Golf ball with dual mantle layers

Abstract

A golf ball with dual mantle layers is disclosed herein. The golf ball comprises a core, an inner mantle layer, an outer mantle layer and a cover layer. The golf ball has a COR greater than 0.77. The inner mantle includes a MBS impact modifier. The outer mantle layer is softer than the inner mantle layer.

Claims

1. A golf ball consisting essentially of: a core comprising the reaction product of a first polybutadiene rubber, a second polybutadiene rubber, a zinc diacrylate in an amount ranging from 30 to 40 parts per hundred of the polybutadiene materials, PPH, a zinc oxide ranging from 15 to 20 PPH, a zinc stearate ranging from 5 to 15 PPH, a peroxide initiator ranging from 1 to 2 PPH, and BaSO4 ranging from 1 to 3 PPH, the core having a diameter ranging from 1.40 inches to 1.55 inches, the core having a COR of at least 0.79; an inner mantle layer disposed over the core, the inner mantle layer having a thickness ranging from 0.025 inch to 0.04 inch, the mantle layer having a Shore D hardness ranging from 55 to 60, the inner mantle layer consisting essentially of a first ionomer ranging from 45-65 weight percent of the mantle layer, a second ionomer ranging from 35-55 weight percent of the mantle layer, a highly neutralized polymer ranging from 10-20 weight percent, an impact modifier ranging from 0.01-0.05 weight percent of the inner mantle layer, wherein the impact modifier is an acrylic/methacrylic core-shell modifier for polycarbonate; and an outer mantle layer disposed over the inner mantle layer, the outer mantle layer having a thickness ranging from 0.025 inch to 0.04 inch, the mantle layer having a Shore D hardness ranging from 45 to 50 and being lower in Shore D hardness than the inner mantle layer, the outer mantle layer comprising a first ionomer ranging from 45-50 weight percent of the outer mantle layer, a second ionomer ranging from 45-50 weight percent of the outer mantle layer, and a third ionomer ranging from 1-10 weight percent of the outer mantle layer; a cover disposed over the outer mantle layer, the cover having a thickness ranging from 0.03 inch to 0.04 inch, the cover having a Shore D hardness ranging from 30 to 40 and being lower in hardness than the outer mantle layer, the cover consisting essentially of a first thermoplastic polyurethane (TPU) ranging from 40-50 weight percent of the cover, a second TPU ranging from 35-45 weight percent of the cover, a third TPU ranging from 5-10 weight percent of the cover; wherein the golf ball has a PGA compression ranging from 95 to 105; wherein the golf ball has a COR ranging of at least 0.78.

2. A golf ball consisting essentially of: a core comprising the reaction product of a first polybutadiene rubber, a second polybutadiene rubber, a zinc diacrylate in an amount ranging from 30 to 40 parts per hundred of the polybutadiene materials, PPH, a zinc oxide ranging from 15 to 20 PPH, a zinc stearate ranging from 5 to 15 PPH, a peroxide initiator ranging from 1 to 2 PPH, zinc-pentachlorothiophenol, and BaSO4 ranging from 1 to 3 PPH, the core having a diameter ranging from 1.40 inches to 1.55 inches, the core having a COR of at least 0.79; an inner mantle layer disposed over the core, the inner mantle layer having a thickness ranging from 0.025 inch to 0.04 inch, the mantle layer having a Shore D hardness ranging from 55 to 60, the inner mantle layer consisting essentially of a first ionomer ranging from 45-65 weight percent of the mantle layer, a second ionomer ranging from 35-55 weight percent of the mantle layer, a highly neutralized polymer ranging from 10-20 weight percent, an impact modifier ranging from 0.01-0.05 weight percent of the inner mantle layer, wherein the impact modifier is an acrylonitrile-butadiene-styrene polymer; and an outer mantle layer disposed over the inner mantle layer, the outer mantle layer having a thickness ranging from 0.025 inch to 0.04 inch, the mantle layer having a Shore D hardness ranging from 45 to 50 and being lower in Shore D hardness than the inner mantle layer, the outer mantle layer comprising a first ionomer ranging from 45-50 weight percent of the outer mantle layer, a second ionomer ranging from 45-50 weight percent of the outer mantle layer, and a third ionomer ranging from 1-10 weight percent of the outer mantle layer; a cover disposed over the outer mantle layer, the cover having a thickness ranging from 0.03 inch to 0.04 inch, the cover having a Shore D hardness ranging from 30 to 40 and being lower in hardness than the outer mantle layer, the cover consisting essentially of a first thermoplastic polyurethane (TPU) ranging from 40-50 weight percent of the cover, a second TPU ranging from 35-45 weight percent of the cover, a third TPU ranging from 5-10 weight percent of the cover, wherein the golf ball has a PGA compression ranging from 95 to 105; wherein the golf ball has a COR ranging of at least 0.78.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 is an exploded partial cut-away view of a golf ball.

