix material,
The golf balls of the preferred embodiments may further comprise one or more optional secondary mantle layers as follows. One or more secondary mantle layers are located in any area within the golf ball between the core and the cover layer. Preferably,
One or more secondary mantle layers are disposed adjacent to the primary mantle layer.

[0101] The secondary mantle layer may include any of the materials noted for use in the primary mantle. For the secondary mantle, preferably a thermoplastic polyetherester,
Examples include thermoplastic polyesters, dynamically sulfurized thermoplastic elastomers, functionalized styrene-butadiene elastomers, thermoplastic polyurethanes or metallocene polymers or blends thereof.

[0102] In a preferred embodiment of the invention, the secondary mantle layer is a thermoplastic polyetherester. Suitable thermoplastic polyetheresters include Hytrel
(Registered trademark) 3078, Hytrel (registered trademark) G3
548W and Hytrel® G4078W
Which are commercially available from DuPont. Hytrel® 3078 is most preferred. The mantle layer preferably has a specific gravity greater than 1 and less than 1.2.

Suitable commercially available dynamically sulfurized thermoplastic elastomers for use in the primary and / or secondary mantle include Santoprene®, Sar
link (registered trademark), Vyram (registered trademark), Dy
ton® and Vistaflex®. Santoprene (registered trademark)
Is the trade name for dynamically sulfurized PP / EPDM.
Santoprene® 203-40 is an example of a preferred Santoprene®,
Advanced Elastmer Systems
It is commercially available from. Suitable functionalized styrene-
Examples of butadiene elastomers include Kraton FG
-1901x, which is available from Shell Cor
It is commercially available from the corporation. Examples of suitable thermoplastic polyurethanes include Estane® 58
133, Estane® 58134 and E
stan® 58144, which are described in US Pat. F. It is commercially available from the Goodrich Company. Suitable metallocene polymers having a higher melting point than the cover material may also be used in the primary and / or secondary mantle layers of the golf balls of the present invention.
Further, the material of the primary and / or secondary mantle layers described above may be in the form of a foamed polymeric material. For example,
Suitable metallocene polymers include metallocene single-site catalysts.
e catalyst) based foams based on thermoplastic elastomers. Such metallocene-based foam resins are available from Sentinel
Products of Hyanis, Mass
commercially available from Achusets. In a preferred embodiment of the present invention, the secondary mantle layer is a Santrop
Rene®, thermoplastic polyurethane or blends thereof.

In another preferred embodiment of the present invention,
One or more second mantle layers comprise a first thermoplastic and a second mantle.
A blend with a thermoplastic, wherein the first thermoplastic is a kinetically vulcanized thermoplastic elastomer, a functionalized styrene-butadiene elastomer, a thermoplastic polyurethane or a metallocene polymer, and 2 Thermoplastics include materials such as thermoplastic polyurethanes, thermoplastic polyetheresters, or polyetheramides, thermoplastic ionomer resins, thermoplastic polyesters, another kinetically vulcanized elastomer,
Another functionalized styrene-butadiene elastomer,
Another metallocene polymer or a blend thereof.

In this blend embodiment, suitable thermoplastic polyetheresters include Hytrel® 3078, Hytrel® G3548
W and Hytrel® G4078W, which are commercially available from DuPont. Suitable thermoplastic polyetheramides include Pebax® 2533, Pebax® 3533 and Pebax® 4033, which are commercially available from Elf-Atochem. Suitable thermoplastic ionomer resins include any number of olefin resin-based ionomers (SURLYN®)
And Iotek®), which are DuPont and Exxo, respectively.
n. The flexural modulus for these ionomers is from about 100 kpsi to about 200 kpsi. Suitable thermoplastic polyesters include polybutylene terephthalate. Similarly, the kinetically vulcanized thermoplastic elastomers, functionalized styrene-butadiene elastomers, thermoplastic polyurethanes or metallocene polymers identified above may also be used as the second thermoplastic in such blends. Useful. Further, the second thermoplastic may be in the form of a foamed polymeric material.

Such a thermoplastic blend may comprise about 1
% To about 99% by weight of the first thermoplastic, and about 9% by weight.
It contains from 9% to about 1% by weight of a second thermoplastic.
Preferably, the thermoplastic blend comprises about 5% by weight
About 95% by weight of the first thermoplastic, and about 5% by weight
Contains from about 95% by weight of a second thermoplastic. In a preferred embodiment of the present invention, the first thermoplastic of the blend is a kinetically vulcanized thermoplastic elastomer (eg, Santoprene®). It is contemplated that such a blend configuration may also be utilized as a primary mantle matrix material.

It is contemplated that any of the foregoing materials suitable for use in the second mantle may be used in the first mantle containing the foam granules. It is also conceivable that the aforementioned foam granules are dispersed in the second mantle.
And still further, it is contemplated that the mantle assembly includes three or more separate mantle layers. As described in more detail herein, foam granules can also be incorporated into a golf ball core.

(Core) The core of the golf ball according to the preferred embodiment of the present invention may contain various substances, including those typically used as golf ball cores. Conventional materials for such cores include basic rubbers, crosslinkers, fillers and co-crosslinkers.
a core composition having a linking agent. The basic rubber typically includes a natural or synthetic rubber. A preferred basic rubber is 1,4-polybutadiene having at least 40% of the cis structure. Natural rubber, polyisoprene rubber and / or styrene-butadiene rubber may be optionally used in 1,4-
It can be added to polybutadiene. The initiator contained in the core composition can be any known polymerization initiator,
It is broken down during the cure cycle. Crosslinking agents include metal salts of unsaturated fatty acids (e.g., zinc or magnesium salts of unsaturated fatty acids having three to eight carbon atoms (e.g., acrylic acid or methacrylic acid)). Fillers typically include materials such as zinc oxide, barium sulfate, silica, calcium carbonate, zinc carbonate, and the like.

Preferably, the core is a crosslinked 1,4-polybutadiene having a specific gravity greater than 1.1 (more preferably, about 1.25). The high specific gravity of this core reduces the spin rate of the ball for lower flight paths. Also, the PGA compression of the core is preferably greater than 60, and more preferably about 65.

