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 multi-piece solid golf ball having a core, an envelope layer, an intermediate layer and a cover, the envelope layer is formed into two layers—an inner envelope layer and an outer envelope layer. The inner envelope layer-encased sphere, outer envelope layer-encased sphere, intermediate layer-encased sphere and ball have respective surface hardness that satisfy a specific relationship. The inner envelope layer or outer envelope layer is formed primarily of one or more elastomer, and further the core has a particular hardness profile. This ball has an excellent flight when struck by golfers whose head speeds are not that fast and has a good, soft feel at impact, thus making it highly suitable for amateur golfers,

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.

In a golf ball having a two-layer core consisting of an inner core layer and an outer core layer, one or more intermediate layer, and a cover serving as an outermost layer, the inner core layer and outer core layer are each formed primarily of a base rubber, the inner core layer has a diameter of at least 19 mm, the intermediate layer and the cover are each formed primarily of a resin material, and the overall core has a specific hardness profile. The golf ball has a high initial velocity while holding down the spin rate on full shots with a driver or long iron, thus enabling a good distance to be achieved. The ball also has a high controllability in the short game.

A golf ball has a core, an inner cover, an outer cover, and dimples. The golf ball satisfies the following mathematical formulas.

Sa=4500+10(A0.5B2Cs)4000

0.04Sa+16020D0.04Sa+160+20 A: a compression (Atti) of the golfball B: a hardness difference (Shore C) between a surface and a center of the core

Cs: (HiTi+2HoTo)/(Ti+2To) D: a total volume (mm.sup.3) of the dimples Hi: a hardness (Shore D) of the inner cover Ho: a hardness (Shore D) of the outer cover Ti: a thickness (mm) of the inner cover To: a thickness (mm) of the outer cover

In a multi-piece solid golf ball having a core, an envelope layer, an intermediate layer and a cover, the envelope layer is formed into two layersan inner envelope layer and an outer envelope layer. The inner envelope layer-encased sphere, outer envelope layer-encased sphere, intermediate layer-encased sphere and ball have respective surface hardnesses that satisfy a specific relationship. The inner envelope layer or outer envelope layer is formed primarily of one or more thermoplastic elastomer selected from the group consisting of polyester elastomers, polyamide elastomers, polyurethane elastomers, olefin elastomers and styrene elastomers. This ball has an excellent flight when struck by golfers whose head speeds are not that fast and has a good, soft feel at impact, thus making it highly suitable for amateur golfers.

A golf ball with a cover layer composed of at least one polymer and a micropowder material is disclosed herein. The micropowder material comprises polybutadiene rubber, isoprene rubber, zinc diacrylate, zinc oxide, zinc stearate, peroxide initiator, a peptizer, barium sulfate, tungsten, bismuth oxide and or bismuth oxychloride, and styrene butadiene rubber.

In a golf ball having a two-layer core consisting of an inner core layer and an outer core layer, an intermediate layer consisting of at least one layer and a cover of one or more layer, the inner core layer and outer core layer are each formed of a rubber composition made up primarily of a base rubber, the inner core layer has a diameter of not more than 30 mm; and the core has specific hardness ratios (JIS-C hardness/Shore D hardness) at specific points on the cross-section thereof and the surface and center of the two-layer core has a specific hardness difference. This golf ball has a reduced spin rate on full shots with a driver and middle irons, thus imparting an excellent flight performance, and moreover has a good controllability in the short game on approach shots, making it ideal as a golf ball for professional golfers and mid- and high-level amateur golfers.

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 multi-piece solid golf ball for professional golfers and skilled amateurs in particular is endowed with an excellent distance, a soft yet good feel at impact and a good durability. In the ball, which includes a core, an envelope layer, an intermediate layer and a cover, the core has a hardness profile which satisfies specific conditions, the envelope layer has a thickness of from 0.3 to 1.2 mm, the intermediate layer has a thickness of from 0.3 to 1.2 mm, and the envelope and intermediate layers have a combined thickness from of 0.8 to 1.7 mm.