The present invention provides methods for producing molded golf balls and the resultant balls. The methods of this invention involve producing foamed polyurethane covers and these methods help reduce dimple distortions and other surface imperfections. These golf balls contain an inner core and outer foamed polyurethane cover. One or more intermediate layers can be disposed between the core and cover. In one embodiment, a castable liquid polyurethane composition containing a foaming agent is dispensed into mold cavities, which are then pressed together to form a foam cover for the ball.

Multi-layered golf balls having at least one layer made from silicone (polysiloxane) elastomers; silicone (polysiloxane) elastomer/polyurethane blends; polycarbonate-polysiloxane blends and copolymers; and polycarbonate-polysiloxane/polyurethane blends are provided. For example, three-piece, four-piece, and five-piece golf balls containing different core and cover structures can be made. The polysiloxane compositions have good thermal stability and durability without sacrificing resiliency. The polysiloxane compositions also have high elongation, tensile strength, chemical/fluid-resistance, and weatherability properties. These compositions can be used to form any layer, for example, core, intermediate, or cover, in the golf ball.

Multi-piece golf balls containing a multi-layered core structure are provided. The core structure includes a small, heavy inner core (center) having a relatively high specific gravity, an intermediate core layer, and a surrounding outer core layer. The layers of the core structure may have different hardness gradients. The center of the core comprises a metal material such as copper, steel, brass, tungsten, titanium, aluminum, and alloys thereof dispersed in a thermoset polymeric matrix. The intermediate core layer is preferably formed from a first thermoplastic composition such as an ethylene acid copolymer ionomer resin; and the outer core layer is preferably formed from a second thermoplastic composition. The resulting ball has high resiliency and good spin control.

Golf balls having a multi-layered core made of a foamed composition are provided. The core assembly preferably includes a foam inner core (center) and surrounding outer core layer. Preferably, a polyurethane foam composition is used to form the foam center. The core layers have different hardness gradients and specific gravity values. The foamed inner core assembly includes a geometric center, outer surface (skin), and thermal barrier layer that helps protect the foamed center region from the negative effects of high temperatures used during the ball-manufacturing process. Non-foamed thermoset materials such as polybutadiene rubber may be used to form the thermal barrier layer. 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.

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.

Multi-piece golf balls having a multi-layered solid core and multi-layered cover are provided.

A golf ball includes a core having an outer surface and a geometric center. The core is formed from a substantially homogenous rubber composition. An ionomeric inner cover layer is formed about the core and has a material hardness of about 60 Shore D or greater. The golf ball includes an outer cover layer formed from a polyurea or a polyurethane and having a material hardness of about 60 Shore D or less. The outer surface of the core has a trans content of about 12% or less and a hardness of about 71 to 88 Shore C. The geometric center of the core has a trans content of about 10% or less and a hardness of about 60 to 80 Shore C. The core has an outer surface hardness greater than a geometric center hardness by about 5 to 19 Shore C to define a positive hardness gradient.

Golf ball comprising one or more layers and/or indicia formed from a fluorescent composition comprising: a base polymer; and a colorant; wherein the colorant is a small-molecule ionic isolation lattice formed from one or more fluorescent dye and one or more cyanostar macrocycles. The one or more fluorescent dyes may include at least one dye selected from xanthenes, oxazines, styryls, cyanines, trianguleniums, or mixtures thereof. The colorant may be a dispersion of the small-molecule ionic isolation lattice in a carrier medium or a powder. In particular embodiments, at least one of the one or more layers is a cover layer and/or a coating layer.

An object of the present invention is to provide a golf ball showing excellent impact durability. The present invention provides a golf ball comprising a spherical core and at least one cover layer covering the spherical core, wherein the golf ball comprises a reinforcing layer containing a polyvinyl acetal resin on the surface of the spherical core.

A golf ball including a thermoplastic inner core layer that has a geometric center hardness greater than its surface hardness to define a negative hardness gradient. An outer core layer is disposed about the inner core and is formed from a thermoplastic material and has an inner surface hardness substantially less than its outer surface hardness to define a positive hardness gradient. An inner cover layer is disposed about the outer core layer and an outer cover layer is disposed about the inner cover layer.