(2) FIG. 2 is top perspective view of a golf ball.

(3) FIG. 3 is a cross-sectional view of a core component of a golf ball.

(4) FIG. 4 is a cross-sectional view of a core component and a mantle component of a golf ball.

(5) FIG. 5 is a cross-sectional view of an inner core layer, an outer core layer, an inner mantle layer, an outer mantle layer and a cover layer of a golf ball.

(6) FIG. 5A is a cross-sectional view of an inner core layer, an intermediate core layer, an outer core layer, a mantle layer and a cover layer of a golf ball.

(7) FIG. 6 is a cross-sectional view of an inner core layer under a 100 kilogram load.

(8) FIG. 7 is a cross-sectional view of a core under a 100 kilogram load.

(9) FIG. 8 is a cross-sectional view of a core component and a mantle component of a golf ball.

(10) FIG. 9 is a cross-sectional view of a core component, the mantle component and a cover layer of a golf ball.

(11) FIG. 10 is an exploded partial cut-away view of a four-piece golf ball.

(12) FIG. 11 is an exploded partial cut-away view of a three-piece golf ball.

(13) FIG. 12 is an exploded partial cut-away view of a two-piece golf ball.

(14) FIG. 13 is a cross-sectional view of a two-piece golf ball.

(15) FIG. 14 is a cross-sectional view of a three-piece golf ball.

(16) FIG. 15 is an exploded partial cut-away view of a three-piece golf ball.

(17) FIG. 16 is a cross-sectional view of a three-piece golf ball with a dual core and a cover.

(18) FIG. 17 is a cross-sectional view of a three-piece golf ball with a core, mantle and cover.

(19) FIG. 18 is a cross-sectional view of a four-piece golf ball with a dual core, mantle layer and a cover.

(20) FIG. 19 is a cross-sectional view of a four-piece golf ball with a core, dual mantle layers and a cover.

DETAILED DESCRIPTION OF THE INVENTION

(21) Golf balls were made by using ingredients listed in Table 1. There are two mantle layers between the core and a cover.

(22) Polybutadiene based cores can be made using following materials. Corresponding levels (% wt) is mentioned next to each material.

(23) Butadiene rubber with more than 60% 1,4-cis structure-(40-90%), Isoprene rubber-(0-30%), Zinc diacrylate-(5-50%), Zinc oxide-(0-30%), Zinc stearate-(0-20%), Peroxide initiator-(0.1-10%), Peptizer-(0-10%), Barium sulfate-(0-20%), and Styrene butadiene rubber-(0.01-30%)-available from various suppliers such as Kumho, Lanxess, Dynasol, and Synthos. Optionally this core can have graphene, graphene oxide, multi walled carbon nanotubes, boron nitride, nanoclay and/or any combination of the above fillers in 0-10% by weight. All these additives can be added in either powder or masterbatch form. Masterbatch can be made by mixing one or any combination of these additives in polybutadiene or polyisoprene based carrier. Internal rubber mixer and or two roll mill can be used for making masterbatch.

(24) Cores were made as per recipe in Table 1. Curing was done at temperatures ranging from 100-300 C for times ranging from 1-30 minutes. Covers were injection molded on these cores using ionomers that are popularly known in the industry. These ionomers can be selected from the following non limiting list-Surlyn 8150, AD1022, 8945, 9945, 1702, 9010, 9120, 9150, 9220, 9450, 9455, 9533, 9650, 9650-S, 9720, 9721, 9722, 9730, 9010, 9120, 9150, 9220, 9450, and 9455. They may also be chosen from a list of highly neutralized ionomers from DuPont such as HPF 1000, HPF 2000, AD1172, AD1035. These ionomers can optionally contain following non limiting ingredients-titanium dioxide, zinc oxide, talc, barium sulfate, antioxidants, nanoclay, dye, and color pigment. Molded balls were then painted and tested for physical properties.

