Customizable golf ball and method of providing a customizable golf ball

The present disclosure is directed to a golf ball and a method for providing a golf ball that is customizable by a golfer to achieve a golfer's desired playing characteristics. The customizable golf ball includes multiple layers of customizable thermoplastic or thermoset materials in varying hardness levels that may be assembled by the golfer to achieve a desired feel in play. After play, the customizable golf ball may be disassembled to again vary the playing characteristics of the ball by substituting layers of varying hardness levels, or to simply replace old or worn out parts.

BACKGROUND

The present disclosure relates generally to a customizable golf ball and a method for providing a customizable golf ball to a golfer.

Golf is a sport that enjoys wide popularity around the world and is played by golfers of all ages, from young to old. To aid and improve their performance, golfers continually search for and adopt the best and newest equipment, including golf clubs, golf balls, apparel and training devices. To that end, there are many equipment choices available, including a number of different golf ball brands and types, each designed to exhibit certain characteristics in play. Golfers typically buy golf balls in a finished state, i.e. ready-to-use, and select a ball that is most suitable for a desired combination of performance characteristics or that is designed for their skill level.

Golf ball constructions may generally include a core made from a resilient material and a cover made from a more durable material, such as synthetic resin. The core is typically made from rubber or a similar material and may have a wound or solid construction. Intermediate layers made from a variety of materials may be provided between the core and cover to vary the perceived feel when the ball is hit, or to exhibit certain performance characteristics in play. Typically, golfers must search for ready-to-use balls with constructions that achieve their desired feel and performance.

SUMMARY

The present disclosure is directed to a golf ball and a method for providing a golf ball that is customizable by a golfer to achieve his or her desired feel and/or performance characteristics. The customizable nature of the disclosed golf ball also allows a golfer to replace or refurbish old or worn-out parts of the ball.

In one aspect, the disclosure provides a method of providing a customizable golf ball to a golfer. The method includes the steps of providing an inner core piece having a first hardness, providing at least two intermediate layer pieces having a second hardness, and providing at least two cover pieces having a third hardness. According to the method, the intermediate layer pieces have interior surfaces configured to mate with an exterior surface of the inner core piece, and the intermediate pieces substantially form a sphere when joined. In addition, the interior surfaces of the at least two cover pieces are configured to mate with an exterior surface of the at least two intermediate layer pieces, and together the at least two cover pieces substantially form a sphere.

In another aspect, the disclosure provides an additional method of providing a customizable golf ball to a golfer. The method involves providing an inner core piece that includes a plurality of apertures, and providing a plurality of tenons, whereby portions of the tenons may be fitted within some or all of the apertures. The method also includes providing at least two intermediate layer pieces configured to create a spherical cover for the inner core piece and that further include interior surfaces with a plurality of apertures for receiving portions of the tenons. The method further includes providing at least two cover pieces configured to mate with and create a spherical cover for the at least to intermediate layer pieces.

In another aspect, the disclosure provides yet another method of providing a customizable golf ball to a golfer. The method involves providing an inner core piece having a plurality of arcuate protrusions evenly spaced around the inner core piece, and beginning at one pole of the inner core piece and ending at an opposite pole of the inner core piece. Further, the method involves providing at least two cover pieces having interior surfaces including a plurality of grooves for receiving the arcuate protrusions of the inner core piece to form a two layer golf ball when assembled. Optionally, two intermediate layer pieces may be provided that are configured to create an intermediate cover layer sphere surrounding the inner core piece, and having interior surfaces including a plurality of grooves for receiving the arcuate protrusions of the inner core piece. The at least two cover pieces may configured to mate with and create a spherical cover for the at least two intermediate layer pieces, forming a three layer golf ball.

In another aspect, the disclosure provides yet another method of providing a customizable golf ball to a golfer. The additional method involves providing an inner core piece having a first hardness. The method further includes providing at least two cover pieces comprising a second hardness. The interior surfaces of the at least two cover pieces are further configured to mate with an exterior surface of the inner core piece and to join together to form a sphere.

DETAILED DESCRIPTION

The present disclosure relates to golf balls that may be customized by a golfer, and methods for providing customizable golf balls.