In one embodiment of the invention, the core includes a liquid-filled or solid central portion around which an elastic thread is wound.
This solid center is typically a homogenous mass of a resilient material such as polybutadiene or natural rubber. The liquid-filled center is typically a thin, enclosed sphere into which a liquid, such as corn syrup, is injected by a hypodermic needle. The sphere is then sealed and solidified, leaving a solid mass at the center. The winding for either type of center is provided by a resilient thread, which is stretched and wrapped around the center to the desired thickness. Although the described foam particles are generally used as an alternative to a wound core, it is understood that both can be used together.

Traditionally, the center of the wound core has a diameter of about 1.0 to about 1.125 inches. The outer diameter of a conventional wound core is about 92% of the total diameter of the finished ball. But,
The outer diameter of the wound core used in this embodiment of the invention has an overall diameter of less than 90% of the overall diameter of the finished ball. Preferably, the wound core has a total diameter of about 75 to
It has a 90% diameter. Most preferably, the wound core of the present invention has a total diameter of about 85% of the diameter of the finished ball.

A wide variety of materials can be used as the core, including solid materials, gels, hot melts, liquids,
It should be understood that other materials that can be handled as liquids when introduced into the shell. Examples of suitable gels include water gelatin gels, hydrogels, and water / methylcellulose gels. Hot melt is a material that becomes liquid when heated and becomes solid at or near room temperature. This property allows easy injection into the interior of the ball and forms the core. Examples of suitable liquids include, for example, glycol /
Examples include water, salts or oils in water or colloidal suspensions (eg, clay, barite, carbon black in water or other liquids), or solutions of the salts in a water / glycol mixture.

A preferred example of a suitable liquid core material is an inorganic salt solution in water. The inorganic salt is preferably calcium chloride. Other liquids that have been successfully used are conventional hydraulic fluids.

The liquid material, which has been introduced inside the golf ball, can also be a reactive liquid system adapted to form a solid. Examples of suitable reactive liquids include silicate gels, agar gels, peroxide-cured polyester resins, two-component epoxy resin systems, and peroxide liquid-cured polybutadiene rubber compositions. It will be appreciated by those skilled in the art that other reactive liquid systems may be used as well, depending on the physical properties of the adjacent mantle and the physical properties required for the resulting finished golf ball.

The core of all embodiments should remain solid, liquid, or ultimately solid, despite becoming solid, ie, throughout its entire range or cross-section. A substantially common material, the outer surface of which is in substantial contact with the entire inner surface of the shell or inner mantle. All cores are also essentially
Substantially homogeneous throughout, except for the cellular or foam embodiments described herein.

In a preferred embodiment, the core material is preferably comprised of a shell or mantle (and an outer cover (such a cover)) to provide a golf ball having physical and functional properties similar to conventional golf balls. Has a specific gravity greater than that of)). In particular, the core material may have a specific gravity between about 0.10 and about 3.9, preferably about 1.05. Thus, the specific gravity of the core may vary depending on the physical size and density of the outer shell, and the diameter of the finished golf ball.

The solid core typically comprises an uncured or high-cis content polybutadiene and a metal salt of an α, β, ethylenically unsaturated carboxylic acid (eg, zinc mono or zinc diacrylate or zinc methacrylate). Or a compact formed from a slag of a slightly cured elastomer composition. To achieve a higher coefficient of restitution in the core, the formulator may include small amounts of metal oxides such as zinc oxide. In addition, the weight of the core is increased so that the finished ball can be S. G. FIG. To approach the upper limit weight of A of 1.620 oz, more metal oxide may be included than is necessary to achieve the desired modulus. Other materials can be used in the core composition,
This includes miscible gums or ionomers, and low molecular weight fatty acids (eg, stearic acid). When a free radical initiator catalyst (eg, a peroxide) is mixed with the core composition where heat and pressure are applied, a complex curing or crosslinking reaction occurs.

As used herein, the term “solid core”
Describes not only one-piece cores but also U.S. Pat.
No. 1,193, incorporated herein by reference, underneath a cover and having a discrete solid layer over the core, and other multi-layer and / or unrolled cores. Indicates the core.

Wound cores are generally made by winding a very long elastic thread around a solid or liquid filling the center of the balloon. The elastic yarn is wound around a solidified center to produce a finished core, typically about 1.4-1.7 inches in diameter.

In a preferred embodiment, the golf ball also includes a cellular core containing a material having a porous or cellular morphology. Suitable materials for the cellular core include foamed elastomeric materials (eg, crosslinked polybutadiene / ZDA blends, polyurethanes, polyolefins, ionomers, metallocenes, polycarbonates,
Nylon, polyester, and polystyrene). Preferred materials include polybutadiene / ZDA mixtures, ionomers, and metallocenes. The most preferred material is a foamed crosslinked polybutadiene / ZDA mixture.

When a cellular core is used for bonding to a relatively dense mantle, the choice of material type for the mantle will determine the size and density of the cellular core. Hard, highly elastic metals require a relatively thin mantle so that the ball does not compress too hard. If the mantle is relatively thin, the ball may be too light, thus adding weight to the cellular core and further oil canning.
g) or need to add resistance to deformation of the mantle.

The weight of the cellular core can be controlled by the density of the cellular material. Typically, this cellular core is
It has a specific gravity of about 0.10 to about 1.0. The coefficient of restitution of this cellular core should be at least 0.500.

The structure of the cellular core can be either open or closed cells. It is preferable to utilize a closed cell configuration with a solid skin that can be metallized or that can accept a conductive coating. Preferred cell sizes are those required to obtain an apparent specific gravity of about 0.10 to about 1.0.

In a preferred method, a cellular core is made up and a metal cover is applied over the core. The metal cover may be deposited by providing a conductive coating or layer around the core and electroplating one or more metals at the required thickness over the coating. Alternatively, the two metal half-shells are welded together, and the flowable cellular material (eg, foam, or a precursor of the cellular core material) is welded to the metal using a binary liquid system. The sphere is injected through the opening, thereby forming a semi-rigid or rigid material or foam.
Fill holes in the mantle can be sealed to prevent the outer cover stock from entering the cellular core while molding the cover. The application of these techniques has been evaluated and can be used as well if the mantle is a ceramic or polymer.

