GOLF BALLS WITH ELECTRONIC COMMUNICATION COMPONENTS AND METHODS FOR MAKING THEM

A method for manufacturing a golf ball. The method includes creating a core with a cavity therein and positioning electronics in the cavity. The method further includes filing the cavity with a fill material while the electronics are positioned in the cavity such that the core, the electronics, and the fill material together form a spherical body, and such that when the fill material is cured the spherical body is balanced about a center thereof. The method further includes curing the fill material and covering the spherical body with an exterior cover.

FIELD

The present disclosure relates to golf balls and methods for making them, and particularly golf balls with electronic communication components.

BACKGROUND

This section includes discussion intended to help understand various aspects of the subject matter presently disclosed below. This discussion should not be interpreted as constituting an admission of prior art.

Golf balls are used by golfers while playing the game of golf, and most golfers tend to lose at least one golf ball per round of golf. The golf balls can be lost due to errant shots that cannot be located by the golfer. For example, the golf ball may come to rest in the water, under a bush, in a dense marsh area, or in tall grass. When the golf ball is lost, the golfer is assessed penalty strokes per the rules of golf and must use a second golf ball.

U.S. Pat. No. 7,691,009 entitled Apparatuses and Methods Relating to Findable Balls discloses golf balls for use with a system for finding golf balls and methods for making such golf balls. In the case of one exemplary golf ball, the ball includes a shell, a core material and a tag having a diode which is coupled to an antenna which has at least a portion formed from an elastic conductive material, such as an elastic conductive ink. The core material may include a void for receiving at least part of the diode. Other golf balls are described and methods for making balls are also described.

U.S. Pat. No. 10,213,646 entitled System for Locating a Golf Ball discloses a golf ball with an outer casing has an electronic device housed in a plastic core and includes at least one receiver, a microelectronic device for evaluating and forwarding the received signals and a transmitter and/or receiver. The transmitter or receiver can communicate with a separate electronic device worn by the user. The invention will enable a player to easily find and locate a ball that is not lying on the fairway that cannot be spotted or found with the naked eye.

U.S. Pat. No. 10,716,971 entitled Game Implements and System for Tracking or Locating Same discloses a system for locating an electronic game implement such as an electronic golf ball. The electronic game implement has an outer shell and internal core, with the core containing graphene coated electronics and a battery, wherein the associated electronics of the electronic game implement includes a processor and transceiver configured to measure data including acceleration, speed, travel trajectory and final location while also being configured to transmit the measured data via a communications protocol. The ball or sports game implement that includes the associated electronics are also an embodiment of the invention. The system includes a smart device having associated electronics to communicate with the electronic game implement ball, with the associated electronics of the smart device including a processor configured to receive the measured data from the electronics of the electronic game implement.

U.S. Pat. No. 11,167,180 entitled Smart Ball, Locator System and Method therefor discloses a wireless signal transmitting ball to be used in practice or gameplay of a sport and/or other entertainment activities. The ball of the disclosure comprises a microprocessor unit configured to record, process, and transmit data to a paired device. Further disclosed is a method of actuating the ball between different modes. The ball could be used by players during practice to record data about their performance. The ball could also be used by players or game officials or referees to keep score, adjudicate and decide the gameplay. For example, the information about location of the ball could be used to track balls that could potentially be lost. Additionally, data about spin, trajectory, speed, force applied, and the like could be used by players or broadcasters for gaining insights to add to viewing pleasure.

SUMMARY

One embodiment of the present disclosure generally relates to a method for manufacturing a golf ball. The method includes creating a core with a cavity therein and positioning electronics in the cavity. The method further includes filing the cavity with a fill material while the electronics are positioned in the cavity such that the core, the electronics, and the fill material together form a spherical body, and such that when the fill material is cured the spherical body is balanced about a center thereof. The method further includes curing the fill material and covering the spherical body with an exterior cover.