The performance of a golf ball may be driven by a number of factors including: the materials that are used to make the ball; the number of layers within the ball; the hardness and/or density of the material that makes up each layer; the thickness of each layer; and the way the layers are assembled to form the ball. Each of these features may affect the feel of the ball when it is struck by a golf club as well as the performance of the ball in flight and after touchdown, including the maximum velocity and spin rate achieved by the ball in flight. For example, golf balls with multiple internal layers may exhibit higher maximum spin rates after impact with a club face. Other features of the core may result in lower spin rates but increased velocity and distance. Golfers typically select a ball based on a desired combination of playing characteristics, often dependent upon the golfer's skill level. According to embodiments set forth herein, golfers may customize a golf ball, such as golf ball10ofFIG. 1, to achieve the exact playing characteristics desired.

FIG. 1depicts a customizable golf ball10, according to at least one embodiment described herein. According toFIG. 1, golf ball10includes an external cover20comprising a first cover piece22and a second cover piece23. External cover20may be provided with a plurality of dimples24arranged in a pattern. According to aspects set forth herein, first cover piece22and second cover piece23may be generally hemispherical in shape and joined together at a seam26such that golf ball10has a spherical shape. Golf ball10may look and feel very similar to currently available golf balls with respect to exterior variations in color, external markings, dimple patterns and cover hardness. Internally, however, golf ball10may exhibit a variety of features made from a variety of materials.

As depicted in the exploded view of golf ball10inFIG. 2, an embodiment of customizable golf ball10exhibits a layered structure having (a) a cover20that forms an exterior portion of golf ball10, (b) an optional intermediate layer or mantle shell30located under cover20, and (c) an internal core40that forms an interior portion of ball10. According to an embodiment set forth herein, golf ball10may also include a plurality of tenons44situated in apertures or core mortises42on core40as well as in mantle mortises36on an interior surface32of mantle shell30. As discussed in more detail below, a golfer may customize golf ball10by selecting layers of varying materials and varying hardnesses to achieve desired performance or playing characteristics, such as feel, spin, velocity or trajectory.

According to at least one embodiment, the internal core40may comprise a solid spherical structure with a plurality of core apertures42spaced evenly over the surface of core40for receiving a plurality of cylindrical tenons44, as shown inFIGS. 3 and 4. Core apertures42may be sized and shaped to receive similarly sized and shaped tenons44. Tenons44may be cylindrically shaped with a first end46placed in an aperture42on core40and a second end48placed in a similarly sized and shaped aperture36on an interior surface32of mantle shell30, as further set forth below. Those skilled in the art will appreciate that the number of tenons44may be fewer or more than is depicted inFIGS. 3 and 4and still achieve the desired effect, described below. Furthermore, those skilled in the art will readily appreciate that the tenon/mortise construction may also be achieved using a variety of different shapes, such as triangular-shaped tenons, rectangular-shaped tenons, pentagonal-shaped tenons, hexagonal-shaped tenons, or other kind of polygonal-shaped tenons, without altering the spirit and scope of the customizable golf ball set forth herein.

Referring to the embodiment ofFIGS. 5 and 6, mantle shell30may be comprised of four quarter-sphere pieces, first quarter-sphere piece34, second quarter-sphere piece37, third quarter-sphere piece38, and fourth quarter-sphere piece39.FIG. 5depicts an exploded view of how mantle shell30may be placed over core40andFIG. 6depicts the two layers in place together. Mantle shell30may also comprise two half-sphere pieces as shown in the embodiments depicted inFIGS. 11-16, discussed below. Mantle shell30has an exterior surface31and an interior surface32that is sized and shaped to mate with internal core40. In the embodiment depicted inFIGS. 5 and 6, interior surfaces32of first quarter-sphere piece34, second quarter-sphere piece37, third quarter-sphere piece38, and fourth quarter-sphere fourth quarter-sphere piece39exhibit a plurality of spaced apart cylindrically-shaped mantle apertures36that are sized and shaped to receive cylindrically-shaped tenons44protruding from core40. When fitted together as seen inFIG. 6, core40, tenons44and mantle shell30together create a tenon and mortise construction, and first quarter-sphere piece34, second quarter-sphere piece37, third quarter-sphere piece38, and fourth quarter-sphere piece39of mantle shell30fit together along seam line12and seam line14.