If the cellular core is preformed or otherwise formed prior to application to the metal layer, the blowing agent may include one or more gases that release gas (eg, nitrogen or carbon dioxide). Conventional reagents. Suitable blowing agents include azodicarbonamide, N, N-dinitros-opentamethylene-tetramine (N, N-dinitros).
-Openmethylene-tetramin
e), 4-4 oxybis (benzenesulfonyl-hydrazide), and sodium bicarbonate, but are not limited thereto. Preferred blowing agents are those that provide a fine, closed cell structure that forms a skin on the outer surface of the core.

The cellular core can be encapsulated or otherwise encased by a mantle, for example by laminating two of the hemispherical halves of the shell together around the cellular core. It is also conceivable to introduce a foamable cellular core material precursor inside a hollow spherical mantle and subsequently foam the material in situ.

In the most preferred aspect of the present invention, it is desirable to incorporate the foam granules into the previously described core or core formulation. The granule sizes and materials previously described, as well as the ratio of granules to matrix material, are utilized for the core and / or the granules incorporated into the core material. Preferably, the foam granules previously formed at the desired size and specific gravity are incorporated and dispersed in the material utilized to form the core.

FIG. 4 shows a golf ball 10 according to the present invention.
FIG. 6 is a cross-sectional view of another preferred embodiment of FIG. Golf ball 10 includes a core 12 with a plurality of foam granules 16 and is dispersed throughout a polymer matrix 15 as described herein. Further, the golf ball 10
Comprises one or more mantles 14, such as a first or second mantle as previously described. The preferred embodiment of the ball 10 also includes a multi-layer cover containing an inner cover 17 and an outer cover 18. The one or more mantle layers 14 may also be dispersed around the core 12 and include foam granules as previously described herein. Preferably, the inner cover layer 17 is distributed around one or more mantle layers 14. The golf ball 10 has a core 1
2, internal foam granules 16, one or more mantle layers 1
Foam granules or core 12 dispersed inside 4
It is contemplated that foam granules 16 may be dispersed both in and in one or more mantle layers 14.

(Cover) The cover layer of the preferred embodiment of the golf ball of the present invention contains at least one layer of a thermoplastic material or a thermosetting material. Any number of a wide variety of cover materials may be used in preferred embodiments of the present invention. Preferred conventional cover materials are 3 to
Polymers of monoolefins having at least one member selected from the group consisting of unsaturated monocarboxylic or dicarboxylic acids having 12 carbon atoms and esters thereof, wherein the polymer comprises 1 to 50% by weight of unsaturated Ionomer resins and low modulus ionomers obtained by providing cross-metal bonds to monocarboxylic or dicarboxylic acids and / or their esters). More specifically, low modulus ionomers such as acid-containing ethylene copolymer ionomers include E / X copolymers, where E is ethylene and X is 5-35% by weight of the polymer (preferably 10% ~ 35% by weight, most preferably 15-20%
Wt%), which is a softening comonomer such as an acrylate or methacrylate, wherein the acid moiety is 1
~ 90% (preferably at least 40%, most preferably at least about 60%) neutralized and a cation such as lithium, sodium, potassium, magnesium, calcium, barium, lead, tin, zinc or aluminum; or The combination of such cations forms an ionomer. Preferably, cations such as lithium, sodium, magnesium, zinc and / or combinations thereof are used. Ethylene copolymers containing specific acids include ethylene / acrylic acid, ethylene / methacrylic acid, ethylene / acrylic acid / n-butyl acrylate, ethylene / methacrylic acid /
n-butyl acrylate, ethylene / methacrylic acid / isobutyl acrylate, ethylene / acrylic acid / isobutyl acrylate, ethylene / methacrylic acid / n-butyl methacrylate, ethylene / acrylic acid / methyl methacrylate, ethylene / acrylic acid / methyl acrylate, ethylene / methacrylic Acid / methyl acrylate, ethylene / methacrylic acid / methyl methacrylate, and ethylene / acrylic acid / n-butyl methacrylate. As preferred acid-containing ethylene copolymers,
Ethylene / methacrylic acid, ethylene / acrylic acid, ethylene / methacrylic acid / n-butyl acrylate, ethylene / acrylic acid / n-butyl acrylate, ethylene /
Methacrylic acid / methyl acrylate, and ethylene /
Acrylic acid / methyl acrylate copolymer. Most preferred acid-containing ethylene copolymers are ethylene / methacrylic acid, ethylene / acrylic acid, ethylene /
(Meth) acrylic acid-n-butyl acrylate, ethylene / (meth) acrylic acid / ethyl acrylate, and ethylene / (meth) acrylic acid / methyl acrylate copolymer.

The methods by which these ionomers are produced are well known in the art, for example, as described in US Pat. No. 3,262,272, which is incorporated herein by reference. You. Such ionomer resins are available from DuPont Co. From, product name SURL
Commercially available as YN®. Existing preferred cover materials are 50/50 of SURLYN® 8140 and SURLYN® SEP671.
Blend, which is lithium SURLYN® with about 19% methacrylic acid. This material has a flexural modulus of about 105 ksi. Preferably, the flexural modulus of the cover is higher than 80 ksi. Still further, a preferred cover has a Shore D hardness of about 70. The high flexural modulus of the cover provides for increased initial speed and low spin speed.

In another preferred embodiment of the present invention,
The cover layer has an inner layer and an outer layer. For example, FIG.
Indicates an inner cover layer 17 and an outermost cover layer 18.
The inner layer of the cover is either a thermoplastic material such as a thermoplastic elastomer or a thermoplastic rubber, or a thermoset rubber or a thermoset elastomeric material.
Some examples of materials suitable for use as the inner cover layer include polyether or polyester thermoplastic urethanes as well as thermoset polyurethanes. A preferred thermosetting material is a rubber-based castable urethane. The outer layer of the cover may be a thermoplastic material such as an elastomer or thermoplastic rubber,
Alternatively, it is either a thermosetting material.

Suitable materials for the outer layer include urethanes, ionomers with low modulus, and other "dead" but durable materials such as EPDM and butyl rubber. In addition, the present invention also provides a polymeric foam material, such as a metallocene-based foam resin as described above, as a material for either the outer cover layer or the inner cover layer (but preferably not both layers). Consider the use of

In another preferred embodiment of the present invention,
Preferably, the thermoplastic or thermoset material of the outer layer has a lower melting point or reaction (curing) temperature heat than the melting point or reaction (curing) temperature heat of the inner layer material.

