Mixed-resin mantle metal-core golf balls and methods of manufacturing same

Abstract

A golf ball is provided. The golf ball includes a hollow metal core made from a work-hardened metal alloy. The golf also includes a mantle layer enveloping the metal core. The mantle layer may be made from a mixture of long-ball resin and soft-ball resin. The golf ball further includes a cover positioned about the mantle layer to protect the mantle layer. A method of manufacturing the golf ball is also provided.

1 . A golf ball comprising:
 a core made from a metal alloy;   a mantle layer enveloping the metal core, the mantle layer including a mixture of a long-ball resin and a soft-ball resin, such that the amount of soft-ball resin is higher than the amount of long-ball resin; and   a cover positioned about the mantle layer, so as to protect the mantle.   
   
   
       2 . A golf ball as set forth in  claim 1 , wherein the core is made from a work-hardened metal alloy. 
   
   
       3 . A golf ball as set forth in  claim 1 , wherein the core is hollow. 
   
   
       4 . A golf ball as set forth in  claim 1 , wherein the core includes two substantially similar hemisphere welded to one another. 
   
   
       5 . A golf ball as set forth in  claim 1 , wherein the metal alloy from which the metal core is made includes iron, nickel, chromium, carbon, silicon, and manganese. 
   
   
       6 . A golf ball as set forth in  claim 1 , wherein the metal alloy from which the metal core is made includes iron, about 6-8(w/w)% nickel, about 16-18(w/w)%) chromium, and at most about 0.15(w/w)% carbon, about 1 (w/w)% silicon and about 2(w/w)% manganese. 
   
   
       7 . A golf ball as set forth in  claim 1 , wherein the metal alloy from which the metal core is made is an AISI type 301 stainless steel. 
   
   
       8 . A golf ball as set forth in  claim 1 , wherein the metal core has an outer diameter ranging from about 0.90 inches to about 1.15 inches. 
   
   
       9 . A golf ball as set forth in  claim 1 , wherein the mixture of long-ball resin and soft-ball resin in the mantle layer includes a mixture of an ethylene methylacrylic acid ionomer (Surlyn®), and an alkylene etherester terephthalic acid polymer (Hytrel®) mixed with ZnO and magnesium stearate. 
   
   
       10 . A golf ball as set forth in  claim 1 , wherein the mixture of long-ball resin and short-ball resin in the mantle layer has a mixture ratio of about 2:3, long-ball resin to soft-ball resin. 
   
   
       11 . A golf ball as set forth in  claim 1 , wherein the long-ball resin is HPF 2000®. 
   
   
       12 . A golf ball as set forth in  claim 1 , wherein the soft-ball resin is AD 1035. 
   
   
       13 . A golf ball as set forth in  claim 1 , wherein the mantle layer has a COR ranging from about 0.800 to about 0.826. 
   
   
       14 . A golf ball as set forth in  claim 1 , wherein the mantle layer has a Comp ranging from about 91 to about 93. 
   
   
       15 . A golf ball as set forth in  claim 1 , wherein the cover has a thickness ranging from about 0.05”to about 0.75”. 
   
   
       16 . A method for manufacturing a golf ball, the method comprising:
 providing a core made from a metal alloy;   enveloping the metal core with a mantle layer made from a mixture of a long-ball resin and a soft-ball resin, wherein the amount of soft-ball resin is relatively higher than the amount of long-ball resin; and   placing a cover about the mantle layer, so as to protect the mantle.   
   
   
       17 . A method as set forth in  claim 16 , wherein the step of providing includes providing two substantially similar hemisphere from which the core can be made. 
   
   
       18 . (canceled) 
   
   
       19 . A method as set forth in  claim 16 , wherein the step of providing includes welding to one another two substantially similar hemispheres stamped from work-hardened metal alloy. 
   
   
       20 . A method as set forth in  claim 16 , wherein, in the step of providing, the metal core has outer diameter ranging from about 0.90 inches to about 1.15 inches. 
   
   
       21 . A method as set forth in  claim 16 , wherein, in the step of providing, the metal alloy from which the metal core is made is an AISI type 301 stainless steel. 
   
   
       22 . A method as set forth in  claim 16 , wherein the step of enveloping includes injection molding the mantle layer about the metal core. 
   
   
       23 . A method as set forth in  claim 16 , wherein the step of enveloping includes providing the mixture of long-ball resin and short-ball resin in the mantle layer with a mixture ratio of about 2:3, long-ball resin to soft-ball resin. 
   
   
       24 . A method as set forth in  claim 16 , wherein the step of enveloping includes providing the mantle layer with a COR ranging from about 0.820 to about 0.826. 
   
   
       25 . A method as set forth in  claim 16 , wherein the step of enveloping includes providing the mantle layer with a Comp ranging from about 60 to about 93. 
   
   
       26 . A method as set forth in  claim 16 , wherein the step of placing includes providing the cover with a thickness ranging from about 0.05”to about 0.75”.