Another embodiment generally relates to another method for manufacturing a golf ball. The method includes providing a spherical core of a first material and providing electronics configured to provide wireless communication. The method further includes machining a cavity in the spherical core so as to accommodate the electronics and a fill material and filling the cavity with the fill material while the electronics are positioned in the cavity. The fill material is different than the first material of the spherical core. The method further includes curing the fill material, where the core, the electronics, and the fill material together form a spherical body, and covering the spherical body with an exterior cover. The fill material is selected such that when cured, the spherical body is balanced about a center thereof.

Another embodiment generally relates to a golf ball having a spherical core of a first material, whereby the spherical core has a cavity therein. Electronics are positioned in the cavity, whereby the electronics include a transmitter for wireless communication. A fill material is positioned in the cavity such that the cavity is entirely filled with the electronics and the fill material. The fill material is different than the first material. The spherical core, the electronics, and the fill material together form a spherical body. An exterior cover covers the spherical body.

DETAILED DESCRIPTION

The present inventors have recognized that a golfer may lose one or more golf balls during a round of golf, and thus, it would be advantageous to develop a golf ball that can be electronically located by the golfer. Locating a golf ball that would otherwise be lost saves the golfer money as the golfer would lose fewer golf balls during a round of golf and thus would need to purchase less replacement golf balls. Likewise, an electronically located golf ball would reduce the time spent searching for the lost ball, saving the golfer's time and those behind golfer on the golf course. Moreover, having the ability to locate a missing golf ball would minimize or eliminate the lost ball penalty strokes assessed to the golfer, improving the golfer's score and game.

The present inventors have observed that conventional golf balls have been made with a variety of materials since the inception of the game of golf. For example, golf balls have been made with wood, rubber, and plastic. More recently, modern golf balls are made of urethane core and a plastic shell.

Modern golf balls typically have two or more components. In particular, a golf ball may include a urethane core and a plastic cover. These golf balls are generally referred to as two-part golf balls. The chemical makeup of urethane or polyurethane can be altered by golf ball designers that seek to change the physical properties of the urethane, and in the turn the golf ball, such as durometer (hardness) and density. For instance, foaming agents can be added to the urethane to change its chemical makeup. Note that it many instances, the urethanes used in modern golf balls are typically thermosets rather than thermoplastics which makes the urethane incompatible with standard conventional injection molding processes. Two-part urethane systems often require elevated temperatures to properly cure.

In addition, the two or more layers of a golf ball can have different durometers and/or densities relative to each other. In some constructions, these layers are formed by consecutive molding processes in which layers are molded over one another resulting in distinct transitions between the layers. Other golf balls, such as the Titleist ProV1, have a diffuse transition layer between larger layers that aims to eliminate sharp material changes between the larger layers when shockwaves waves propagate through the golf ball when struck with a club.

The evolution of the materials used to form golf balls indicates that prior golf ball designers often endeavored to improve the performance of the golf ball by changing the materials used to form the golf ball. The designers also may seek to optimize many factors and parameters such as how well the golf ball returns energy when hit with a driver (e.g., how far one can drive the golf ball), how well the golf ball is balanced, polar moment of inertia of the golf balls, responsiveness/predictability of putt hits, and the like.

The present inventors endeavored to develop the improved golf balls of the present disclosure (described herein below) that perform well in use while also being configured to be electronically located by the golfer. Additional details regarding the electronic components that facilitate electronic communications between the user and the golf ball are also provided below.

In view of this, the present inventors have recognized challenges in incorporating electronic components within the golf ball, which require several considerations to be considered when designing the golf ball. For example, while golf balls can be formed from many different materials (as illustrated by the different golf ball constructions briefly noted above), private organizations, such as the United States Golf Association (USGA), have rules that govern certain form factors of golf balls. The rules set forth by the USGA specify that the golf ball must have a minimum outside diameter of 1.680 inches and a maximum weight of 1.620 ounces. Only golf balls that conform to these rules may be used in USGA sanctioned competitions. Many local golf clubs and organization also follow the rules set forth by the USGA. Therefore, the USGA rules apply to many golfers at many different skill levels and are thereby important to consider when designing a golf ball.