In yet another embodiment, the polymeric outer cover layer comprises a low acid (less than about 16% by weight acid) ionomer, a high acid (more than about 16% acid by weight) ionomer, an ionomer blend, a non-ionomer elastomer, It is composed of a thermosetting material, or a blend or combination thereof. For some applications, relatively soft and low modulus (from about 1,000 psi to about 1 psi)
It may be desirable to provide an outer layer having a thickness of about 0.00000 psi). Non-ionomer elastomers are preferably polyurethane, DuPont trademark Hyte.
Polyester elastomers such as those marketed under the trade name ElfAtochem S.L. A. Or a thermoplastic elastomer such as, but not limited to, a polyester amide, such as those marketed under the trademark Pebax®.

For outer cover compositions containing high acid ionomers, high acid ionomer resins neutralized with some new metal cations are particularly suitable. These high acid ionomers were produced by neutralizing, to varying degrees, a high acid copolymer of an alpha olefin and an alpha, beta unsaturated carboxylic acid with a wide variety of different metal cation salts. More specifically, a high acid ionomer resin neutralized with many new metal cations is a high acid copolymer (ie, about 1
More than 6% by weight acid, preferably from about 17% to about 25%
% By weight of an acid, and more preferably about 20% by weight of an acid), with a metal cation salt capable of ionizing or neutralizing the copolymer to a desired degree (ie, about 10% to 90%). Has been found to be obtained.

The base copolymer is composed of more than 16% by weight of α, β unsaturated carboxylic acids and α olefins. Generally, the alpha olefin will have from 2 to 10 carbon atoms, and preferably will be ethylene, and the unsaturated carboxylic acid will be a carboxylic acid having about 3 to 8 carbons. Examples of such acids are acrylic acid, methacrylic acid, ethacrylic acid, chloroacrylic acid, crotonic acid (c
rotomic acid), maleic acid, fumaric acid,
And itaconic acid, with acrylic acid being preferred.

Accordingly, examples of many copolymers suitable for use in the present invention include, but are not limited to, high acid, such as ethylene / acrylic acid copolymers, ethylene / methacrylic acid copolymers, ethylene / itaconic acid copolymers, ethylene / maleic acid copolymers. Embodiments are included. The base copolymer broadly comprises more than 16% by weight of unsaturated carboxylic acids and less than 84% by weight of alpha olefins. Preferably, the copolymer contains about 20% by weight of unsaturated carboxylic acid and about 80% by weight of ethylene. Most preferably, the copolymer contains about 20% acrylic acid, with the balance being ethylene.

Along these lines, examples of suitable high acid-based copolymers that meet the criteria set forth above are Th
e Dow Chemical Company, Mi
Dutch, Michigan, "Primaco
A series of ethylene-acrylic copolymers marketed under the name "r". These high acid copolymers are disclosed in U.S. Pat. No. 5,539, both of which are incorporated herein by reference.
Nos. 688,869 and 5,542,677.

Alternatively, the outer layer can be prepared as described in US Pat. No. 4,884,8, both of which are incorporated herein by reference.
Hard and soft ionomers (low acid) as described in No. 14 and 5,120,791
It may include a blend of resins. In particular, the materials desired for use in forming the outer layer include a blend of a high modulus (hard) ionomer with a low modulus (soft) ionomer to form a base ionomer mixture. The high-modulus ionomer herein is referred to by ASTM method D-7.
From about 15,000 to about 70,
It has a measured value of 000 psi. Hardness is A
When measured according to STM method D-2240, Shore D
It can be defined as at least 50 on the scale. Low modulus ionomers suitable for use in the outer layer blend have a flexural modulus measured from about 1,000 to about 10,000 psi and are from about 20 to about 4 on the Shore D scale.
It has a hardness of 0.

The hard ionomer resin utilized to form the hard / soft blend of the outer cover layer composition comprises an olefin having 2 to 8 carbon atoms and 3 to 8 carbon atoms.
Ionic copolymers which are sodium, zinc, magnesium or lithium salts of the reaction product of an unsaturated monocarboxylic acid having a carbon atom of The carboxylic acid groups of the copolymer may be wholly or partially (i.e., about 15-75
%).

The hard ionomer resin is probably a copolymer of ethylene and either acrylic acid and / or methacrylic acid, with a copolymer of ethylene and acrylic acid being most preferred. Two or more types of hard ionomer resins can be blended into the outer cover layer composition to produce the resulting golf ball with the desired properties.

The hard ionomer resin developed by Exxon Corporation and introduced under the name Escor® and sold under the name “Iotek” is E.C. I. DuPont
It is somewhat similar to the hard ionomer resin developed by de Nemours & Company and sold under the Surlyn® trademark. However, the “Iotek” ionomer resin is a sodium or zinc salt of poly (ethylene-acrylic acid) and the Surlyn® resin is a zinc or sodium salt of poly (ethylene-methacrylic acid), There are some clear differences in As shown in more detail in the data presented below, this rigid "Iotek" resin (i.e., an acrylic acid based rigid ionomer resin) can be used to formulate an outer cover layer blend for use in the present invention. Are more suitable hard resins for use in In addition, various blends of “Iotek” and Surlyn® hard ionomer resins, as well as other available ionomer resins, can be utilized in the present invention in a similar manner.

Examples of commercially available hard ionomer resins that can be used in the present invention in formulating outer cover blends are the hard sodium ion copolymer sold under the trademark Surlyn® 8940 and the trademark S
Includes a hard zinc ion copolymer sold under urlyn® 9910. Surlyn® 8940 is a copolymer of ethylene with methacrylic acid, and about 15 weight percent is an acid, which is about 29% neutralized with sodium ions.
This resin has an average melt flow index of about 2.8.
Surlyn® 9910 is a copolymer of ethylene and methacrylic acid, about 15% by weight of an acid, which is about 58% neutralized with zinc ions. Surlyn® 9910 has an average melt flow index of about 0.7. Surlyn® 9
Representative properties of 910 and Surlyn® 8940 are shown in Table 1 below.

