Multi-piece golf balls having a solid core made of a foamed composition and a cover are provided. Preferably, the core is dual-layered having has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition containing mineral filler particulate, for example, nanoclay particles, is used to form the foam center. The concentration of clay particulate is preferably in a range of 0.1 to 60% by weight. The surrounding outer core layer may be made from non-foamed or foamed compositions. For example, polybutadiene rubber or highly neutralized olefin acid copolymers may be used in the outer core layer. The core layers have different hardness gradients and specific gravity values.

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. In one preferred embodiment, each core layer has a positive hardness gradient. The center of the core comprises a metal material such as copper, steel, brass, tungsten, titanium, aluminum, and alloys thereof. The intermediate core layer is preferably formed from a first thermoset composition such as polybutadiene rubber, and the outer core layer is preferably formed from a second thermoset composition. The resulting ball has high resiliency and good spin control.

Golf balls comprising a core having at least one layer and a cover having at least one layer are provided. At least one of the layers is made from a thermoplastic composition preferably comprising a telechelic ionomer derived from alkyl-cis-cyclooctene and cis-cyclooctene. The telechelic ionomer composition also may be used to form intermediate layers. Blends of telechelic ionomers and polybutadiene rubbers or ethylene acid copolymers can be prepared. The telechelic ionomer compositions can be used to make a cover layer having good impact durability and shear resistance and that also helps provide the ball with high resiliency.

In a multi-piece solid golf ball made up of, successively, a core, an intermediate layer and a cover having numerous dimples on the surface thereof, the intermediate layer is formed of a resin material and the cover is formed of a urethane resin material, each having a specific respective Shore D hardness. The ball has a specific (intermediate layer thickness)/(core diameter) value and a specific (cover thickness)/(core diameter) value, and the core has a specific deflection and has a specific hardness profile from a center to a surface thereof. This golf ball provides an increased distance and has both a soft feel when played and a high durability to repeated impact.

In a golf ball having a core, an intermediate layer and a cover, the intermediate layer-encased sphere has a higher surface hardness than the ball. The core hardness profile in the ball is designed such that the core surface has a Shore C hardness value which is at least 28 higher than the Shore C hardness value at the core center, and the surface areas A to F calculated from hardness differences between positions located at specific distances in the core and differences between the specific distances satisfy a specific formula. This golf ball has an excellent flight performance when struck by skilled amateur golfers and professionals, and also has a good controllability on shots with an iron.

A golf ball including a core; an inner cover layer formed from a first thermoplastic composition and having a thickness of about 0.005 inches to 0.40 inches and a surface hardness of about 60 Shore D or greater; and an outer cover layer formed from a thermoplastic polyurethane material and having a thickness of about 0.01 inches to 0.075 inches and a surface hardness of about 60 Shore D or less. The thermoplastic composition has a first melt flow index at 280 C. under a 10-kg load of less than about 35 g/10 min and a second melt flow index at 265 C. under a 5-kg load of less than about 10 g/10 min.

A golf ball for amateur golfers is endowed with both an excellent flight and a good feel at impact that is soft and solid when hit by the average golfer whose head speed is not very high. The golf ball, which includes a core and a cover, has a compressive deformation A when subjected to a final load of 5 kg from an initial load of 0.2 kg that is 0.21 mm or less, a compressive deformation B when subjected to a final load of 30 kg from an initial load of 5 kg that is from 0.72 to 0.90 mm and a compressive deformation C when subjected to a final load of 60 kg from an initial load of 5 kg that is from 1.55 to 1.80 mm.

Multi-piece golf balls having a solid core made of a foamed composition and a cover are provided. Preferably, the core is dual-layered having has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition containing mineral filler particulate, for example, nanoclay particles, is used to form the foam center. The concentration of clay particulate is preferably in a range of 0.1 to 60% by weight. The surrounding outer core layer may be made from non-foamed or foamed compositions. For example, polybutadiene rubber or highly neutralized olefin acid copolymers may be used in the outer core layer. The core layers have different hardness gradients and specific gravity values.

Multi-piece golf balls containing a dual-layered core structure are provided. The core structure includes a small, heavy inner core (center) having a relatively high specific gravity, 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 preferably dispersed in a thermoplastic polymeric matrix. Different plasticizers such as fatty acid esters may be used. The outer core layer is preferably formed from a thermoset composition such as polybutadiene. The resulting ball has high resiliency and good spin.

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.