The exterior surface31of mantle shell30may also include provisions that can impact the ball's structure, according to aspects set forth herein. For example, the exterior surface31of mantle shell30may include small projections33to assist with positioning cover20over mantle shell30. In the embodiment shown inFIGS. 5-7, projections33create small spherical protrusions on the exterior surface31of mantle shell30. It should be understood that projections33may be sized and shaped in a variety of manners, or may be absent altogether, and still meet the spirit and scope of the present disclosure.

After core40is covered by mantle shell30to form a complete inner ball50as inFIGS. 6 and 7, inner ball50may be covered by two dimpled cover shells22and23.FIG. 7depicts an exploded view of how cover20may be placed over inner ball50to create finished golf ball10(as seen inFIG. 1). Cover20has an exterior surface27separated from an interior surface28by a thickness21selected to allow the interior surface to mate with inner ball50. In particular, thickness21may be decreased or increased based on the size of inner ball50. In the embodiment depicted inFIGS. 5 and 6, interior surfaces28are smooth, and projections33on inner ball50may be pressed against interior surfaces28; however, in other embodiments, interior surfaces28may have impressions that are sized and shaped to receive projections33. When fitted together as seen inFIGS. 1 and 7, first cover piece22and second cover piece23come together at seam line26. Referring toFIG. 7, seam line26of cover20may be offset from seam line12and seam line14of mantle shell30to increase durability across the layers of golf ball10.

Internal core40, tenons44, intermediate mantle shell30, projections33, and cover20may all be made from a variety of thermoplastic or thermoset materials in a variety of hardness levels to achieve desired playing characteristics. Exemplary thermoplastic materials may include, but are not limited to, ionomer resins, highly neutralized acid polymer compositions, polyamide resins, polyester resins, polyurethane resins, or a combination thereof. Exemplary thermoset materials may include, but are not limited to, natural and synthetic rubber and rubber compositions, polyurethane elastomers, polyamide elastomers, polyurea elastomers, diene-containing polymers, crosslinked metallocene catalyzed polyolefins, silicones, or combinations thereof. Those skilled in the art will readily acknowledge the full breadth of materials available for use beyond those specified, that would still fall within the spirit and scope of the present disclosure.

According to aspects described herein, the hardness of the layers of golf ball10may be assessed using techniques well-known in the art. In some cases, a durometer measurement may be taken on the surface of any of the layers of golf ball10. For example, a Shore® durometer measurement may be taken using the Shore scales set forth in the ASTM D2240 testing standards. In at least one embodiment, the hardness of the layers may be assessed using the ASTM D2240 Type D scale (also known as Shore D), as is well-known in the art. In other cases, the ASTM D2240 Type C or other scales may be used to assess the hardness of each of the layers. In still other cases, other well-known methods for measuring hardness may be used, such as JIS-C or JIS K 6253.

According to the present disclosure, the surface hardness level relationship between the layers of golf ball10may be dictated by the golfer assembling the customizable ball (assembly discussed in further detail below).

To achieve a variety of desired playing characteristics, a golfer may customize golf ball10by using materials of varying hardness levels for the multiple layers of golf ball10. For example, tenons44may have the same or a different surface hardness level from that of core40and mantle shell30. Likewise, projections33on mantle shell30may have the same or a different surface hardness level from that of mantle shell30. In addition, the hardness level of core40tenons44and mantle shell30may each be higher or lower in relation to the hardness level of cover20. As is known in the art, the variation in hardness levels among the multiple layers can create a different feel when the ball is hit. A golfer may customize the feel of golf ball10to his/her particular skill level or liking by using layers of varying hardness levels, varying thicknesses or varying materials throughout golf ball10.

While the hardness level of the layers of the varying embodiments described herein may be any desired value known in the art, typical golf ball configurations include a cover layer that is softer than the mantle shell, as well as a mantle shell that is harder than the core. In particular, hardness levels according to at least one embodiment set forth herein may be in the following ranges: a cover layer with a Shore hardness range between about 25 and 60; an intermediate mantle shell layer with a Shore D hardness range between about 40 and 80; and a core with a Shore D hardness range between about 30 and 65.