[0144]

[Table 1] Exxon Corporation as product name "Iotek"
Examples of more appropriate acrylic acid-based hard ionomer resins suitable for use in the outer cover compositions sold by Iotek 4000, Iotek
tek4010, IoTek8000, IoTek80
20 and Iotek 8030. These and other I suitably used in the preparation of the present outer layer cover composition
Typical properties of the otek hard ionomer are shown in Table 2 below:

[0145]

[Table 2] As a comparison, a hard / soft blend of the outer cover composition is prepared using a soft ionomer. These ionomers include acrylic acid-based soft ionomers. These generally contain sodium or zinc salts of terpolymers of olefins having about 2 to 8 carbon atoms, acrylic acid, and acrylate ester-class unsaturated monomers having 1 to 21 carbon atoms. Characterized as: The soft ionomer is preferably a zinc-based ionomer made from an acrylic acid-based polymer and an acrylate ester class unsaturated monomer. Soft (low modulus) ionomers have a hardness of about 20 to about 40 in Shore D scale measurements and about 1,1 in measurements based on ASTM method D-790.
It has a flexural modulus from 000 to about 10,000.

The name “Iotek 7520” (due to differences in neutralization and melting index, experimentally LDX 195,
LDX 196, LDX 218, and LDX 21
Exxon Corporation
Certain ethylene acrylic acid based soft ionomer resins developed by ion can be combined with known hard ionomers as described above to produce the outer cover. This combination results in a higher COR (coefficient of restitution) and a higher melt flow at equivalent or softer hardness, which leads to improved, more efficient molding, ie, less rejects. Achieved, and as a result of lower overall material costs and improved yields, a significant cost savings is achieved for the outer layers of multilayer balls made with other known hard / soft ionomer blends.

The exact chemical composition of the resin sold under the name Iotek 7520 by Exxon is
xxon considers it confidential and proprietary information,
Exxon's Experimental Product Datasheet lists the following physical properties of the ethylene zinc acrylate ionomer developed by Exxon: Table 3 Physical Properties of Iotek 7520 Properties ASTM Method Unit Typical Value Melting Index D-1238 g / 10 min 2 Density D-1505 kg / m ³ 0.962 Cation Zinc Melting Point D-3417 66 Crystallization Point D-3417 ° C. 49 Vicat softening point D-1525 ° C 42 Plaque characteristics (2 mm thick compression molded plaque) Tensile at break D-638 MPa 10 Yield point D-638 MPa None Extension at break D-638% 760 1% Secant modulus D-638 MPa 22 Shore D hardness D-2240 32 Flexural modulus D-790 MPa 26 Bikkuribound ISO4862% 52 Dematia bending resistance D-430 Period> 5000 Further, the test data collected by the present inventors was
Iotek 7520 resin is about 32-36 (ASTM
D-2240), Shore D hardness, 3 ± 0.5 g /
A melt flow index of 10 minutes (per ASTM D-1288 at 190 ° C.), and about 2500-3500 psi
(About ASTM D-790). In addition, another laboratory test using pyrolysis mass spectrometry has shown that Iotek 7520 resin is generally a zinc salt of a terpolymer of ethylene, acrylic acid and methyl acrylate.

Further, the present inventor has proposed that Iotek 751
Exxon Corporation under the name 0
Newly developed grades of acrylic acid-based soft ionomers available from the Company also provide golf balls that, when combined with the hard ionomers described above, have higher COR values at softer hardness than or equivalent to those produced by known hard / soft ionomer blends It has been found to be effective in manufacturing covers. In this regard, Iot
ek 7510 is a methacrylic acid-based soft ionomer known in the art (eg, US Pat. No. 4,884).
Surlyn 8625 disclosed in U.S. Pat.
And the combination of Surlyn 8629) (i.e., improved flow, higher CO at the same hardness) produced by the Iotek 7520 resin.
R value, improved clarity, etc.).

In addition, Iotek 7510 is
Slightly higher C with the same softness / hardness as compared to ek 7520
Has an OR value. This is due to the higher hardness and neutralization of Iotek 7510. Similarly, Iot
ek 7510 produces better release properties (from mold, cavity) due to slightly higher stiffness and lower flow rate than Iotek 7520. This is important in manufacturing. This is because the soft cover ball sticks to the mold, and a protrusion mark is formed by the protrusion pin, so that the yield is easily reduced.

According to Exxon, Iotek 751
0 has the same chemical composition as Iotek 7520 (ie,
Terpolymers of ethylene, acrylic acid and methyl acrylate), but are more highly neutralized. According to FTIR analysis, Iotek 7520 was estimated to be about 30-40% by weight neutralized,
ek 7510 is estimated to be about 40-60% by weight neutralized. Iotek compared to Iotek7520
Typical characteristics of the 7510 are shown below. Table 4 Physical properties of Iotek 7510 compared to Iotek 7520 Iotek 7520 Iotek 7510 MI g / 10 min 2.0 0.8 Density g / cc 0.96 0.97 Melting point ° F 151 149 Vicat softening point ° F 108 109 Flexural modulus psi 3800 5300 Tensile strength psi 1450 1750 Elongation% 760 690 Hardness Shore D 3235 When using a hard / soft ionomer blend for the outer cover layer, the relative combination is about 90 for the hard ionomer.
About 10 percent, about 10 to about 90 soft ionomers
It has been found that good results are obtained when in the percentage range. This result is improved by adjusting the above range to about 75 to 25 percent of the hard ionomer and 25 to 75 percent of the soft ionomer. Better results are obtained when the relative range is about 60 to 90 percent of the hard ionomer resin and about 40 to 60 percent of the soft ionomer resin.

Specific preparations that can be used in cover compositions are described in US Pat. Nos. 5,120,791 and 4,8
No. 84,814. These US patents are incorporated herein by reference. The invention is in no way limited to these examples. It is understood that ionomer compositions containing about 16 weight percent acid can be referred to as low acid or high acid. However, for purposes of the present invention, such compositions are generally considered to be low acidic.

