In a golf ball having a core and a cover, the core is formed of a rubber composition, has center and surface portions which are unfoamed regions and has an intermediate portion containing a foamed region. The core is produced by charging the rubber composition, which contains a blowing agent, into a first curing mold and curing under given conditions, then removing the molded rubber material in a semi-cured state from the first mold, transferring the semi-cured material to a second curing mold and curing under given conditions. The foamed region of the core deforms by a certain degree at the time of impact, decreasing the radius of gyration of the ball and enabling a lower spin rate to be achieved. The decrease in resilience due to expansion of the molded material can be held to a minimum.

In a method and related system of the invention, each golf ball component is progressed while being coated, without contacting another surface until after curing, and without the margin for error created in prior systems/methods using physical or air stream up-take supports. In one embodiment, a method of the invention comprises the steps of: progressing a golf ball component within an enclosed chamber for a controlled duration of time; at least partially covering the golf ball component with a coating material while the ball is progressed within the enclosed chamber; and at least partially curing the coating material on golf ball component in the chamber. The golf ball component may be in a state of free fall while progressed within the enclosed chamber, and in some embodiments, also during the step of curing the coating material on the golf ball component.

In a method and related system of the invention, each golf ball component is progressed while being coated, without contacting another surface until after curing, and without the margin for error created in prior systems/methods using physical or air stream up-take supports. In one embodiment, a method of the invention comprises the steps of: progressing a golf ball component within an enclosed chamber for a controlled duration of time; at least partially covering the golf ball component with a coating material while the ball is progressed within the enclosed chamber; and at least partially curing the coating material on golf ball component in the chamber. The golf ball component may be in a state of free fall while progressed within the enclosed chamber, and in some embodiments, also during the step of curing the coating material on the golf ball component.

In an aspect, an apparatus is provided and includes an air-tight object having an outer layer, an inner layer, and a cover, and a light module. The opacity of the outer layer is greater than the opacity of the inner layer. The outer layer defines a first aperture and a second aperture. The inner layer and the cover define a first interior region. The inner layer defines a second interior region. The light module is encapsulated within the first interior region and is configured to send light through the inner layer, through the second interior region of the air-tight object, and through the second aperture of the outer layer, wherein the cover is disposed between the light module and the outer layer.

In an aspect, an apparatus is provided and includes an air-tight object having an outer layer, an inner layer, and a cover, and a light module. The opacity of the outer layer is greater than the opacity of the inner layer. The outer layer defines a first aperture and a second aperture. The inner layer and the cover define a first interior region. The inner layer defines a second interior region. The light module is encapsulated within the first interior region and is configured to send light through the inner layer, through the second interior region of the air-tight object, and through the second aperture of the outer layer, wherein the cover is disposed between the light module and the outer layer.

A golf ball of one aspect of the present invention includes a spherical core, one or more cover members to cover the core, and a coating layer to coat a cover member configuring an outermost layer of the one or more cover members. A plurality of dimples is formed in the cover member of the outermost layer. Roughness is produced on a surface of the coating layer after applying a coat over the cover member of the outermost layer. An average value Fa (mm) of maximum depths of the plurality of dimples and arithmetic average roughness Ra (μm) on the surface of the coating layer, satisfy a relational expression:
−1.5×Fa+0.8≦Ra≦−1.5×Fa+1.8.

A golf ball of one aspect of the present invention includes a spherical core, one or more cover members to cover the core, and a coating layer to coat a cover member configuring an outermost layer of the one or more cover members. A plurality of dimples is formed in the cover member of the outermost layer. Roughness is produced on a surface of the coating layer after applying a coat over the cover member of the outermost layer. An average value Fa (mm) of maximum depths of the plurality of dimples and arithmetic average roughness Ra (μm) on the surface of the coating layer, satisfy a relational expression:
−1.5×Fa+0.8≦Ra≦−1.5×Fa+1.8.

The present invention is directed to a method of forming plurality of golf balls comprising steps of: providing plurality of inner cores; forming sheet of uncured rubber; forming plurality of preps in the sheet of uncured rubber such that each prep contains a concave top surface and is detachably connected to coupling material; loading the preps and coupling material into a core mold; loading plurality of inner cores into mold such that the inner cores are aligned with the concave surface of each prep; molding the preps about the inner cores to form outer core layers; and forming covers about outer core layers.

The present invention is directed to a method of forming plurality of golf balls comprising steps of: providing plurality of inner cores; forming sheet of uncured rubber; forming plurality of preps in the sheet of uncured rubber such that each prep contains a concave top surface and is detachably connected to coupling material; loading the preps and coupling material into a core mold; loading plurality of inner cores into mold such that the inner cores are aligned with the concave surface of each prep; molding the preps about the inner cores to form outer core layers; and forming covers about outer core layers.

Dual core golf ball constructions achieving consistent and repeatable concentricity by incorporating/using an assembly of dual core components comprising a solid spherical inner core component and three outer core components that are collectively compression molded about the solid spherical inner core component to create an outer core layer thereabout. The three outer core components include a first half-shell, a second half-shell; and a ring-shaped securing plate such that the solid spherical inner core component is immovably centered within the outer core layer. Each of the first half-shell, the ring-shaped securing plate, and the second half-shell is comprised of the same rubber composition(s) and possess strong cohesive and adhesive bonds at parting lines between the three molded assembly parts and collectively create an outer core layer having one or more uniform property profile, such as a hardness gradient throughout, without interruption at parting lines between the three outer core components.