An object of the present invention is to provide a golf ball having excellent durability and good shot feeling. The present invention provides a golf ball comprising a core, wherein a difference (crosslinking density at surface of core-crosslinking density at center of core) between a crosslinking density at a surface of the core and a crosslinking density at a center of the core is more than 1.0×10.sup.2 mol/m.sup.3 and less than 9.0×10.sup.2 mol/m.sup.3, and a hardness difference (Hs−Ho) between Hs and Ho is 13.0 or more and 30.0 or less, and the core satisfies H50-Ho>Hs-H50, wherein Hs (Shore C hardness) is a hardness at the surface of the core, Ho (Shore C hardness) is a hardness at the center of the core, and H50 (Shore C hardness) is a hardness at a midpoint between the center of the core and the surface of the core.

Golf balls having covers made of thermoplastic polyurethane compositions are provided. Multi-piece golf balls can be made. In one embodiment, the outer cover layer is formed from a composition comprising a thermoplastic polyurethane and polydimethylsiloxane compound. Functionalized polydimethylsiloxane compounds also can be used to treat thermoplastic polyurethane golf ball covers. The cover composition and surface coatings can further include catalysts, ultraviolet (UV)-light stabilizers, and other additives. The coating methods have many benefits and the finished balls with thermoplastic polyurethane covers have good physical properties.

An object of the present invention is to provide a golf ball having excellent resilience performance. The present invention provides a golf ball having a spherical core and at least one cover layer, wherein the spherical core is formed from a rubber composition containing (a) a base rubber, (b) an α,β-unsaturated carboxylic acid having 3 to 8 carbon atoms and/or a metal salt thereof as a co-crosslinking agent, and (c) a crosslinking initiator, provided that the rubber composition further contains (d) a metal compound in the case of containing only (b) the α,β-unsaturated carboxylic acid having 3 to 8 carbon atoms as the co-crosslinking agent, wherein (c) the crosslinking initiator includes a peroxy ketal represented by the formula (1), and substituents represented by R.sup.1 and R.sup.2 have a bond dissociation energy of 435 KJ/mol or more.

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Golf balls of the invention include at least one core layer comprised or consisting of a homogenous rubber-based core composition with a plurality of functionalized inorganic aluminosilicate ceramic microspheres dispersed throughout without agglomerating to create a relatively higher cross-link density of the core layer material. In golf balls of the invention, cross-link density gradients may be created between core layers by pre-electing the presence/absence, amount, type, and degree of functionalization of the plurality of functionalized inorganic aluminosilicate ceramic microspheres in two given core layers to target important properties such as resilience/CoR and desired playing characteristics such as distance.

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.

The invention relates to golf balls having at least one layer formed from a highly-neutralized polymer material that has been crosslinked. In particular, the compositions of the invention include a highly-neutralized polymer, at least one crosslinking initiator, and at least one coagent. The invention also relates to methods of making the compositions and golf ball constructions that incorporate the compositions of the invention in at least a portion thereof.

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.

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.

A golf ball is provided which suppresses twisting due to external forces while maintaining sufficient deflection at the time of impact, reduces the spin rate without lowering ball rebound, and is thus able to effectively increase the distance traveled by the ball, particularly on shots with a driver. In the golf ball, which includes a core and a cover, the core has a core body made of a first polybutadiene rubber and having a surface with a plurality of groves or holes thereon, which grooves or holes are filled with a second polybutadiene rubber of a differing composition from the first polybutadiene rubber. The polybutadiene rubber-filled groove portions or hole portions have a higher surface hardness than the core body.