In yet another embodiment, the outer cover layer preparation comprises B.I. F. Goodrich's Esta
ne® polyester polyurethane X-451
Soft, low modulus, non-ionomeric thermoplastic elastomers, including polyester polyurethanes such as 7, may also be included. B. F. According to Goodrich, Estan
e (registered trademark) X-4517 has the following characteristics. Table 5 Properties of Estane® X-4517 Tension 1430 100% 815 200% 1024 300% 1193 Elongation 641 Young's Modulus 1826 Hardness A / D 88/39 Bayshore Rebound 59 Water Soluble Insoluble Melting Temperature> 350 ° F (> 177 ° C.) Specific Gravity (H ₂ O = 1) 1.1-1.3 Non-ionomeric thermoplastic elastomers have the desired play without adversely affecting the improved distance properties provided by the highly acidic ionomer resin composition. Other soft, relatively low modulus, non-ionomeric thermoplastic elastomers can be used to create the outer cover layer, as long as they provide properties and durability properties.
They include Mobay Chemical Co. Texin thermoplastic polyurethane and Dow Che
medical Co. Thermoplastic polyurethanes, such as Pellethane thermoplastic polyurethane from Spard;
No. 4,986,545, and US Pat.
No. 98,105, and 5,187,013, all of which are incorporated herein by reference; ionomer / rubber blends; and DuPont's Hytrel polyester elastomer and Elf. Atochem S.A. A. Peb
ax polyesteramide, but is not limited thereto.

In addition to or instead of the following thermoplastics, it is also possible to use one or more thermosetting polymer materials for the outer cover. Preferred thermosetting polymeric materials include, but are not limited to, diene rubbers such as polyurethane, metallocene, cis 1,4 polybutadiene, trans polyisoprene EDPM or EPR. Preferably, all thermosetting materials are crosslinked. Crosslinking may be performed by chemical crosslinking and / or may be initiated by free radicals generated by peroxide, gamma or electron beam irradiation.

This polymer outer cover layer has a thickness of about 0.0
20 inches to about 0.120 inches. The outer cover layer preferably has a thickness of about 0.050 inch to about 0.5 inch.
075 inches. The mantle and outer cover layer are combined together to form a single ball having a diameter of at least 1.680 inches, the minimum diameter permitted by the Rules of the Golf Association of America, and weighing about 1.620 ounces. To form

The inner and outer cover layers of this embodiment of the present invention can be molded around the core and mantle layers through various conventional molding methods. For example, these cover layers may be molded by compression molding, shrink pin injection molding, fixed pin injection molding, casting around the core and mantle, or a combination thereof. However, the material of the outer layer has such a thermal property that the material of the inner layer does not flow out during the formation of the outer cover layer around the inner layer, regardless of the process used to form the layer. It is important to be characterized by

The inner cover layer of this embodiment of the present invention has a thickness from about 0.005 inches to about 0.040 inches. The outer cover layer can be from about 0.010 inches to about 0.10 inches
It has a thickness of 0 inches. Preferably, the inner cover layer has a thickness of about 0.010 inches to about 0.030 inches and the outer cover layer has a thickness of about 0.030 inches to about 0.09 inches.
It has a thickness of 0 inches.

The present invention also contemplates using various non-conventional cover materials. The cover of the present invention is especially useful for ethylene or propylene-based homopolymers and copolymers containing functional monomers such as acrylic acid and methacrylic acid and for fully or partially neutralized ionomers and mixtures thereof, , Homopolymers and copolymers of methyl methacrylate and imidized polymers containing amino groups, polycarbonate, reinforced polyamide, polyphenylene oxide, high impact polystyrene, polyetherketone, polysulfone, poly (phenylene sulfide), reinforced engineering plastic , Acrylonitrile-butadiene, acryl-styrene-acrylonitrile, poly- (ethylene terephthalate), poly- (butylene terephthalate), poly- (ethylene-vinyl alcohol) Lumpur), poly - (including the tetrafluoroethylene) and functional comonomers, such as copolymers thereof and mixtures thereof, may comprise a thermoplastic or engineering plastics. These polymers or copolymers can be further reinforced by mixing a wide range of fillers and glass fibers or spheres or wood pulp. (Other Aspects) The properties of the golf ball of the present invention, such as hardness, bayshore elasticity, elastic modulus, core diameter, and mantle layer thickness, affect the play characteristics of the golf ball of the present invention, such as spin, initial velocity, and feel. Has been found to give.

In particular, the total thickness of the primary and optional secondary mantle layers of the ball according to the preferred embodiment of the present invention is from about 0.005 inches to about 0.6 inches. Preferably, the thickness of the primary and optional secondary mantle layers is from about 0.04 inches to about 0.10 inches. Most preferably, the diameter of the primary and secondary mantle layers is about 0.
06 inches. Similarly, the core diameter of a golf ball according to a preferred embodiment of the present invention is between about 1.25 inches and about 1.51 inches. Preferably, the core diameter is about 1.
30 inches to about 1.48 inches. Most preferably,
The core diameter is about 1.39 inches. The total diameter of the core and mantle layer (s) is from about 84% to about 97% of the total diameter of the finished ball, and is preferably about 1.51 inches.

The multi-layer golf balls of the present invention can have any size of any diameter. United States Golf Association (USGA)
Specifications limit the minimum size of a competition golf ball to a size greater than 1.680 inches in diameter, but there is no specification for a maximum diameter. Furthermore, golf balls of any size can be used for recreational play. The preferred diameter of the golf balls of the present invention is from about 1.680 inches to about 1.800 inches.
A more preferred diameter is from about 1.680 inches to about 1.760.
Inches. The most preferred diameter is from about 1.680 inches to about 1.740 inches. However, oversized game balls, significantly greater than 1.800 inches, are also within the scope of the present invention.

The hardness of the various layers of the golf ball of the present invention,
Some physical properties, such as elasticity and modulus, are believed to affect the play characteristics of such golf balls. For example, the bending and / or tensile modulus of the mantle layer can be determined by the "feel" of the golf ball of the present invention.
It is thought to affect. Thus, to provide a softer "feel" to the golf ball of the present invention, the golf ball of the present invention may have a thickness of from about 500 psi to about 50,000.
It is preferred to have a mantle layer having a flexural modulus of psi. Similarly, it is preferred that the one or more mantle layers have a tensile modulus from about 500 psi to about 50,000 psi to provide a softer "feel" to the golf balls of the present invention. More preferably, the one or more mantle layers have both a flexural modulus and a tensile modulus of less than about 10,000 psi. Most preferably, the flexural modulus of the mantle layer is less than 5000 psi.