(25) TABLE-US-00001 TABLE 1 Core and ball formulation and properties Formula Formula Formula Formula Control 1 2 3 4 Component % Wt % Wt % Wt % Wt % Wt Butadiene 65.1 58.8 52.3 58.8 52.3 rubber Isoprene 0.0 6.5 13.1 0.0 0.0 rubber Zinc 20.4 19.6 19.6 19.6 19.6 diacrylate Zinc oxide 6.5 6.5 6.5 6.5 6.5 Peroxide 1.0 1.0 1.0 1.0 1.0 Peptizer 0.6 0.6 0.6 0.6 0.6 Zinc stearate 2.0 2.0 2.0 2.0 2.0 Barium 4.4 5.0 5.0 5.0 5.0 sulfate SBR rubber 0.0 0.0 0.0 6.5 13.1 Core properties Core 61 49 41 57 63 compression Core COR 0.796 0.781 0.768 0.780 0.766 Cover material (% wt) Ionomer 1 43 43 43 43 43 Ionomer 2 23.5 23.5 23.5 23.5 23.5 Ionomer 3 23.5 23.5 23.5 23.5 23.5 Ionomer 4 10 10 10 10 10 Ball properties Ball 71 61 55 66 72 compression Ball COR 0.797 0.784 0.771 0.783 0.770

(26) Compression and COR of golf ball can be easily altered by incorporation of styrene butadiene rubber in the core.

(27) Durability, speed, and spin profile of a golf ball can be modified without changing its cover.

(28) A golf ball of the present invention preferably has a diameter of at least 1.68 inches and a mass no greater than 45.93 grams, and preferably a mass of 45.6 grams. The golf ball preferably has an Instron compression of 0.115 inches under a 200 pound load. The golf ball preferably has a COR of at least 0.790.

(29) The outer core preferably has a diameter of from 1.4 to 1.65 inches, and most preferably from 1.5 to 1.62 inches. The outer core is preferably composed of a polybutadiene (KUMHO NDBR 60), graphene, ZDA, zinc oxide, peroxide, a peptizer (zinc penta) and barium sulfate.

(30) The inner core preferably has a diameter ranging from 1.0 to 1.5 inches, and most preferably from 1.2 to 1.3 inches. The inner core preferably has an Instron compression of 0.2 inches under a 200 pound load. The inner core is preferably composed a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material. The inner core preferably has a mass ranging from 15 to 25 grams, and most preferably 18 to 22 grams.

(31) A preferred HNP is HPF 2000 available from DuPont Chemical. Another preferred HNP is HPF 1000, also available from DuPont.

(32) The PARALOID impact modifier (available from Dow Chemical) is at least one of acrylonitrile-butadiene-styrene polymer (ABS), methyl methacrylate-butadiene-styrene polymer (MBS) impact-property modifiers for poly(vinyl chloride), and acrylic/methacrylic core-shell modifiers for polycarbonate.

(33) Dymalink Metallic Coagents are acrylate and methacrylate functional metal-centered monomers. Dymalink 548, a zinc diacrylate, is used in the core.

(34) Crast et al., U.S. Pat. No. 6,632,877, for a Dual Curable Coating, is hereby incorporated by reference in its entirety.

(35) Skrabski et al., U.S. Pat. No. 6,544,337, for a Golf ball Painting System, is hereby incorporated by reference in its entirety.

(36) Crast et al., U.S. Pat. No. 6,365,679, for a Two component polyurethane clear coat for golf balls, is hereby incorporated by reference in its entirety.

(37) Crast et al., U.S. Pat. No. 6,165,564, for a UV Clearable Clear Coat For Golf Balls, is hereby incorporated by reference in its entirety.

(38) Skrabski et al., U.S. Pat. No. 6,319,563, for a Golf ball Painting Method, is hereby incorporated by reference in its entirety.