Furthermore, the weight of the golf ball is preferably balanced about all axes to avoid weight inconsistences that could change the spin of the golf ball during flight (or when putting) and thus change the direction the ball travels. The golf ball may also have varying hardness along different radii. In this case, it is preferable that the rate of hardness change is consistent along all radii. Hardness rate non-homogeneity along one or more of the axes could cause inconsistencies between hits or prevent symmetrical shockwave propagation through the golf ball which could cause the golf ball to fly at an unexpected angle.

Accordingly, through research and experimentation, the present inventors developed the golf balls2described herein below.FIGS.1and2shows a completed golf ball2according to the present disclosure. The golf ball2extends from a center4to an outer surface6along an X-axis, a Y-axis, and a Z-axis that are each perpendicular to each other.FIG.1shows a front view in which the Z-axis extends into the page andFIG.2shows a side view in which the X-axis extends into the page.FIG.2also shows a section removed to reveal an interior of the golf ball2. The golf ball2is also shown rotated slightly about the Z-axis to provide a perspective view of components inside the golf ball2, discussed further below.

The golf ball2is generally spherical and includes a cover10that surrounds a generally spherical core12. A center of the core12is coincident with the center4of the golf ball2. The core12extends between the center4and an outer surface14that is radially inward of the outer surface6of the golf ball2as a whole. The core12comprise a urethane material. An inner surface16of the cover10surrounds the outer surface14of the core12. A cavity20extends into the core12from the outer surface14to a position beyond the center4. The cavity20has a top surface22, a bottom surface24, side surfaces26, and an end surface28. In the embodiment shown, the electronics assembly30(also referred to as electronics, discussed below) rest upon the bottom surface24and, in certain embodiments, abuts the end surface28. The side surfaces26of the cavity20have a shelf32corresponding to a shape of the electronics assembly30. The end surface28of the cavity20extends beyond the center4such that the electronics assembly30can be centered within the golf ball2along at least the X-axis and the Z-axis when positioned in the cavity20. A fill material40is also provided within the cavity20, which for clarity is omitted inFIG.2.

FIG.3shows an example of electronics assembly30separate from the golf ball2, which as discussed above is configured for wirelessly communicating the location of the golf ball2to the user. The electronics assembly30include a battery34, a printed circuit board (PCB)36, and an integrated circuit (IC)38. In one example, the battery34is a CR1025 coil cell battery manufactured by Digikey. The battery34may be rechargeable, such as by positioning the golf ball2within a cradle that charged the battery34via induction in a similar manner to modern smart phones and electric toothbrushes.

The electronics assembly30further includes a wireless transmitter or a wireless transceiver35configured to wirelessly communicate with a user interface device, such as a personal cellular phone or a handheld golf ball tracking unit. By way of example, the electronics assembly30may communicate wirelessly using a Bluetooth® low energy integrated circuit (BTLE) or another wireless communication device that communicate via Bluetooth®, near-field communication (NFC), Wi-Fi, and/or other wireless communication protocols known in the art. In certain configurations, NFC is used to initially connect to and configure the golf ball2to activate the golf ball2for use. In further embodiments, the golf ball2may be specifically configured for use for a particular round, such as a particular hole or golf course.

With continued reference toFIG.3, the electronics assembly30further includes a GPS module37for determining the GPS location of the golf ball2in a manner known in the art. Other types of location detectors may be used in addition to, or as an alternative to, the GPS module37for determining the location of the golf ball2using techniques known in the art. The electronics assembly30ofFIG.3further includes a sensor39(e.g., an accelerometer) that is configured to detect an impact of the golf ball2, such as when the golf ball2is struck by a driver. Likewise, other conventionally known components may also be provided with the electronics assembly30. A simplified version of the electronics assembly30is shown inFIG.4for showing in subsequent figures, particularly for being shown within the cavity20in the golf ball2.

In certain embodiments, the electronics assembly30is configured such that when the sensor39detects an impact of the golf ball2(e.g., via a golf club), the wireless transceiver35is powered on or otherwise activated to begin transmitting the location of the golf ball2. This preserves the power of the battery34, extending the life of the golf ball2. Similar power savings may also be provided for the GPS module37, which also be powered on or awoken from a low power standby mode upon impact via detection by the sensor39. The detected impact may also be used to record and/or report that a “hit” has occurred. In certain embodiments, metrics such as flight time may be calculated by detecting the first impact corresponding to the hit, then a subsequently impact when the golf ball2hits the ground again.