FIG. 8depicts a golfer80in the beginning stages of assembling a customizable golf ball10, i.e., joining a tenon44to core40, according to at least one embodiment set forth herein. Also present inFIG. 8are additional layers of golf ball10that have not yet been fully assembled, i.e., mantle shell first quarter-sphere piece34, mantle shell second quarter-sphere piece37, mantle shell third quarter-sphere piece38, mantle shell fourth quarter-sphere piece39, first cover piece22, and second cover piece23, as well as an adhesive82and solvent84. According to aspects set forth herein, golfer80may join the multiple layers together using adhesive82, such as a thermoplastic adhesive, or by other suitable method as is well-known in the art. This may include placing ends46of tenons44in core apertures42and joining by adhesive82, as well as by placing mantle apertures36of mantle shell30over ends48of tenons44and joining by adhesive82. After internal ball50is assembled by joining core40, tenons44and mantle shell30, golfer80may join first cover piece22and second cover piece23to form a cover20of golf ball10such that a seam line26is offset from seam line12and seam line14(or any other seam line created by a mantle shell layer). After cover20is secured, a golfer may also apply a top coating to the cover as is known in the art. After assembly, golf ball10may be ready for play by golfer80as shown inFIG. 9.

According to aspects set forth herein, customizable golf ball10may also be disassembled after play to replace existing layers with layers of a varying material or hardness layer to achieve a different feel, or simply to replace old or worn out parts or layers.FIG. 10depicts golfer80beginning disassembly of golf ball10by applying a solvent84to seam26of cover20to remove cover20from inner ball50. Solvent84may be any solvent suitable for reversing the adhesive properties of an adhesive used during assembly, as would be readily known to those of skill in the art. Examples of solvents include but are not limited to water, alcohols, and acid compounds such as vinegar. In addition, a golfer may reverse adhesive properties by other known means, such as exposure to heat or other types of radiation, such as microwaves.

FIGS. 11-16depict various layers of a customizable golf ball110according to an additional embodiment set forth herein. As seen inFIG. 16, which depicts an assembled golf ball110according to aspects set forth herein, the exterior surface of golf ball110may include external cover120made up of third cover piece122and fourth cover piece123, joined at seam126. Similar to the previously described embodiments, external cover120may be provided with a plurality of dimples124, to create a dimple pattern as is known in the art.

Referring to the partial views inFIGS. 11-15, an embodiment of golf ball110may exhibit a layered structure having (a) cover120that forms an exterior portion of golf ball110(as seen inFIGS. 15 and 16), (b) an intermediate layer or mantle shell130under cover120(as seen inFIGS. 13-15), and (c) an internal core140that forms an interior portion of ball110(as seen inFIGS. 11-13). According to an embodiment set forth herein, core140and mantle shell130may also include a plurality of arcuate projections, i.e. first projection142, second projection144, third projection146, and fourth projection148on core140and fifth projection152, sixth projection154, seventh projection156, and eighth projection158on an exterior surface133of mantle shell130. As previously discussed, a golfer may customize golf ball110by including layers of varying materials and varying hardnesses to achieve a desired playing characteristic, such as feel, spin, velocity, or trajectory.

According to an embodiment set forth herein, internal core140may comprise a solid spherical structure with a plurality of arcuate projections, first projection142, second projection144, third projection146, and fourth projection148, which may be referred to, collectively, as alternate core projections149. Each of alternate core projections149may form an arcuate protrusion from a first end141(or pole) of core140to a second end143(or opposite pole) of core140. Further, each of alternate core projections149may exhibit a rectangular-shaped cross-section as depicted in the cross-sectional view ofFIG. 12. Those skilled in the art will appreciate that the number of alternate core projections149may be fewer or more than is depicted inFIGS. 11-13and that the cross-sectional shape of alternate core projections149may be varied without altering the spirit and scope of the customizable golf ball set forth herein.