Further, the core of the golf ball according to the preferred embodiment of the golf ball of the present invention has a Bayshore elasticity of about 30 to about 80. Preferably, the core is about 40-
It has a Bayshore elasticity of about 70. One or more mantle layers of the present invention have a Bayshore elasticity of about 35 to about 75. Preferably, the mantle layer has a Bayshore elasticity of about 60-70.

A golf ball according to a preferred embodiment of the present invention has a mantle layer having a Shore D hardness of less than about 60. Preferably, the Shore D hardness of the mantle layer is about 2
0 to about 60. Most preferably, the mantle layer has a Shore D hardness of about 30 to provide the desired soft "feel". The core has a Shore D hardness of about 30 to about 65. Preferably, the core has a Shore D hardness of about 35 to about 60.

In a ball according to another preferred embodiment, the specific gravity of the ball material increases toward the center of the ball. In other words, the specific gravity of the core is greater than the specific gravity of the mantle layer (s), and the specific gravity of the mantle layer (s) is greater than the specific gravity of the cover. More specifically, the core preferably has a specific gravity greater than about 1.2, the mantle layer (s) has a specific gravity between about 1 and 1.2, and the cover has a specific gravity less than about 1.1. Having a specific gravity of

The golf balls of the present invention can be made using any of the conventional processes used in the golf ball art. For example, a solid core can be made by either injection or compression molding. Similarly, the small wound core of the present invention is made by conventional means.
Next, a mantle layer is injected or compression molded around the core. It is important that the mantle material be able to maintain the applied temperature during application of the cover layer. The cover layer (s) is then poured or compression molded or cast around the mantle layer.

During the manufacture of the ball, the core is compression molded. One or more primary and secondary mantle layers are molded over the core using fixed pin molding such that a plurality of openings are formed in the mantle layer. Thereafter, a cover is molded over the mantle layer. At this time, a part of the cover material is caused to flow into the opening in the mantle layer. This forms a mechanical connection.

[0166]

EXAMPLE A series of experiments could be performed to make a primary golf ball mantle as described in Table 6 below.

[0167]

[Table 3] In each of Examples 1 to 10, the cover or the mantle layer had an improved soft feeling as compared with the 100% ionomer cover or the mantle layer. O. R
Or, the change in durability (scratch or crack resistance) is minimized and molding is easier compared to a cover or mantle layer containing 100% foam material. Example 1
In 1-16, the cover or mantle layer is 100
% Softness as compared to a cover or mantle layer containing a 0.1% thermosetting polyurethane, and thus a C.I.
O. Changes in R or persistence are minimized and molding is simplified. The foamed polymers in Examples 5 to 8 and 13 to 16 are matrix materials (ionomers)
The foam does not need to be crosslinked because it melts at temperatures higher than the processing or molding temperatures of the foam.

A multi-component golf ball is described that includes one or more inner mantle layers, wherein at least one mantle layer includes a plurality of relatively small foam granules dispersed within a polymer matrix. In other aspects, the multi-component golf ball may comprise a plurality of foam-like granules dispersed within the core of the ball, instead of or in addition to utilizing foam granules in one or more mantle layers. The golf balls described herein provide the distance and durability characteristics typically associated with two-piece balls, while also providing the desired playing characteristics associated with three-piece or wound balls.

The invention has been described with reference to the preferred embodiment. Obviously, upon reading and understanding the above detailed description, those skilled in the art will perceive changes and modifications. It is intended that the present invention be construed as including all such modifications and alterations that fall within the scope of the appended claims and their equivalents.

[0170]

[Effect] High initial velocity or coefficient of restitution (COR),
Can be relatively long distance in regular play,
And a golf ball which can be manufactured easily and inexpensively and which exhibits desirable click and feel characteristics can be provided.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a preferred embodiment golf ball according to the present invention.

FIG. 2 is an illustration of the preferred embodiment golf ball shown in FIG. 1 in accordance with the present invention.

FIG. 3 is a detailed schematic view of a portion of a mantle layer of another preferred embodiment golf ball according to the present invention.

FIG. 4 is a cross-sectional view of yet another preferred embodiment golf ball according to the present invention.

[Explanation of symbols]

 4,14 Mantle layer 5,15 Polymer matrix 10 Golf ball 12 Core 16 Foam granules

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Claims (50)