The wireless transceiver35and/or GPS module37may be configured to remain powered on for a pre-determined time following the detected impact, such as 5 minutes. Other power saving features may include sending at different communication rates after the impact is detected or sending at different rates as a function of how long ago the impact was detected. For example, the location of the golf ball2may communicated every 5 seconds within the first 5 minutes after detecting an impact, then every 10 seconds between 5 and 10 minutes after impact, every 30 seconds from 10 minutes to 15 minutes, and off after 15 minutes.

In general, the electronics assembly30may be configured like the control system100ofFIG.5. The control system100ofFIG.5includes a processing system110(which may be generally equivalent to the IC38), a memory system120, and an I/O system130as discussed further below. The I/O system130may include the wireless transceiver35discussed above for wirelessly communicating with the golf ball2. By way of example, a smart phone, smart watch, and/or tablet may function as an input device99and/or output device101communicating with the control system100(and the electronics assembly30more generally).

Additional information is now provided for control systems100and communication with the electronics assembly30and the golf ball2more generally. Certain aspects of the present disclosure are described or depicted as functional and/or logical block components or processing steps, which may be performed by any number of hardware, software, and/or firmware components configured to perform the specified functions. For example, certain embodiments employ integrated circuit components, such as memory elements, digital signal processing elements, logic elements, look-up tables, or the like, configured to carry out a variety of functions under the control of one or more processors or other control devices. The connections between functional and logical block components are merely exemplary, which may be direct or indirect, and may follow alternate pathways.

In certain examples, communication amongst and between components within the control system100, as well as with input device99and output device101, is provided via a communication link CL. The communication links CL may be wired (e.g., within the electronics assembly30) or wireless (e.g., communication with output devices101such as smart phones). The control system100is capable of receiving information and/or controlling one or more operational characteristics of the electronics assembly30and its various sub-systems by sending and receiving control signals via the communication links CL. It will be recognized that the extent of connections and the communication links CL may in fact be one or more shared connections, or links, among some or all of the components in the electronics assembly30. Moreover, the communication link CL lines are meant only to demonstrate that the various control elements are capable of communicating with one another, and do not represent actual wiring connections between the various elements, nor do they represent the only paths of communication between the elements. Additionally, the electronics assembly30may incorporate various types of communication devices and systems, and thus the illustrated communication links CL may in fact represent various different types of wireless and/or wired data communication systems.

The control system100may be a computing system that includes a processing system110, memory system120, and input/output (I/O) system130for communicating with other devices, such as input devices99and output devices101, either of which may also or alternatively be stored in a cloud102. The processing system110loads and executes an executable program122from the memory system120, accesses data124stored within the memory system120, and directs the electronics assembly30to operate as described in further detail below.

The processing system110may be implemented as a single microprocessor or other circuitry or be distributed across multiple processing devices or sub-systems that cooperate to execute the executable program122from the memory system120. Non-limiting examples of the processing system include general purpose central processing units, application specific processors, and logic devices.

The memory system120may comprise any storage media readable by the processing system110and capable of storing the executable program122and/or data124. The memory system120may be implemented as a single storage device or be distributed across multiple storage devices or sub-systems that cooperate to store computer readable instructions, data structures, program modules, or other data. The memory system120may include volatile and/or non-volatile systems and may include removable and/or non-removable media implemented in any method or technology for storage of information. The storage media may include non-transitory and/or transitory storage media, including random access memory, read only memory, magnetic discs, optical discs, flash memory, virtual memory, and non-virtual memory, magnetic storage devices, or any other medium which can be used to store information and be accessed by an instruction execution system, for example.

