Methods for coatings for golf balls, particularly golf balls having thermoplastic polyurethane covers, and the resulting finished balls are provided. The coating is preferably a topcoat comprising a polyurethane composition containing optical brighteners. The topcoat composition preferably comprises a low concentration of optical brighteners. For example, the concentration of optical brightener can be in the range of 0.01 to about 0.20 weight %. The optical brighteners provide the desired brightness to the golf ball without sacrificing color stability. Multi-piece golf balls having inner cores, outer cores, inner covers, and intermediate layers can be made. The finished ball with the topcoat has many advantageous physical and playing performance properties.

Golf balls having covers made of thermoplastic polyurethane compositions are provided. Multi-piece golf balls can be made. Polyurethane primer coatings and polyurethane top-coatings are applied to the thermoplastic polyurethane cover. Isocyanate-rich and polyol-rich polyurethane coatings can be applied. In one embodiment, multi-functional imine and amine compounds can be used to treat the golf ball. The resulting coating may contain polyurethanes, polyureas, and hybrids, copolymers, and blends thereof. The cover composition and surface coatings can further include catalysts, ultraviolet (UV)-light stabilizers, and other additives. Heat is used to cure the coatings. The coating methods have many benefits and the finished balls have good physical properties.

The present invention provides methods for producing molded golf balls and the resultant balls. The methods of this invention involve producing foamed polyurethane covers and these methods help reduce dimple distortions and other surface imperfections. These golf balls contain an inner core and outer foamed polyurethane cover. One or more intermediate layers can be disposed between the core and cover. In one embodiment, a castable liquid polyurethane composition containing a foaming agent is dispensed into mold cavities, which are then pressed together to form a foam cover for the ball.

Multi-layered golf balls having at least one layer made from silicone (polysiloxane) elastomers; silicone (polysiloxane) elastomer/polyurethane blends; polycarbonate-polysiloxane blends and copolymers; and polycarbonate-polysiloxane/polyurethane blends are provided. For example, three-piece, four-piece, and five-piece golf balls containing different core and cover structures can be made. The polysiloxane compositions have good thermal stability and durability without sacrificing resiliency. The polysiloxane compositions also have high elongation, tensile strength, chemical/fluid-resistance, and weatherability properties. These compositions can be used to form any layer, for example, core, intermediate, or cover, in the golf ball.

Multi-piece golf balls containing a multi-layered core structure are provided. The core structure includes a small, heavy inner core (center) having a relatively high specific gravity, an intermediate core layer, and a surrounding outer core layer. The layers of the core structure may have different hardness gradients. The center of the core comprises a metal material such as copper, steel, brass, tungsten, titanium, aluminum, and alloys thereof dispersed in a thermoset polymeric matrix. The intermediate core layer is preferably formed from a first thermoplastic composition such as an ethylene acid copolymer ionomer resin; and the outer core layer is preferably formed from a second thermoplastic composition. The resulting ball has high resiliency and good spin control.

A golf ball is provided that achieves a satisfactory distance on full shots with an iron, is superior in the short game, and has a good feel at impact and a good durability. The golf ball has a core formed of a rubber composition as one or more layer, an envelope layer formed of a resin material as one or more layer, an intermediate layer formed of a resin material as one layer, and a cover formed of a resin material as one layer having a thickness of not more than 1.0 mm. The layers of the ball have Shore C hardnesses at the respective surfaces thereof which together satisfy certain specific conditions, the core and the ball have respective deflections which satisfy certain conditions and the core has a specific internal hardness profile.

Golf ball multi-layered core sub-assemblies and the resulting golf balls are provided. The core structure includes a foam inner core (center); and intermediate and outer core layers. Foamed polyurethane is preferably used to make the inner core. The intermediate and outer core layers are preferably made from non-foamed thermoplastic compositions such as ethylene acid copolymer ionomer. In an alternative version, the intermediate core layer may be made of a thermoset rubber such as polybutadiene. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.

In a multi-piece solid golf ball having a core, an envelope layer encasing the core, an intermediate layer encasing the envelope layer, and an outermost layer encasing the intermediate layer, the envelope layer-encased sphere, the intermediate layer-encased sphere and the ball have surface hardnesses which satisfy a specific relationship, the intermediate layer and the cover have thicknesses which satisfy a specific relationship, and the core has a hardness profile in which the hardnesses at the core surface, core center, a position 5 mm from the core center, and a position midway between the core surface and center satisfy specific relationships. This golf ball satisfies at a high level the flight and control performances desired for use by professional golfers and skilled amateurs. In particular, it holds down the spin rate on full shots and follows a straight trajectory, thus having a superior flight performance, and moreover is endowed with an excellent scuff resistance.

An object of the present invention is to provide a golf ball traveling a great distance on driver shots and on iron shots. The present invention provides a golf ball comprising a spherical core including an inner layer and an outer layer, and a cover, wherein a difference (H.sub.X+1−H.sub.X−1) between a hardness (H.sub.X+1) at a point outwardly away in a radial direction from a boundary between the inner layer and the outer layer of the spherical core by 1 mm and a hardness (H.sub.X−1) at a point inwardly away in the radial direction from the boundary between the inner layer and the outer layer of the spherical core by 1 mm is 0 or more in Shore C hardness, a surface hardness (H.sub.X+Y) of the spherical core is more than 65 in Shore C hardness, an angle α of a hardness gradient of the inner layer is 0° or more, a difference (α−β) between the angle α and an angle β of a hardness gradient of the outer layer is 0° or more, a thickness of the cover is 3 mm or less, a difference (Hc−H.sub.x+y) between a hardness (Hc) of the cover and the surface hardness (H.sub.X+Y) of the spherical core is 2 or more in Shore C hardness, and the cover has a highest hardness among the constituent members of the golf ball.

A golf ball with a core comprising polybutadiene and graphene is disclosed herein. The golf ball has a single core comprising polybutadiene and graphene. Alternatively, the golf ball has a dual core with an inner core comprising polybutadiene and graphene. Alternatively, the golf ball has a dual core with an outer core comprising polybutadiene and graphene.