Golf ball including metal foam layer

Abstract

A golf ball composition is disclosed herein that includes at least one layer formed from metal foam. The metal foam can provide lightweight, durable, and high strength design parameters for golf ball constructions in order to provide greater adaptability and customizability, among other advantages. In other aspects, the metal foam can be filled with a polymeric foam, or a liquid.

What is claimed is: 
     
         1 . A golf ball comprising:
 at least one first layer comprised of at least one metal foam having a first specific gravity of no greater than 0.25; and   at least one second layer that is disposed radially outward from the at least one first layer;   wherein the golf ball has a weight of less than 1.600 ounces.   
     
     
         2 . The golf ball according to  claim 1 , wherein the golf ball has a weight that is no greater than 1.575 ounces. 
     
     
         3 . The golf ball according to  claim 1 , wherein the golf ball has a weight that is no greater than 1.525 ounces. 
     
     
         4 . The golf ball according to  claim 1 , wherein the golf ball has a weight of 1.450 ounces-1.599 ounces. 
     
     
         5 . The golf ball according to  claim 1 , wherein the at least one first layer is a layer of a core, and the core has a weight of less than 1.250 ounces. 
     
     
         6 . The golf ball according to  claim 1 , wherein the at least one first layer is a layer of a core, and the core has a weight of less than 1.115 ounces. 
     
     
         7 . The golf ball according to  claim 5 , wherein the at least one second layer is a casing layer, and the golf ball further comprises a cover layer. 
     
     
         8 . The golf ball according to  claim 6 , wherein the core includes at least one additional layer, the at least one second layer is a casing layer, and the golf ball further comprises a cover layer. 
     
     
         9 . The golf ball according to  claim 1 , wherein the at least one metal foam has a closed cell structure with an average cell wall thickness of 5 microns-100 microns and a porosity of at least 90%. 
     
     
         10 . The golf ball according to  claim 1 , wherein the at least one metal foam has an open cell structure with an average cell wall thickness of at least 100 microns and a porosity of no greater than 70%. 
     
     
         11 . The golf ball according to  claim 10 , wherein the average cell wall thickness is at least 250 microns. 
     
     
         12 . The golf ball according to  claim 10 , wherein the average cell wall thickness is at least 500 microns. 
     
     
         13 . The golf ball according to  claim 1 , wherein the at least one metal foam is formed from at least one of: aluminum, copper, tantalum, tin, titanium, or zinc. 
     
     
         14 . The golf ball according to  claim 1 , wherein the golf ball is comprised of a core, an intermediate layer, and a cover, and the at least one first layer is the core. 
     
     
         15 . The golf ball according to  claim 1 , wherein the golf ball is comprised of an inner core, an outer core, an intermediate layer, and a cover, and the at least one first layer is the inner core. 
     
     
         16 . The golf ball according to  claim 1 , wherein the at least one second layer has a second specific gravity, and a density layer gradient ratio is defined by a ratio of the first specific gravity to the second specific gravity, and the density layer gradient ratio is no greater than 0.30. 
     
     
         17 . The golf ball according to  claim 1 , wherein the at least one metal foam of the at least one first layer has a first tensile strength, and the at least one second layer is formed from a material having a second tensile strength, wherein the golf ball has a strength gradient ratio defined by a ratio of the first tensile strength to the second tensile strength, and the strength gradient ratio is at least 2.0. 
     
     
         18 . The golf ball according to  claim 1 , wherein the at least one first layer also includes at least one polymeric foam portion, and the at least one polymeric foam portion is formed from at least one of: polyurethane, polystyrene, polyethylene, polyvinyl chloride, polybutadiene, polypropylene, neoprene, ethylene vinyl acetate, silicone, polyimide, or phenolic. 
     
     
         19 . The golf ball according to  claim 18 , wherein the golf ball is a three layer golf ball including a core, a casing, and a cover,
 wherein the at least one first layer is the core,   wherein the core accounts for no greater than 75% of a total mass of the golf ball.   
     
     
         20 . The golf ball according to  claim 18 , wherein the golf ball is a four layer golf ball including a dual layer core, a casing, and a cover,
 wherein the at least one first layer is an inner core layer of the dual layer core, and an outer core layer of the dual layer core is formed from a rubber composition,   wherein the inner core layer accounts for no greater than 30% of a total mass of the golf ball.