Referring toFIGS. 13-15, mantle shell130may be comprised of two half-sphere pieces, piece135and piece137, according to at least one embodiment described herein.FIG. 13depicts an exploded view of how mantle shell130may be placed over core140andFIGS. 14 and 15depict the two layers in place together. Mantle shell130includes an interior surface131and an exterior surface133, both of which may be sized and shaped to mate with core140and cover120, respectively. In the embodiment depicted inFIGS. 13-15, interior surfaces131of intermediate layer piece135and piece137exhibit a plurality of spaced apart grooves, i.e., first groove132, second groove134, third groove136, and fourth groove138, which may be collectively referred to as interior grooves139. Interior grooves139may be sized and shaped to receive alternate core projections149protruding from core140when lined up as depicted inFIG. 13. Thus, interior grooves139may exhibit a rectangular-shaped cross-section. The exterior surface133of mantle shell130may also include arcuate first exterior projection152, second exterior projection154, third exterior projection156, and fourth exterior projection158, which may be referred to, collectively, as exterior projections159. Similar to alternate core projections149of core140, exterior projections159may form an arc-shape protrusion from a first end151of mantle shell130to a second end153of mantle shell130. Further, each of exterior projections159may exhibit a rectangular-shaped cross-section, similar to alternate core projections149of core140. Again, those skilled in the art will appreciate that mantle shell130may comprise fewer or more pieces. Further, those of skill will readily acknowledge that the number of exterior projections159may be fewer or more than is depicted inFIGS. 13-15and that the cross-sectional shape of exterior projections159may be varied without altering the spirit and scope of the customizable golf ball set forth herein.

Inner ball150may be covered by a cover layer120which may be formed by third cover piece122and fourth cover piece123, as depicted inFIGS. 15-16. Cover layer120includes an exterior surface127and an interior surface128with a thickness121that is sized and shaped to mate with inner ball150. In particular, thickness121may be decreased or increased based on the size of inner ball150. In the embodiment depicted inFIGS. 15 and 16, interior surfaces128of cover layer piece122and piece123exhibit a plurality of spaced apart alternate cover grooves, i.e., first cover groove162, second cover groove,164, third cover groove166, and fourth cover groove168, which may be collectively referred to as cover grooves169. Cover grooves169may be sized and shaped to receive exterior projections159protruding from inner ball150when lined up as depicted inFIG. 15. Thus, cover grooves169may exhibit a rectangular-shaped cross-section, but as discussed above, are not limited in this way. When fitted together as seen inFIG. 16, third cover piece122and fourth cover piece123form seam line126. Referring toFIG. 15, seam line126of cover120may be offset from seam line155of mantle shell130to increase durability across the layers of golf ball110.

Similar to previously discussed embodiments, internal core140, intermediate mantle shell130, cover120may all be made from a variety of thermoplastic or thermoset materials, as set forth above, in a variety of hardness levels to achieve desired playing characteristics. Further, it is contemplated that each piece of core140, mantle shell130and cover120may be formed by one-time molding, by attaching alternate core projections149to core140and projections139to mantle shell130separately by thermoplastic adhesive, or by any other method known to those of skill. Thus, those skilled in the art will readily acknowledge the full breadth of materials available for use beyond those specified, as well as the method of forming the layers of golf ball110, which would still fall within the spirit and scope of the present disclosure.

According to aspects described herein, the hardness of the layers of golf ball110may be assessed using techniques known in the art. In some cases, a durometer measurement may be taken on the surface of any of the layers of golf ball110, as set forth above. According to the present disclosure, the hardness level of each of the layers of golf ball110may be dictated by the golfer assembling the customizable ball (assembly discussed in further detail below).

As previously discussed, to achieve a variety of desired playing characteristics, a golfer may customize golf ball110by using materials of varying hardness levels for the multiple layers of golf ball110. For example, core140may have the same or a different surface hardness level from that of mantle shell130. Likewise, the hardness level of core140and mantle shell130may each be higher or lower in relation to the hardness level of cover120. In addition, alternate core projections149on core140and exterior projections159on mantle shell130may have the same or a different surface hardness level from that of the other layers of golf ball110. As is known in the art, the variation in hardness levels among the multiple layers can create a different feel when the ball is hit. A golfer may customize the feel of golf ball110to his/her particular skill level or liking by using layers and/or projections of varying hardness levels, varying thicknesses or varying materials throughout golf ball110.

Customizable golf ball110may be assembled by a golfer in the manner depicted inFIGS. 13 and 15. According to aspects set forth herein, and similar to the assembly described above in relation toFIG. 8, a golfer may join the multiple layers together using adhesive, such as a thermoplastic adhesive, or by other suitable method as is well-known in the art. This may include placing alternate core projections149of core140in interior grooves139of mantle core130and securing with adhesive, as well as by placing exterior projections159of mantle shell130in cover grooves169of cover120and securing with adhesive. After cover120is secured, a golfer may also apply a top coating to the cover as is known in the art. After assembly, golf ball110may be ready for play by the golfer.

