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.

Golf ball comprising a core and a cover, wherein the core includes between 2 and 20 smaller spheres that are surrounded by a second core composition having at least one different physical property than the composition(s) forming the smaller spheres. The smaller spheres can be entirely surrounded by the second core composition; or, at least two smaller adjacent spheres may each be partially surrounded by the second core composition while also being in partial contact with each other.

An object of the present disclosure is to provide a golf ball having excellent durability and flight distance and good shot feeling for an average golfer who hits a golf ball at a slow head speed. The present disclosure provides a golf ball comprising a spherical core and at least two cover layers covering the spherical core, wherein a difference between a core surface crosslinking density and a core center crosslinking density is more than 1.0×10.sup.2 mol/m.sup.3 and less than 9.0×10.sup.2 mol/m.sup.3, a hardness difference between a core surface hardness Cs (Shore C hardness) and a core center hardness Co (Shore C hardness) is 13.0 or more and 30.0 or less, a compression deformation amount of the core when applying a load from an initial load of 98 N to a final load of 1275 N to the core is 3.8 mm or more, and the at least two cover layers include a first cover layer and a second cover layer positioned closer to the spherical core than the first cover layer, an average hardness Dave=(Ti×Hi+To×Ho)/(Ti+To) of the first cover layer and the second cover layer is 55 or more, where To (mm) is a thickness of the first cover layer, Ho (Shore D) is a slab hardness of the first cover layer, Ti (mm) is a thickness of the second cover layer, and Hi (Shore D) is a slab hardness of the second cover layer.

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 of a foamed silicone composition are provided. Multi-layered golf balls having at least one layer made of non-foamed silicone elastomer composition also are provided. For example, three-piece, four-piece, and five-piece golf balls containing different core and cover structures can be made. The foamed silicones have good thermal stability and durability without sacrificing resiliency. The non-foamed silicone elastomers 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-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.

A golf ball comprising a core composed of a fully neutralized polymer material is disclosed herein. The golf ball also preferably has multiple mantle layers and a cover.

An object of the present disclosure is to provide a golf ball having excellent durability and flight distance and good shot feeling for an average golfer who hits a golf ball at a slow head speed. The present disclosure provides a golf ball comprising a spherical core and at least two cover layers covering the spherical core, wherein a difference between a core surface crosslinking density and a core center crosslinking density is more than 1.0×10.sup.2 mol/m.sup.3 and less than 9.0×10.sup.2 mol/m.sup.3, a hardness difference between a core surface hardness Cs (Shore C hardness) and a core center hardness Co (Shore C hardness) is 13.0 or more and 30.0 or less, a compression deformation amount of the core when applying a load from an initial load of 98 N to a final load of 1275 N to the core is less than 3.8 mm, and the at least two cover layers include a first cover layer and a second cover layer positioned closer to the spherical core than the first cover layer, an average hardness Dave=(Ti×Hi+To×Ho)/(Ti+To) of the first cover layer and the second cover layer is 55 or more, wherein To (mm) is a thickness of the first cover layer, Ho (Shore D) is a slab hardness of the first cover layer, Ti (mm) is a thickness of the second cover layer, and Hi (Shore D) is a slab hardness of the second cover layer.

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.

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.