(39) FIGS. 1, 3, 4 and 5 illustrate a five piece golf ball 10 comprising an inner core 12a, an outer core 12b, an inner mantle 14a, an outer mantle 14b, and a cover layer 16, wherein the inner core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(40) FIG. 5A illustrates a five piece golf ball 10 comprising an inner core 12a, an intermediate core 12b, an outer core 12c, a mantle 14, and a cover layer 16, wherein the inner core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(41) FIGS. 8 and 9 illustrate a six piece golf ball 10 comprising an inner core 12a, an intermediate core 12b, an outer core 12c, an inner mantle 14a, an outer mantle 14b, and a cover layer 16 wherein the inner core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(42) FIG. 10 illustrates a four piece golf ball comprising a dual core, a boundary layer and a cover layer 16, wherein a center core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(43) FIG. 11 illustrates a three piece golf ball comprising a core, a boundary layer and a cover layer 16, wherein the core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(44) FIGS. 12 and 13 illustrate a two piece golf ball 20 with a core 25 and a cover layer 30, wherein the core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(45) FIGS. 14 and 15 illustrate a three-piece golf ball 5 comprising a core 10, a mantle layer 14 and a cover layer 16, wherein the core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(46) FIG. 16 illustrates a dual core three piece golf ball 35 comprising an inner core 30, and outer core 32 and a cover layer 34 wherein the inner core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(47) FIG. 17 illustrates a three piece golf ball 45 comprising a core 40, a mantle layer 42 and a cover layer 44 wherein the core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(48) FIG. 18 illustrates a dual core four piece golf ball 55 comprising an inner core 50, an outer core 52, a mantle layer 54 and a cover layer 56 wherein the inner core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(49) FIG. 19 illustrates a four piece golf ball 65 comprising a core 60, an inner mantle 62, an outer mantle 64 and a cover layer 66 wherein the inner core comprises a polybutadiene rubber ranging from 40 to 90 weight percent of a center core material, a zinc diacrylate ranging from 5 to 50 weight percent of a center core material, a zinc oxide ranging from 0.1 to 30 weight percent of a center core material, a zinc stearate ranging from 0.1 to 20 weight percent of a center core material, a peroxide initiator ranging from 0.1 to 10 weight percent of a center core material, a peptizer ranging from 0.1 to 10 weight percent of a center core material, and a styrene butadiene rubber ranging from 0.1 to 30 weight percent of a center core material.

(50) The mantle component is preferably composed of the inner mantle layer and the outer mantle layer. The mantle component preferably has a thickness ranging from 0.05 inch to 0.15 inch, and more preferably from 0.06 inch to 0.08 inch. The outer mantle layer is preferably composed of a blend of ionomer materials. One preferred embodiment comprises SURLYN 9150 material, SURLYN 8940 material, a SURLYN AD1022 material, and a masterbatch. The SURLYN 9150 material is preferably present in an amount ranging from 20 to 45 weight percent of the cover, and more preferably 30 to 40 weight percent. The SURLYN 8945 is preferably present in an amount ranging from 15 to 35 weight percent of the cover, more preferably 20 to 30 weight percent, and most preferably 26 weight percent. The SURLYN 9945 is preferably present in an amount ranging from 30 to 50 weight percent of the cover, more preferably 35 to 45 weight percent, and most preferably 41 weight percent. The SURLYN 8940 is preferably present in an amount ranging from 5 to 15 weight percent of the cover, more preferably 7 to 12 weight percent, and most preferably 10 weight percent.

(51) SURLYN 8320, from DuPont, is a very-low modulus ethylene/methacrylic acid copolymer with partial neutralization of the acid groups with sodium ions. SURLYN 8945, also from DuPont, is a high acid ethylene/methacrylic acid copolymer with partial neutralization of the acid groups with sodium ions. SURLYN 9945, also from DuPont, is a high acid ethylene/methacrylic acid copolymer with partial neutralization of the acid groups with zinc ions. SURLYN 8940, also from DuPont, is an ethylene/methacrylic acid copolymer with partial neutralization of the acid groups with sodium ions.

