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.

Golf ball methods and molds for quickly and efficiently eliminating air/gas from within a mold during golf ball manufacture and the improved golf balls resulting therefrom.

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.

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

Golf balls having covers made of thermoplastic polyurethane compositions are provided. Multi-piece golf balls can be made. Polyurethane primer coatings and polyurethane top-coatings are applied to the thermoplastic polyurethane cover. Isocyanate-rich and polyol-rich polyurethane coatings can be applied. In one embodiment, multi-functional imine and amine compounds can be used to treat the golf ball. The resulting coating may contain polyurethanes, polyureas, and hybrids, copolymers, and blends thereof. The cover composition and surface coatings can further include catalysts, ultraviolet (UV)-light stabilizers, and other additives. Heat is used to cure the coatings. The coating methods have many benefits and the finished balls have good physical properties.

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.

A golf ball is provided that achieves a satisfactory distance on full shots with an iron, is superior in the short game, and has a good feel at impact and a good durability. The golf ball has a core formed of a rubber composition as one or more layer, an envelope layer formed of a resin material as one or more layer, an intermediate layer formed of a resin material as one layer, and a cover formed of a resin material as one layer having a thickness of not more than 1.0 mm. The layers of the ball have Shore C hardnesses at the respective surfaces thereof which together satisfy certain specific conditions, the core and the ball have respective deflections which satisfy certain conditions and the core has a specific internal hardness profile.