Likewise, customizable golf ball110may also be disassembled after play to switch out layers to achieve a different “feel” or to replace old or worn out parts or layers. Disassembly of golf ball110may be accomplished by applying a solvent as discussed above, or by using any suitable means known in the art for reversing adhesive properties of an adhesive used during assembly.

FIGS. 17-19depict various layers of a customizable alternate golf ball210according to yet another embodiment set forth herein. As seen inFIG. 19, which depicts an assembled alternate golf ball210according to aspects set forth herein, the exterior surface of alternate golf ball210may include external cover220made up of fifth cover piece222and sixth cover piece222, joined at seam226. Again, similar to the previously described embodiments, external cover220may be provided with a plurality of dimples224, to create dimple pattern as is known in the art.

Referring to the partial views inFIGS. 17 and 18, the embodiment of alternate golf ball210may exhibit a layered structure similar to previous embodiments having (a) cover220that forms an exterior portion of alternate golf ball210, (b) an intermediate layer or mantle shell230under cover120(as seen inFIGS. 17 and 18), and (c) an internal core140that forms an interior portion of ball210(as seen inFIG. 17and previously described in relation toFIGS. 11-13). As previously discussed, a golfer may customize alternate golf ball210by including layers of varying materials and varying hardnesses to achieve a desired playing characteristic, such as feel, spin, velocity, or trajectory.

According to the embodiment set forth herein and depicted inFIG. 17, internal core140may comprise a solid spherical structure with a plurality of arcuate projections, first core projection142, second core projection144, third core projection146, and fourth core projection148, referred to, collectively, as alternate core projections149. Internal core140is discussed above in relation toFIGS. 11-13, and those skilled in the art will appreciate that the exact configuration of internal core140may be varied without altering the spirit and scope of the customizable golf ball set forth herein.

Referring toFIGS. 17 and 18, mantle shell230of alternate golf ball210may be comprised of two half-sphere pieces, piece235and piece237, according to an embodiment described herein.FIG. 17depicts an exploded view of how mantle shell230may be placed over core140andFIG. 18depicts mantle shell230and core140together as inner ball250. Mantle shell230includes an interior surface231and an exterior surface233, both of which may be sized and shaped to mate with core140and cover220, respectively. In the embodiment depicted inFIGS. 17-19, interior surfaces231of first intermediate layer piece235and second intermediate layer piece237exhibit a plurality of spaced apart intermediate grooves, i.e., first intermediate groove232, second intermediate groove234, third intermediate groove236, and fourth intermediate groove238, which may be collectively referred to as intermediate grooves239. Intermediate grooves239may be sized and shaped to receive alternate core projections149protruding from core140when lined up as depicted inFIG. 17. Thus, intermediate grooves239may exhibit a rectangular-shaped cross-section. According to one embodiment, the exterior surface233of mantle shell230may be smooth. Again, those skilled in the art will appreciate that the configuration of mantle shell230may be varied without altering the spirit and scope of the customizable alternate golf ball210set forth herein.

Inner ball250may be covered by an alternate cover layer220which may be formed by fifth cover piece222and sixth cover piece222, as depicted inFIGS. 18 and 19. Alternate cover layer220includes an exterior surface227and an interior surface228with a thickness221that is sized and shaped to mate with inner ball250. In particular, thickness221may be decreased or increased based on the size of inner ball250. In the embodiment depicted inFIGS. 17-19, interior surfaces228of cover layer piece222and piece223are smooth to fit against the exterior surface233or mantle shell230.

Alternate cover layer220may include provisions for securing fifth cover piece222and sixth cover piece223. In particular, fifth cover piece222and sixth cover piece223may further include threaded area225and threaded area265, respectively. Threads225may be positioned on an interior surface228of fifth cover piece222and configured to engage with threads265, positioned slightly inward of exterior surface227of sixth cover piece223. Threaded areas225and threaded area265may be engaged and secured in a manner similar to engaging a cap on a bottle.

Similar to previously discussed embodiments, internal core140, intermediate mantle shell230, alternate cover220may all be formed according to methods set forth above and may be made from a variety of thermoplastic or thermoset materials, as set forth above, in a variety of hardness levels to achieve desired playing characteristics. Those skilled in the art will readily acknowledge the full breadth of materials available for use beyond those specified, as well as the breadth of methods available for forming the layers of alternate golf ball210, that would still fall within the spirit and scope of the present disclosure.