(52) The inner mantle layer is preferably composed of a blend of ionomers, preferably comprising a terpolymer and at least two high acid (greater than 18 weight percent) ionomers neutralized with sodium, zinc, magnesium, or other metal ions. The material for the inner mantle layer preferably has a Shore D plaque hardness ranging preferably from 35 to 77, more preferably from 36 to 44, a most preferably approximately 40. The thickness of the outer mantle layer preferably ranges from 0.025 inch to 0.050 inch, and is more preferably approximately 0.037 inch. The mass of an insert including the dual core and the inner mantle layer preferably ranges from 32 grams to 40 grams, more preferably from 34 to 38 grams, and is most preferably approximately 36 grams. The inner mantle layer is alternatively composed of a HPF material available from DuPont. Alternatively, the inner mantle layer 14b is composed of a material such as disclosed in Kennedy, III et al., U.S. Pat. No. 7,361,101 for a Golf Ball And Thermoplastic Material, which is hereby incorporated by reference in its entirety.

(53) The outer mantle layer is preferably composed of a blend of ionomers, preferably comprising at least two high acid (greater than 18 weight percent) ionomers neutralized with sodium, zinc, or other metal ions. The blend of ionomers also preferably includes a masterbatch. The material of the outer mantle layer preferably has a Shore D plaque hardness ranging preferably from 55 to 75, more preferably from 65 to 71, and most preferably approximately 67. The thickness of the outer mantle layer preferably ranges from 0.025 inch to 0.040 inch, and is more preferably approximately 0.030 inch. The mass of the entire insert including the core, the inner mantle layer and the outer mantle layer preferably ranges from 38 grams to 43 grams, more preferably from 39 to 41 grams, and is most preferably approximately 41 grams.

(54) In an alternative embodiment, the inner mantle layer is preferably composed of a blend of ionomers, preferably comprising at least two high acid (greater than 18 weight percent) ionomers neutralized with sodium, zinc, or other metal ions. The blend of ionomers also preferably includes a masterbatch. In this embodiment, the material of the inner mantle layer has a Shore D plaque hardness ranging preferably from 55 to 75, more preferably from 65 to 71, and most preferably approximately 67. The thickness of the outer mantle layer preferably ranges from 0.025 inch to 0.040 inch, and is more preferably approximately 0.030 inch. Also in this embodiment, the outer mantle layer 14b is composed of a blend of ionomers, preferably comprising a terpolymer and at least two high acid (greater than 18 weight percent) ionomers neutralized with sodium, zinc, magnesium, or other metal ions. In this embodiment, the material for the outer mantle layer 14b preferably has a Shore D plaque hardness ranging preferably from 35 to 77, more preferably from 36 to 44, a most preferably approximately 40. The thickness of the outer mantle layer preferably ranges from 0.025 inch to 0.100 inch, and more preferably ranges from 0.070 inch to 0.090 inch.

(55) In yet another embodiment wherein the inner mantle layer is thicker than the outer mantle layer and the outer mantle layer is harder than the inner mantle layer, the inner mantle layer is composed of a blend of ionomers, preferably comprising a terpolymer and at least two high acid (greater than 18 weight percent) ionomers neutralized with sodium, zinc, magnesium, or other metal ions. In this embodiment, the material for the inner mantle layer has a Shore D plaque hardness ranging preferably from 30 to 77, more preferably from 30 to 50, and most preferably approximately 40. In this embodiment, the material for the outer mantle layer has a Shore D plaque hardness ranging preferably from 40 to 77, more preferably from 50 to 71, and most preferably approximately 67. In this embodiment, the thickness of the inner mantle layer preferably ranges from 0.030 inch to 0.090 inch, and the thickness of the outer mantle layer ranges from 0.025 inch to 0.070 inch.

(56) Preferably the inner core has a diameter ranging from 0.75 inch to 1.20 inches, more preferably from 0.85 inch to 1.05 inch, and most preferably approximately 0.95 inch. Preferably the inner core 12a has a Shore D hardness ranging from 20 to 50, more preferably from 25 to 40, and most preferably approximately 35. Preferably the inner core has a mass ranging from 5 grams to 15 grams, 7 grams to 10 grams and most preferably approximately 8 grams.

(57) Preferably the outer core has a diameter ranging from 1.25 inch to 1.55 inches, more preferably from 1.40 inch to 1.5 inch, and most preferably approximately 1.5 inch. Preferably the outer core has a Shore D surface hardness ranging from 40 to 65, more preferably from 50 to 60, and most preferably approximately 56. Preferably the outer core is formed from a polybutadiene, zinc diacrylate, zinc oxide, zinc stearate, a peptizer and peroxide. Preferably the combined inner core and outer core have a mass ranging from 25 grams to 35 grams, 30 grams to 34 grams and most preferably approximately 32 grams.

