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.

In a golf ball having a core, envelope layer, intermediate layer and cover, the core has a specific hardness profile, the resin materials making up either or both of the envelope layer and the intermediate layer has a material hardness on the Shore D hardness scale of at least 65 and has a specific gravity of at least 1.05, and the Shore C hardness relationships among the core center, surface of the envelope-encased layer and surface of the intermediate layer-encased sphere satisfy the following conditions:

surface hardness of envelope layer-encased sphere<surface hardness of intermediate layer-encased sphere,  (1)

surface hardness of intermediate layer-encased sphere−center hardness of core≥40.  (2)

This ball achieves a good distance on shots with utility and iron clubs, is receptive to spin in the short game, and has a soft feel at impact on all shots, making it useful to amateur golfers.

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.

A golf ball with a center core comprising 1,4 polybutadiene with a cis content more than 50% and containing a metal salt of acrylate, wherein the 1,4 polybutadiene has 5 to 60 weight percent of a metal salt of acrylate, is disclosed herein. The metal salt of acrylate is preferably selected from zinc, magnesium, sodium, and calcium.

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.

Golf ball having CoR of at least 0.700 and Atti compression of at least about 50 and comprising layer comprising a mixture of ionomer composition and a plurality of particulates, at least some being surface-treated with alkoxylated siloxanes and/or polyether-modified siloxanes, and selected from titanium dioxide particles, barium sulfate particles, zinc sulfide particles, and/or zinc oxide particulates. At least some particulates may be contacted with compound having the formula: ##STR00001## Compound (I) may be included in amount of 0.01 to 2% by weight based on total weight of portion of plurality being contacted. The plurality may be included in mixture in amount such that the layer has specific gravity of from 0.5 to about 5.0, tensile strength of from about 300 psi to about 50,000 psi, and elongation at break of from about 20% to about 1000%, each being greater than that of the ionomer composition portion of the mixture.

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-piece golf balls having a solid core made of a foamed composition and a cover are provided. Preferably, the core is dual-layered having has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. Preferably, a polyurethane foam composition containing mineral filler particulate, for example, nanoclay particles, is used to form the foam center. The concentration of clay particulate is preferably in a range of 0.1 to 60% by weight. The surrounding outer core layer may be made from non-foamed or foamed compositions. For example, polybutadiene rubber or highly neutralized olefin acid copolymers may be used in the outer core layer. The core layers have different hardness gradients and specific gravity values.