Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.

Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core assembly preferably has a positive hardness gradient extending across the entire assembly. The core structure and resulting ball have relatively good resiliency.

Abstract: Multi-layered, golf balls having a core made of a particle-based polyurethane foam composition are provided. The ball includes a dual-layered core having a foam inner core (center) and surrounding outer core layer. The surrounding outer core layer may be made from a non-foamed thermoset material such as polybutadiene rubber. In one embodiment, pre-expanded thermoplastic polyurethane foam beads containing a blowing agent are used to form the foam center. In another embodiment, pre-formed polyurethane foam particles are used. The foam cores have good resiliency, thermal stability, and durability over a wide temperature range. The ball further includes a cover that may be multi-layered.

Abstract: Multi-layered golf balls having a core made of a foamed polyurethane composition are provided. The ball includes a dual-layered core having a foam inner core (center) and surrounding outer core layer. The outer core layer may be made from a non-foamed thermoset material such as polybutadiene rubber. The ball further includes an inner cover, preferably made from a thermoplastic ionomer. The outer cover may be made from a non-foamed thermoset or thermoplastic material such as polyurethane. The core and inner cover layers preferably have different densities so the Moment of Inertia of the ball is adjusted. Preferably, the specific gravity of the inner cover is greater than the specific gravity of the outer core, which is greater than the specific gravity of the inner core. The finished ball has good distance and low-spin properties.

Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate core layer is preferably formed from a thermoplastic composition such as an ethylene acid copolymer ionomer resin; and the outer core layer is preferably formed from a thermoset composition such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.

Abstract: Multi-piece golf balls having a solid core made of a foamed silicone composition and a cover are provided. For example, three-piece, four-piece, and five-piece golf balls containing different core structures can be made. Preferably, a dual-core having has a silicone foam inner core (center) and surrounding thermoset or thermoplastic outer core layer is made. The silicone foam center has good thermal stability and durability without sacrificing resiliency. The surrounding outer core layer may be made from non-foamed or foamed compositions. For example, silicone foams, polyurethanes, polybutadiene rubber, or highly neutralized olefin acid copolymers may be used in the outer core layer.

Abstract: 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 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.

Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core assembly preferably has a positive hardness gradient extending across the entire assembly. The core structure and resulting ball have relatively good resiliency.

Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.

Abstract: A golf ball includes a core and a three-layer cover disposed about the core. The cover includes a thermoplastic inner cover layer having a hardness of about 66 to 90 Shore C; an outer cover layer formed from a polyurethane, a polyurea, or a hybrid thereof, and an intermediate cover layer disposed between the inner and outer cover layers. The outer cover layer has a hardness of about 52 to 85 Shore C. The intermediate cover layer has a hardness of about 74 to 100 Shore C and greater than the inner cover layer hardness and the outer cover layer hardness. The thermoplastic inner cover comprises a highly-neutralized ionomer comprising a copolymer of ethylene and an ?,?-unsaturated carboxylic acid, an organic acid or salt thereof, and sufficient cation source to neutralize the acid groups of the copolymer by about 100%.

Abstract: A golf ball having a cover material made from a polyurea or polyurea/urethane hybrid composition is provided. The polyurea or polyurea/urethane composition is produced by the reaction of an isocyanate blend having an average NCO functionality in the range of 2.05 to 2.35, a polyamine compound, and amine or hydroxyl curing agent. The resulting cover material has many advantages including improved thermal-stability, durability, toughness, and cut/tear-resistance. The preferred isocyanates in the blend include isophorone diisocyanate (“IPDI”); 1,6-hexamethylene diisocyanate (“HDI”); 4,4?-dicyclohexylmethane diisocyanate (“H12 MDI”); 4,4?-diphenylmethane diisocyanate (4,4?-MDI); toluene diisocyanate (“TDI”); and homopolymers and copolymers thereof.

Abstract: Multi-piece golf balls containing a dual-core structure are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The outer core layer is preferably formed from a non-foamed thermoplastic composition such as ethylene acid copolymer ionomer. Preferably, the specific gravity (density) of the foam inner core is less than the density of the outer core layer. The ball further includes a cover of at least one layer and may include at least one casing layer. The core structure and resulting ball have relatively good resiliency.

Abstract: Golf ball multi-layered core sub-assemblies and the resulting golf balls are provided. The core structure includes a foam inner core (center); and intermediate and outer core layers. Foamed polyurethane is preferably used to make the inner core. The intermediate and outer core layers are preferably made from non-foamed thermoplastic compositions such as ethylene acid copolymer ionomer. In an alternative version, the intermediate core layer may be made of a thermoset rubber such as polybutadiene. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.

Abstract: Multi-layered golf balls containing a dual-core structure are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The outer core layer is preferably formed from a non-foamed thermoset composition such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The specific gravity (density) of the foam inner core is preferably less than the density of the outer core layer. The core assembly preferably has a positive hardness gradient extending across the entire assembly. The core structure and resulting ball have relatively good resiliency.

Abstract: Multi-piece golf balls containing a dual-core structure are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The outer core layer is preferably formed from a non-foamed thermoset composition such as polybutadiene rubber. Preferably, the specific gravity (density) of the foam inner core is less than the density of the outer core layer. The ball further includes a cover of at least one layer and may include at least one casing layer. The core structure and resulting ball have relatively good resiliency.

Abstract: A golf ball is formed including a core and a cover. The cover includes a thermoplastic inner cover layer and having a hardness between 55 and 60 Shore D, an outer cover layer having a hardness between 55 and 60 Shore D, and a non-ionomeric thermosetting polyurethane or polyurea intermediate cover layer disposed between the inner and outer cover layers. The intermediate cover layer has a hardness greater than the inner cover layer hardness and the outer cover layer hardness. The inner cover is formed from a partially- or fully-neutralized ionomer and the outer cover layer is formed from a polyurethane, a polyurea, or a urethane-urea blend.

Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.

Abstract: Methods for making golf balls having a cover made from polyurea and polyurethane compositions are provided. The methods for making the polyurea and polyurethane composition involve preparing an amine-terminated or hydroxyl-terminated first prepolymer by reacting a first isocyanate compound with a stoichiometric excess of polyamine or polyol (depending on the type of prepolymer desired). The first prepolymer is then reacted with a stoichiometric excess of a second isocyanate compound to form an isocyanate-terminated second prepolymer. The second prepolymer is then reacted with a chain extender.

Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate and outer core layers are preferably formed from non-foamed thermoset compositions such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core assembly preferably has a positive hardness gradient extending across the entire assembly. The core structure and resulting ball have relatively good resiliency.

Abstract: Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate core layer is preferably formed from a thermoplastic composition such as an ethylene acid copolymer ionomer resin; and the outer core layer is preferably formed from a thermoset composition such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. The core structure and resulting ball have relatively good resiliency.