(58) Preferably the inner core has a deflection of at least 0.230 inch under a load of 220 pounds, and the core has a deflection of at least 0.080 inch under a load of 200 pounds. As shown in FIGS. 6 and 7, a mass 50 is loaded onto an inner core and a core. As shown in FIGS. 6 and 7, the mass is 100 kilograms, approximately 220 pounds. Under a load of 100 kilograms, the inner core preferably has a deflection from 0.230 inch to 0.300 inch. Under a load of 100 kilograms, preferably the core has a deflection of 0.08 inch to 0.150 inch. Alternatively, the load is 200 pounds (approximately 90 kilograms), and the deflection of the core 12 is at least 0.080 inch. Further, a compressive deformation from a beginning load of 10 kilograms to an ending load of 130 kilograms for the inner core ranges from 4 millimeters to 7 millimeters and more preferably from 5 millimeters to 6.5 millimeters. The dual core deflection differential allows for low spin off the tee to provide greater distance, and high spin on approach shots.

(59) In an alternative embodiment of the golf ball shown in FIG. 5A, the golf ball 10 comprises an inner core 12a, an intermediate core 12b, an outer core 12b, a mantle 14 and a cover 16. The golf ball 10 preferably has a diameter of at least 1.68 inches, a mass ranging from 45 grams to 47 grams, a COR of at least 0.79, a deformation under a 100 kilogram loading of at least 0.07 mm.

(60) In one embodiment, the golf ball comprises a core, a mantle layer and a cover layer. The core comprises an inner core sphere, an intermediate core layer and an outer core layer. The intermediate core layer is composed of a highly neutralized ionomer and has a Shore D hardness less than 40. The outer core layer is composed of a highly neutralized ionomer and has a Shore D hardness less than 45. A thickness of the intermediate core layer is greater than a thickness of the outer core layer. The mantle layer is disposed over the core, comprises an ionomer material and has a Shore D hardness greater than 55. The cover layer is disposed over the mantle layer comprises a thermoplastic polyurethane material and has a Shore A hardness less than 100. The golf ball has a diameter of at least 1.68 inches. The mantle layer is harder than the outer core layer, the outer core layer is harder than the intermediate core layer, the intermediate core layer is harder than the inner core sphere, and the cover layer is softer than the mantle layer.

(61) In another embodiment, shown in FIGS. 8 and 9, the golf ball 10 has a multi-layer core and multi-layer mantle. The golf ball includes a core, a mantle component and a cover layer. The core comprises an inner core sphere, an intermediate core layer and an outer core layer. The inner core sphere has a diameter ranging from 0.875 inch to 1.4 inches. The intermediate core layer is composed of a highly neutralized ionomer and has a Shore D hardness less than 40. The outer core layer is composed of a highly neutralized ionomer and has a Shore D hardness less than 45. A thickness of the intermediate core layer is greater than a thickness of the outer core layer 12c. The inner mantle layer is disposed over the core, comprises an ionomer material and has a Shore D hardness greater than 55. The outer mantle layer is disposed over the inner mantle layer, comprises an ionomer material and has a Shore D hardness greater than 60. The cover layer is disposed over the mantle component, comprises a thermoplastic polyurethane material and has a Shore A hardness less than 100. The golf ball has a diameter of at least 1.68 inches. The outer mantle layer is harder than the inner mantle layer, the inner mantle layer is harder than the outer core layer, the outer core layer is harder than the intermediate core layer, the intermediate core layer is harder than the inner core sphere, and the cover layer is softer than the outer mantle layer.

(62) In a particularly preferred embodiment of the invention, the golf ball preferably has an aerodynamic pattern such as disclosed in Simonds et al., U.S. Pat. No. 7,419,443 for a Low Volume Cover For A Golf Ball, which is hereby incorporated by reference in its entirety. Alternatively, the golf ball has an aerodynamic pattern such as disclosed in Simonds et al., U.S. Pat. No. 7,338,392 for An Aerodynamic Surface Geometry For A Golf Ball, which is hereby incorporated by reference in its entirety.