As discussed above, the electronics assembly30together provide the functions of the golf ball2described herein. Based on the USGA's rules related to the minimum outside diameter and maximum weight, the outside diameter of the golf ball2is 4.3 cm (1.68 in) and the weight of the golf ball2is 45.9 g (1.62 oz). Thus, the average density of the golf ball2will be 1.13 grams per cubic centimeter (g/cc). However, the present inventors recognized that the inclusion of the electronics assembly30within the golf ball2requires the core12of the golf ball2to be modified further in order to meet the USGA rules and also maintain a weight balance within the golf ball2. As such, the densities of the core12, the electronic assembly30, and the fill material40may all be different, for example with the density of the core12equaling the sum of the densities of the electronic assembly30and the fill material40(when cured).

In one example, the electronics assembly30has a volume of 1.31 cubic centimeter (cc) and a mass of 3.61 grams (g). Table 1 below lists the components of the electronics assembly30and corresponding volumes and weights.

It will be recognized that golf ball design can and does include varying materials, hardness, or density along a radius through the golf ball. However, performance is often related to the consistency of these changes about all radii of the golf ball. Looking toFIG.1, it is noted that while the radii of the X-axis and the Z-axis are similar, the radii of the Y-axis is different, both from the X-axis and the Z-axis, but also in opposite directions along the Y-axis. Therefore, still further examples of the golf ball2as disclosed herein create an insert comprising the electronics assembly30and ballast of fill material40that provides symmetrical physical properties (e.g., one or more of mass, volume, density, hardness) along not only the X-axis, Y-axis, and Z-axis, but along intermediate radii as well.

However, as noted above, the total volume and mass of the golf ball2must also meet the USGA (or other) specifications and also must be balanced about the center of the ball to provide desired performance. In examples, the electronics assembly30may have a greater density due to the battery34and other components compared to the urethane materials of core12. Thus, the mass of the core12may need to be adjusted and or balanced, including the use of a ballast, also referred to as fill material40, to either increase or decrease the mass of the combined core12and fill material40and to balance the combination of the core12, fill material40, and electronics assembly30about the center of the core12(and thus, about the center4of the golf ball2). The fill material40thus may be a void or low-density urethane material, while in other examples, the fill material40may be a high-density urethane material or further include weights (not depicted) to balance the mass of the electronics assembly30.

In the example ofFIGS.1and2, a void42remains within the cavity20in the core12of the golf ball2after the electronics assembly30is positioned within the cavity. The electronics assembly30may be positioned in the cavity20so as to be balanced in one, two, or all three axes when the void42has not yet been filled by the filling material40. The core12is configured such that volume of the void42corresponds to a volume of the material forming the core12that equals the mass of the electronics (in this example, 3.61 grams). The void42is exemplarily filled with fill material40of an associated density to achieve the overall physical requirements noted above. example, if the fill material40is the same volume as the electronics (e.g., 1.31 cc), then a mass of 2.96 g will produce the same average density of the combined ballast (fill material40) and the electronics assembly30as the overall ball specification (e.g., 1.13 g/cc). In this manner, the golf ball2as a whole is balanced about its center4along all three axes when the electronics assembly30is positioned in the cavity and the electronics assembly30and the fill material40together entirely fill the cavity20.

It will be recognized that in a further example, the core12of the golf ball2may be more or less dense, and therefore, the ballast may be adjusted to balance the physical properties of the electronics assembly relative to specified physical properties of a portion of the golf ball instead of the golf ball as a whole. Moreover, it should be recognized that the present disclosure also contemplates configurations in which the fill material40and the electronics assembly30are together balanced about the center4of the golf ball2along fewer than all three axes, including being balanced along one axes or two axes.

Additional information is now provided for how to make golf balls2according to the present disclosure. Known techniques manufacturing golf balls involve an automated multiple-step manufacturing process that builds layers around a hard spherical molded core of natural rubber or synthetic rubber, collectively rubber. The core of the golf ball is typically the densest layer in the construction and therefore the portion of the manufacturing process to create the core uses the most heat and pressure. The present inventors have discovered that such conditions limit manufacturing achievement of the ball construction described above, particularly as these known techniques would damage or destroy the electronics assembly30described above. In other words, the presently disclosed golf ball2cannot be made via methods presently known in the art.

