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 portion having a first specific gravity of no greater than 0.25; and 
 at least one polymeric foam portion; and 
   at least one second layer that is disposed radially outward from the at least one first layer.   
     
     
         2 . The golf ball according to  claim 1 , wherein an outermost diameter of the at least one metal foam portion and an outermost diameter of the at least one polymeric foam portion are congruent, such that the at least one metal foam portion and the at least one polymeric foam portion both partially define an outer surface of the at least one first layer. 
     
     
         3 . The golf ball according to  claim 1 , wherein an outermost diameter of the at least one metal foam portion is smaller than an outermost diameter of the at least one polymeric foam portion such that only the at least one polymeric foam portion defines an outer surface of the at least one first layer. 
     
     
         4 . The golf ball according to  claim 1 , wherein a porosity of the at least one metal foam portion is greater than a porosity of the at least one polymeric foam portion. 
     
     
         5 . The golf ball according to  claim 1 , wherein the at least one second layer has a second specific gravity, and the at least one polymeric foam portion has a third specific gravity that is greater than the first specific gravity of the at least one metal foam portion and less than the second specific gravity of the at least one second layer. 
     
     
         6 . The golf ball according to  claim 1 , wherein the at least one second layer has a second specific gravity, and the at least one polymeric foam portion has a third specific gravity that is greater than the first specific gravity of the at least one metal foam portion and greater than a second specific gravity of the at least one second layer. 
     
     
         7 . The golf ball according to  claim 1 , wherein 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. 
     
     
         8 . The golf ball according to  claim 1 , wherein the golf ball is comprised of a core, at least one intermediate layer, and a cover, and the at least one first layer is the core. 
     
     
         9 . 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. 
     
     
         10 . 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 outer core. 
     
     
         11 . The golf ball according to  claim 1 , wherein the at least one second layer has a second specific gravity, and wherein 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. 
     
     
         12 . The golf ball according to  claim 1 , wherein the at least one metal foam portion 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. 
     
     
         13 . A golf ball comprising:
 at least one first layer comprised of:
 at least one metal foam portion having a first specific gravity of no greater than 0.25; and 
 a fluid; 
   an enveloping layer directly surrounding the least one first layer; and   at least one second layer that is disposed radially outward from the enveloping layer.   
     
     
         14 . The golf ball according to  claim 13 , wherein the fluid in the at least one first layer is a non-Newtonian fluid. 
     
     
         15 . The golf ball according to  claim 13 , wherein the fluid in the at least one first layer is a shear thickening colloid. 
     
     
         16 . The golf ball according to  claim 13 , wherein the at least one first layer is further comprised of at least one polymeric foam. 
     
     
         17 . The golf ball according to  claim 13 , wherein the enveloping layer is formed from at least one of: latex, polyethylene, polyurethane, polystyrene, polyvinyl chloride, polybutadiene, polypropylene, neoprene, ethylene vinyl acetate, silicone, polyimide, or phenolic; and
 the enveloping layer has a thickness of no greater than 0.20 inches.   
     
     
         18 . The golf ball according to  claim 13 , wherein the enveloping layer has a thickness of no greater than 0.010 inches. 
     
     
         19 . The golf ball according to  claim 13 , wherein the at least one second layer has a second specific gravity, 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. 
     
     
         20 . The golf ball according to  claim 13 , wherein the at least one metal foam portion 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.