(63) Various aspects of the present invention golf balls have been described in terms of certain tests or measuring procedures. These are described in greater detail as follows.

(64) As used herein, Shore D hardness of the golf ball layers is measured generally in accordance with ASTM D-2240 type D, except the measurements may be made on the curved surface of a component of the golf ball, rather than on a plaque. If measured on the ball, the measurement will indicate that the measurement was made on the ball. In referring to a hardness of a material of a layer of the golf ball, the measurement will be made on a plaque in accordance with ASTM D-2240. Furthermore, the Shore D hardness of the cover is measured while the cover remains over the mantles and cores. When a hardness measurement is made on the golf ball, the Shore D hardness is preferably measured at a land area of the cover.

(65) As used herein, Shore A hardness of a cover is measured generally in accordance with ASTM D-2240 type A, except the measurements may be made on the curved surface of a component of the golf ball, rather than on a plaque. If measured on the ball, the measurement will indicate that the measurement was made on the ball. In referring to a hardness of a material of a layer of the golf ball, the measurement will be made on a plaque in accordance with ASTM D-2240. Furthermore, the Shore A hardness of the cover is measured while the cover remains over the mantles and cores. When a hardness measurement is made on the golf ball, Shore A hardness is preferably measured at a land area of the cover

(66) The resilience or coefficient of restitution (COR) of a golf ball is the constant e, which is the ratio of the relative velocity of an elastic sphere after direct impact to that before impact. As a result, the COR (e) can vary from 0 to 1, with 1 being equivalent to a perfectly or completely elastic collision and 0 being equivalent to a perfectly or completely inelastic collision.

(67) COR, along with additional factors such as club head speed, club head mass, ball weight, ball size and density, spin rate, angle of trajectory and surface configuration as well as environmental conditions (e.g. temperature, moisture, atmospheric pressure, wind, etc.) generally determine the distance a ball will travel when hit. Along this line, the distance a golf ball will travel under controlled environmental conditions is a function of the speed and mass of the club and size, density and resilience (COR) of the ball and other factors. The initial velocity of the club, the mass of the club and the angle of the ball's departure are essentially provided by the golfer upon striking. Since club head speed, club head mass, the angle of trajectory and environmental conditions are not determinants controllable by golf ball producers and the ball size and weight are set by the U.S.G.A., these are not factors of concern among golf ball manufacturers. The factors or determinants of interest with respect to improved distance are generally the COR and the surface configuration of the ball.

(68) The coefficient of restitution is the ratio of the outgoing velocity to the incoming velocity. In the examples of this application, the coefficient of restitution of a golf ball was measured by propelling a ball horizontally at a speed of 125+/5 feet per second (fps) and corrected to 125 fps against a generally vertical, hard, flat steel plate and measuring the ball's incoming and outgoing velocity electronically. Speeds were measured with a pair of ballistic screens, which provide a timing pulse when an object passes through them. The screens were separated by 36 inches and are located 25.25 inches and 61.25 inches from the rebound wall. The ball speed was measured by timing the pulses from screen 1 to screen 2 on the way into the rebound wall (as the average speed of the ball over 36 inches), and then the exit speed was timed from screen 2 to screen 1 over the same distance. The rebound wall was tilted 2 degrees from a vertical plane to allow the ball to rebound slightly downward in order to miss the edge of the cannon that fired it. The rebound wall is solid steel.

(69) As indicated above, the incoming speed should be 1255 fps but corrected to 125 fps. The correlation between COR and forward or incoming speed has been studied and a correction has been made over the 5 fps range so that the COR is reported as if the ball had an incoming speed of exactly 125.0 fps.

(70) The measurements for deflection, compression, hardness, and the like are preferably performed on a finished golf ball as opposed to performing the measurement on each layer during manufacturing.

(71) Preferably, in a five layer golf ball comprising an inner core, an outer core, an inner mantle layer, an outer mantle layer and a cover, the hardness/compression of layers involve an inner core with the greatest deflection (lowest hardness), an outer core (combined with the inner core) with a deflection less than the inner core, an inner mantle layer with a hardness less than the hardness of the combined outer core and inner core, an outer mantle layer with the hardness layer of the golf ball, and a cover with a hardness less than the hardness of the outer mantle layer. These measurements are preferably made on a finished golf ball that has been torn down for the measurements.