As previously discussed, to achieve a variety of desired playing characteristics, a golfer may customize alternate golf ball210by using materials of varying hardness levels for the multiple layers of alternate golf ball210. As is known in the art, the variation in hardness levels among the multiple layers can create a different feel when the ball is hit. A golfer may customize the feel of alternate golf ball210to his/her particular skill level or liking by using layers and/or projections of varying hardness levels, varying thicknesses or varying materials throughout alternate golf ball210.

Alternate golf ball210may be assembled by a golfer as previously discussed, and in the manner depicted inFIGS. 17-19. According to aspects set forth herein, a golfer may join the multiple layers together using adhesive, such as a thermoplastic adhesive, or by other suitable method as is well-known in the art. This may include placing alternate core projections149of core140in grooves239of mantle core230as shown inFIG. 17, and securing with adhesive to form inner ball250. Further, inner ball250may be placed within alternate cover220as shown inFIG. 18, and threaded area225of fifth cover piece222and threaded area265of sixth cover piece223may be engaged as shown inFIG. 19. Seam line226of alternate cover220may be offset from seam line239of mantle shell230to increase durability across the layers of alternate golf ball210. When joined, fifth cover piece222and sixth cover piece223form seam line226. After alternate cover220is secured, a golfer may also apply a top coating to the cover as is known in the art. After assembly, alternate golf ball210may be ready for play by the golfer.

Customizable alternate golf ball210may also be disassembled after play to switch out layers to achieve a different feel or to replace old or worn out parts or layers. Disassembly of alternate golf ball210may be accomplished by disengaging threaded area225and threaded area265of cover layer220, and applying a solvent as discussed above to those layers secured with adhesive, or by using other suitable means known in the art for reversing adhesive properties of an adhesive used during assembly.

FIGS. 20-22andFIGS. 23-24depict various layers and views of customizable golf balls310and410, respectively, according to additional embodiments set forth herein. Referring toFIG. 22, which depicts an assembled golf ball310according to aspects set forth herein, the exterior surface of golf ball310may include external cover320made up of seventh cover piece322, eighth cover piece324, ninth cover piece326and tenth cover piece328. In at least one configuration, seventh cover piece322, eighth cover piece324, ninth cover piece326and tenth cover piece328may each have a general shape of a quarter sphere, and may be joined together at seam312, seam314, seam316and seam318, respectively. Similar to the previously described embodiments, external cover320may be provided with a plurality of dimples324, to create a dimple pattern as is known in the art.

As depicted in the exploded view of golf ball310inFIG. 20, an embodiment of customizable golf ball310exhibits a layered structure having: a cover320that forms an exterior portion of golf ball310; and an internal core340that forms an interior portion of ball310. According to an embodiment set forth herein, golf ball310may also include a plurality of tenons344situated in apertures or core mortises342on core340as well as in cover mortises336on an interior surface332of cover320. Similar to the previously discussed embodiments, a golfer may customize golf ball310by selecting layers of varying materials and varying hardnesses to achieve desired performance or playing characteristics, such as feel, spin, velocity or trajectory.

According to at least one embodiment, and similar to previously discussed embodiments, the internal core340may comprise a solid spherical structure with a plurality of core apertures342spaced evenly over the surface of core340for receiving a plurality of cylindrical tenons344, as shown inFIG. 20. Core apertures342may be sized and shaped to receive similarly sized and shaped tenons344. Tenons344may be cylindrically shaped with a first end346placed in an aperture342on core340and a second end348placed in a similarly sized and shaped aperture336on an interior surface332of cover320. Those skilled in the art will appreciate that the number of tenons344may be fewer or more than is depicted inFIGS. 20-22and still achieve the desired effect, described below. Furthermore, those skilled in the art will readily appreciate that the tenon/mortise construction disclosed in the embodiment ofFIGS. 20-22may also be achieved using a variety of different shapes, such as triangular-shaped tenons, rectangular-shaped tenons, pentagonal-shaped tenons, hexagonal-shaped tenons, or other kind of polygonal-shaped tenons, without altering the spirit and scope of the customizable golf ball set forth herein.