[Claims] 1. A polymer matrix material comprising: a core; at least one cover layer disposed around the core; and a mantle layer disposed around the core and between the core and the cover layer. And a mantle layer comprising a plurality of foam granules dispersed in the polymer matrix material, the granules comprising:
A mantle layer having an average diameter from about 0.001 inches to about 0.200 inches. 2. The golf ball of claim 1, wherein the granules have an average diameter from about 0.0012 inches to about 0.180 inches. 3. The golf ball according to claim 1, wherein the granules have a specific gravity of about 0.01 to about 0.8. 4. The golf ball of claim 3, wherein the granules have a specific gravity of about 0.1 to about 0.7. 5. The golf ball of claim 1, wherein the mantle layer has a thickness from about 0.005 inches to about 0.500 inches. 6. The golf ball of claim 5, wherein the mantle layer has a thickness from about 0.02 inches to about 0.300 inches. 7. The golf ball of claim 6, wherein the mantle layer has a thickness from about 0.050 inches to about 0.250 inches. 8. The golf ball of claim 1, wherein the weight ratio of the matrix material to the granules ranges from about 5 to 90% granules to about 10 to 95% matrix material. 9. The golf ball of claim 8, wherein the weight ratio of the matrix material to the granules ranges from about 25-90% matrix to about 10-75% granules. 10. The golf ball of claim 9, wherein the weight ratio of the matrix material to the granules ranges from about 50 to 85% matrix to about 15 to 50% granules. 11. The golf ball according to claim 1, further comprising a secondary mantle layer disposed around the mantle layer and between the mantle layer and the cover layer. 12. A core, a cover layer disposed around the core, and an inner mantle layer surrounding the core and disposed between the core and the cover layer, the core comprising a core, A mantle comprising a plurality of foam particles dispersed in an ionomer, a non-ionomer polyolefin, a metallocene catalyzed polymer, polyethylene ethyl or methyl acrylate, a styrene butadiene elastomer, a thermoplastic polyester, a thermoplastic polyetherester, a thermoplastic. A material selected from the group consisting of polyetheramides, polyamides, polycarbonates, polyphenylene oxides, thermoplastic or thermoset polyurethanes, silicone elastomers, dynamically vulcanized elastomers, and combinations or blends thereof. More including, golf ball comprising a internal mantle layer. 13. The particle of claim 12, wherein the particles have an average diameter from about 0.001 inches to about 0.200 inches.
3. The golf ball according to item 1. 14. The particle of claim 1, wherein the particles have an average diameter from about 0.0012 inches to about 0.180 inches.
4. The golf ball according to 3. 15. The golf ball of claim 12, wherein the particles have a specific gravity of about 0.01 to about 0.8. 16. The golf ball of claim 15, wherein the particles have a specific gravity of about 0.1 to about 0.7. 17. The method of claim 1, wherein the mantle layer has a thickness from about 0.005 inches to about 0.500 inches.
3. The golf ball according to 2. 18. The golf ball of claim 17, wherein the mantle has a thickness from about 0.02 inches to about 0.300 inches. 19. The mantle having a thickness from about 0.050 inches to about 0.250 inches.
3. The golf ball according to item 1. 20. The golf ball of claim 12, wherein the weight ratio of the matrix material to the particles ranges from about 5 to 90% granules to about 10 to 95% matrix material. 21. The golf ball of claim 20, wherein the weight ratio of the matrix material to the particles ranges from about 25-90% matrix to about 10-75% granules. 22. The golf ball of claim 21, wherein the weight ratio of the matrix material to the particles ranges from about 50 to 85% matrix to about 15 to 50% granules. 23. The golf ball according to claim 12, further comprising a secondary mantle layer disposed around the mantle layer and between the mantle layer and the cover layer. 24. A core, at least one cover layer disposed around the core, and an inner primary mantle layer surrounding the core and disposed between the core and the cover layer, the matrix comprising: a matrix; A primary mantle comprising a material and a plurality of foam granules dispersed in the matrix material, wherein the weight ratio of the granules to the matrix material is about 5 to 90% of the granules and about 10 to about 10% of the matrix material. ~ 95% range,
A golf ball comprising: an inner primary mantle layer; 25. The granule having an average diameter of about 0.001 inches to about 0.200 inches.
3. The golf ball according to item 1. 26. The granule having an average diameter of from about 0.0012 inches to about 0.180 inches.
6. The golf ball according to 5. 27. The golf ball of claim 24, wherein the granules have a specific gravity of about 0.01 to about 0.8. 28. The golf ball of claim 27, wherein the granules have a specific gravity of about 0.1 to about 0.7. 29. The golf ball of claim 24, wherein the primary mantle layer has a thickness from about 0.005 inches to about 0.500 inches. 30. The primary mantle having a thickness from about 0.02 inches to about 0.300 inches.
10. The golf ball according to 9. 31. The golf ball of claim 30, wherein the primary mantle has a thickness from about 0.050 inches to about 0.250 inches. 32. The golf ball of claim 24, wherein the weight ratio of the matrix material to the granules ranges from about 5 to 90% granules to about 10 to 95% matrix material. 33. The golf ball of claim 32, wherein the weight ratio of the matrix material to the granules ranges from about 25-90% matrix to about 10-75% granules. 34. The golf ball of claim 33, wherein the weight ratio of the matrix material to the granules ranges from about 50 to 85% matrix to about 15 to 50% granules. 35. The golf ball of claim 24, further comprising a secondary mantle layer disposed around the primary mantle layer and between the primary mantle layer and the cover layer. 36. A core, at least one cover layer disposed about the core, and a plurality of foam granules dispersed within the core, wherein the foam granules are from about 0.001 inches to about 0.200 inches. And a granule having an average diameter of 37. The granules having an average diameter from about 0.0012 inches to about 0.180 inches.
7. The golf ball according to 6. 38. The golf ball of claim 36, wherein the granules have a specific gravity of about 0.01 to about 0.8. 39. The golf ball of claim 38, wherein the granules have a specific gravity of about 0.1 to about 0.7. 40. The core comprising a matrix material,
The weight ratio of the matrix material to the granules is from about 5 to 90% granules to about 10 to 95% matrix material.
37. The golf ball of claim 36, wherein 41. The golf ball of claim 40, wherein the weight ratio of the matrix material to the granules ranges from about 25-90% matrix to about 10-75% granules. 42. The golf ball of claim 41, wherein the weight ratio of the matrix material to the granules ranges from about 50 to 85% matrix to about 15 to 50% granules. 43. A core comprising a first matrix material, at least one cover layer disposed around the core, and an inner mantle surrounding the core and disposed between the core and the cover layer. A mantle layer comprising a second matrix material, and a plurality of foam particles dispersed in at least one of the first matrix material of the core and the second matrix material of the mantle layer. An ionomer, non-ionomer polyolefin, metallocene catalyzed polymer, polyethylene ethyl or methyl acrylate, styrene butadiene elastomer, thermoplastic polyester, thermoplastic polyetherester, thermoplastic polyetheramide, polyamide, polycarbonate, polyphenylene oxide, thermoplastic or Thermosetting polyurethane A particle comprising one or more materials selected from the group consisting of urethanes, silicone elastomers, dynamically vulcanized elastomers, and combinations or blends thereof. 44. The particles of claim 43, wherein the particles have an average diameter from about 0.001 inches to about 0.200 inches.
3. The golf ball according to item 1. 45. The particles of claim 4, wherein the particles have an average diameter from about 0.0012 inches to about 0.180 inches.
5. The golf ball according to item 4. 46. The golf ball of claim 43, wherein the particles have a specific gravity of about 0.01 to about 0.8. 47. The golf ball of claim 46, wherein the particles have a specific gravity of about 0.1 to about 0.7. 48. The mantle layer has a thickness from about 0.005 inches to about 0.500 inches.
4. The golf ball according to 3. 49. The golf ball of claim 48, wherein the mantle has a thickness from about 0.02 inches to about 0.300 inches. 50. The mantle having a thickness from about 0.050 inches to about 0.250 inches.
3. The golf ball according to item 1.