(72) Preferably the inner mantle layer is thicker than the outer mantle layer or the cover layer. The dual core and dual mantle golf ball creates an optimized velocity-initial velocity ratio (Vi/IV), and allows for spin manipulation. The dual core provides for increased core compression differential resulting in a high spin for short game shots and a low spin for driver shots. A discussion of the USGA initial velocity test is disclosed in Yagley et al., U.S. Pat. No. 6,595,872 for a Golf Ball With High Coefficient Of Restitution, which is hereby incorporated by reference in its entirety. Another example is Bartels et al., U.S. Pat. No. 6,648,775 for a Golf Ball With High Coefficient Of Restitution, which is hereby incorporated by reference in its entirety.

(73) Alternatively, the cover 16 is composed of a thermoplastic polyurethane/polyurea material. One example is disclosed in U.S. Pat. No. 7,367,903 for a Golf Ball, which is hereby incorporated by reference in its entirety. Another example is Melanson, U.S. Pat. No. 7,641,841, which is hereby incorporated by reference in its entirety. Another example is Melanson et al, U.S. Pat. No. 7,842,211, which is hereby incorporated by reference in its entirety. Another example is Matroni et al., U.S. Pat. No. 7,867,111, which is hereby incorporated by reference in its entirety. Another example is Dewanjee et al., U.S. Pat. No. 7,785,522, which is hereby incorporated by reference in its entirety.

(74) Bartels, U.S. Pat. No. 9,278,260, for a Low Compression Three-Piece Golf Ball With An Aerodynamic Drag Rise At High Speeds, is hereby incorporated by reference in its entirety.

(75) Chavan et al, U.S. Pat. No. 9,789,366, for a Graphene Core For A Golf Ball, is hereby incorporated by reference in its entirety.

(76) Chavan et al, U.S. patent application Ser. No. 15/705,011, filed on Sep. 14, 2017, for a Graphene Core For A Golf Ball, is hereby incorporated by reference in its entirety.

(77) Chavan et al, U.S. patent application Ser. No. 15/729,231, filed on Oct. 10, 2017, for a Graphene And Nanotube Reinforced Golf Ball, is hereby incorporated by reference in its entirety.

(78) TABLE-US-00002 TABLE A CORE 1 Characteristic/Variable Value/Range/Feature Material Composition (parts CB 22-97 PPH per base, i.e. polybutadiene) Natsyn-3 PPH Dymalink548-34.7 PPH ZnO-19.7 PPH ZnSt-11.5 PPH Peroxide-0.8 PPH ZnPCTP-0.92 PPH BaSO-2 PPH Diameter (in. and mm) 1.50 in Specific Gravity (g/cc) 1.1738 Mass per step (g) PGA Compression (200 lb) 77 Deformation (200 lb, in inches) Deformation (100 kg loading) Compression Deformation (10 kg-130 kg) COR (125 fps) 0.7982

(79) TABLE-US-00003 TABLE B MANTLE OVER MANTLE 2 CORE Value/ Characteristic/Variable Value/Range/Feature Range/Feature Material Composition S8150-40.18% S8150-41.34% S9945-44.41% S9950-9.55% HPF2000-15.38% AD1022-49.11% ParaloidEXL2650-0.03% Thickness (in. and mm) 0.03 in 0.03 in Material Shore D Hardness 58 48 JIS-C Hardness Shore C Hardness Shore D Hardness Specific Gravity (g/cc) COR (125 fps) 0.8061 0.8030 200 lb (PGA) 84.74 94.85

(80) TABLE-US-00004 TABLE C COVER Characteristic/Variable Value/Range/Feature Material Composition Texin 1208-45.46% Texin 1211-39.30% Texin 1213-5.24% Thickness (in. and mm) 0.031 in Material Shore A Hardness 91 Shore D Hardness 37

(81) TABLE-US-00005 TABLE D FINISHED GOLF BALL Characteristic/Variable Value/Range/Feature Mass (g) 45.75 Diameter (in. and mm) 1.6833 PGA Compression (200 lb) 101.12 COR (125 fps) 0.7885

(82) From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.