According to aspects described herein, cover320may be comprised of four quarter-sphere pieces, seventh cover piece322, eighth cover piece324, ninth cover piece326and tenth cover piece328.FIG. 20depicts an exploded view of how cover320may be placed over core340andFIG. 22depicts the two layers in place together. As depicted, cover320has an exterior surface321as well as an interior surface332that is sized and shaped to mate with core340. In the embodiment depicted inFIGS. 20 and 21, interior surfaces332of seventh cover piece322, eighth cover piece324, ninth cover piece326and tenth cover piece328each exhibit a plurality of spaced apart cylindrically-shaped apertures336that are sized and shaped to receive cylindrically-shaped tenons344protruding from core340. When fitted together as seen inFIG. 22, core340, tenons344and cover320together create a tenon and mortise construction, similar to previous embodiments, and seventh cover piece322, eighth cover piece324, ninth cover piece326and tenth cover piece328of cover320fit together along seam line312and seam line314.

Similar to previously discussed embodiments,FIG. 21depicts an exploded view of how cover320may be placed over core340to create finished golf ball310(as seen inFIG. 22). In particular, according to aspects set forth herein, a golfer may join the multiple layers together using an adhesive82, such as a thermoplastic adhesive, or by other suitable method as is well-known in the art. This may include placing ends346of tenons344in core apertures342and joining by adhesive82to create an assembled core340. After assembled core340is constructed, a golfer may place cover apertures336of each quarter-sphere of cover330over ends348of tenons344, joining each quarter-sphere of cover320both to core320and an adjoining quarter-sphere. As may be seen inFIG. 21, adjoining flat surfaces323of seventh cover piece322, eighth cover piece324, ninth cover piece326and tenth cover piece328may be joined together and sealed with adhesive82. After cover320is secured, a golfer may also apply a top coating to the cover as is known in the art (not shown).

Likewise, customizable golf ball310may also be disassembled after play to switch out layers to achieve a different feel or to replace old or worn out parts or layers. Disassembly of golf ball310may be accomplished by applying a solvent as discussed above, or by using any suitable means known in the art for reversing adhesive properties of an adhesive used during assembly.

Core340, tenons344and cover320may all be made from a variety of thermoplastic or thermoset materials, as set forth in relation to previously discussed embodiments, in a variety of hardness levels to achieve desired playing characteristics. Further, those skilled in the art will readily acknowledge the full breadth of materials available for use beyond those specified, that would still fall within the spirit and scope of the present disclosure.

According to the present disclosure, the surface hardness level relationship between the layers of golf ball310may be dictated by the golfer assembling the customizable ball in order to customize playing characteristics of the ball. As previously discussed, to achieve a variety of desired playing characteristics, a golfer may customize golf ball310by using materials of varying hardness levels for the multiple layers of golf ball310. For example, core340may have the same or a different hardness level from that of cover320. Likewise, the hardness level of tenons344may be higher or lower in relation to the hardness levels of core340and cover320. Each of the hardness levels of the varying layers of golf ball310may be assessed using the standard techniques discussed above and as would be well-known in the art. For example, in some cases, a durometer measurement may be taken using the ASTM D2240 Type D scale (also known as Shore D).

According to aspects set forth herein, a golf ball may be further enhanced with an outer layer to provide additional stability to the surface of the golf ball or to enhance the aesthetics of the golf ball. For example, in some cases, a thin outer layer may be applied to further seal seam lines or to provide a color or other aesthetic effect to the ball. Referring toFIGS. 23 and 24, in at least one configuration, a golf ball such as golf ball310may be inserted in a heat-shrinkable sleeve420to create an outer layer430when heat is applied to heat-shrinkable sleeve420.

Heat-shrinkable sleeve420may be sized to fit snugly around a golf ball, such as golf ball310inFIG. 23. Heat-shrinkable sleeve420may be made of any malleable and heat-shrinkable material known in the art. In at least one configuration, sleeve420may be made of a thermoplastic polymer membrane that will shrink to the surface of golf ball310when heated, for example, by dipping in a boiling water bath or other method contemplated by a skilled artisan. Once heated, sleeve420may conform to the surface of golf ball310to create an outer layer430and additional embodiment, i.e., golf ball410ofFIG. 24. In some cases, heat-shrinkable sleeve420may be colored or improved with an indicia422to also enhance the aesthetics of the golf ball.