Therefore, a new manufacturing process has been developed and will be described herein.FIG.6depicts a method200for making a golf ball2according to the present, which can be viewed with reference to the elements described above and shown inFIGS.1and2. Step202provides for creating a core12with a cavity20therein, the result of which is exemplified inFIG.8. By way of example, the core12may be manufactured by heating a fixed amount of the rubber material and molding it under pressure to form the core12. In the method200ofFIG.6, instead of progressing to the manufacture of the additional layers, the core12is removed and cooled. A pocket or cavity20is then machined into the core12, whereby the cavity20is of a volume configured to receive the electronics assembly30and the ballast or fill material40as previously described. The present disclosure also contemplates methods in which the cavity20is formed with the formation of the core12, rather than the cavity20being subsequently machined. By way of example, this may be achieved by3D printing a core12so as to include the cavity20from the onset.

In step204, the electronics assembly30is positioned within the cavity20, which may be centered along one, two, or three axes within the core12, as exemplified inFIG.9. With continued reference toFIG.6, step206provides for filling the cavity20with the fill material40(e.g., urethane that cures at the density needed to serve as the ballast) while the electronic assembly30is positioned in the cavity20. The fill material40may be injected into the cavity20so as to surround the electronics assembly30, and such that the core12, the electronics assembly30, and the fill material40together form a spherical body13that when cured will be balanced about the center of the spherical body13.

With continued reference toFIG.6, step208provides for curing the fill material40, which may be performed by the passage of time, using heat, ultra-violet light, or other techniques known in the art (exemplified inFIG.10). It should be recognized that the fill material40may be more than one material, for example with a first material being injected to fill the cavity20in the region balanced about the center4of the golf ball2, with a second material used to fill the remainder of the cavity20(i.e., from the portion of the cavity20radially outwardly from the electronics assembly30). Likewise, other ballasts may be included within the cavity20in addition to the fill material, such as an additional weight positioned at a determined location within the cavity20and effectively sealed therein via the fill material40.

In certain embodiments, the fill material40when cured expands and thus extends outwardly from the outer surface14of the core12. In this case, the method may further include the step of removing the excess material44(e.g., via a blade46) such that the fill material40is contoured to match the outer surface14of the core12. The core12and the fill material40therefore together form the spherical body13(as exemplified inFIG.11).

Returning to the method200ofFIG.6, step210provides for covering the spherical body with the cover10, which may be dimpled like a conventional golf ball. The cover10may be provided around the spherical body13of the core12and the fill material40via injection molding or compression molding in a conventional manner without the heat and/or pressure damaging the electronic assembly30. The completed golf ball2produced according to method200is exemplified byFIG.12.

Another method300is provided inFIG.7. In step302, a spherical core is provided as the core12, which comprises a first material. In step304, the electronics assembly30is provided, the electronics assembly30being configured to provide wireless communication via the techniques described above. The core12is machined in step306to create a cavity20therein. In particular, the cavity20is machined so as to accommodate the electronics assembly30and the volume of fill material40needed to (when cured) provide for a balance combination of the core12, the electronics assembly30, and the fill material40.

In step308, the cavity20is filled with the fill material40, which is different than the first material of the core12, while the electronics assembly30is positioned in the cavity20. As discussed above, the fill material40is selected such that when cured, the volume of the fill material40, the core12, and the electronics assembly30form a spherical body13that are balanced about a center of the spherical body13. As also discussed above, the balance about the center of the spherical body13may be only after excess fill material extending beyond the outer surface14of the core12is trimmed and contoured to match the curved outer surface14of the core12. The fill material40is cured in step310, followed by covering the spherical body13with the cover10in step12.

In this manner, the presently disclosed golf balls provide for electronic communication of their locations with a user, but without sacrificing homogeneity and balance from incorporating the electronic assemblies within the golf balls. In particular, the presently disclosed golf balls and methods for making them provide for restoring balance and recreating the correct spring-force response through the golf ball, despite the addition of the electronics assembly, via the proper positioning and combination of carefully selected materials.