In a multi-piece solid golf ball having a core, a cover and an intermediate layer therebetween, the core, an intermediate layer-encased sphere and the ball have surface hardnesses which satisfy a specific relationship, and the intermediate layer and the cover have thicknesses which satisfy a specific relationship. Also, 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 surface and center of the core satisfy specific relationships. This golf ball, when used by mid- and high-level amateurs, enables the golfer to maintain an adequate distance on shots with a driver and achieve a good distance on iron shots, has a good spin performance on approach shots and has a good feel on impact. In addition, the ball has an excellent scuff resistance when struck with a grooved wedge.

Golf balls having a multi-layered core made of a foamed composition are provided. The core preferably has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition is used to form the foam center. The foam inner core preferably includes a fully-foamed center region and a partially or completely-collapsed foam outer region. The hardness of the fully-foamed region is different than the hardness of the collapsed foam region. Non-foamed thermoset or thermoplastic materials such as polybutadiene rubbers or ethylene acid copolymer ionomer may be used to form the outer core layer. The ball further includes a cover that may be multi-layered. The foam cores have good resiliency.

In a golf ball having a core and a cover consisting of a plurality of layers that encases the core, adhesion between adjoining cover layers is improved by judicious selection of the materials making up the cover layers, providing the ball with an improved durability to impact without diminishing the ball initial velocity.

In a multi-piece solid golf ball having a core, an envelope layer, an intermediate layer, and a cover with a plurality of dimples thereon, the core is a two-layer core consisting of an inner core layer and an outer core layer each formed primarily of a base rubber, the envelope layer, the intermediate layer and the cover layer are each composed of at least one layer and formed primarily of a synthetic resin material, and the initial velocities and surface hardnesses of the core, the envelope layer-encased sphere and the intermediate layer-encased sphere are designed within specific ranges. This golf ball satisfies at a very high level the flight and control performances expected for use by professional golfers and skilled amateurs, has the ability to move forward on a straight path particularly on full shots, and also has an excellent scuff resistance.

In a multi-piece solid golf ball having a core, an envelope layer, an intermediate layer, and a cover with a plurality of dimples formed thereon, the core is formed primarily of a base rubber, the envelope layer and the intermediate layer are formed primarily of synthetic resin materials, and the cover layer is formed primarily of a urethane material. The relationships between, respectively, the surface hardnesses of the envelope layer-encased sphere and the ball, the thicknesses of the intermediate layer and the cover layer, the deflections of the core and the ball, and the initial velocities of the core and various layer-encased spheres of the ball each satisfy specific conditions. This golf ball makes it possible for amateur golfers, while maintaining a good distance on shots with a driver (W#1), to obtain a good ball controllability on approach shots and moreover experience a soft feel at impact.

Golf balls having a multi-layered core made of a foamed composition are provided. The core preferably has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition is used to form the foam center. The foam inner core preferably includes a fully-foamed center region and a partially or completely-collapsed foam outer region. The hardness of the fully-foamed region is different than the hardness of the collapsed foam region. Non-foamed thermoset or thermoplastic materials such as polybutadiene rubbers or ethylene acid copolymer ionomer may be used to form the outer core layer. The ball further includes a cover that may be multi-layered. The foam cores have good resiliency.

In a multi-piece solid golf ball having a rubber two-layer core consisting of an inner layer and an outer layer, a cover, and at least one intermediate layer therebetween, the inner core layer has a diameter of at least 30 mm, the difference in JIS-C hardness between the center of the inner core layer and the surface of the outer core layer is at least 25, the ball satisfies the relationship A/B1.5, where A and B are the deflections of, respectively, the inner core layer and the two-layer core when compressed under specific loading conditions, and the intermediate layer has a higher material hardness than the cover. This ball enables mid- to high-level golfers both to achieve even longer distances and to maintain the spin performance on approach shots at a high level.

The present invention is directed to multi-layer golf balls including a layer formed from a composition comprising a relatively soft or low modulus HNP, a layer formed from a composition comprising a relatively hard or high modulus HNP, an inner cover layer formed from a thermoplastic composition, and an outer cover layer.

Golf balls having an initial velocity greater than 255 ft/sec and/or an overall distance of greater than 320 yards are disclosed. The golf balls comprise one or more core layers, one or more cover layers, and optionally one or more intermediate layers disposed between the core and the cover. At least one layer is optionally formed from a composition comprising from 2 wt % to 50 wt % of a plasticizer, based on the total weight of the composition.

Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from foamed and non-foamed thermoset compositions. For example, the intermediate core can be formed from a thermoset rubber so there are adjoining foam core layers (inner and intermediate) and the outer core layer can be formed from a non-foamed thermoset rubber. The core layers have different hardness and specific gravity levels. The core assembly preferably has a positive hardness gradient extending across the entire assembly. The core structure and resulting ball have relatively good resiliency.