A method for forming a golf ball core with a nanofiller masterbatch is disclosed herein. The method includes mixing the nanofiller masterbatch, a graphene masterbatch material with other materials to form a core mixture, wherein the masterbatch preferably comprises 1-80% by weight of nanofillers and 20-99% by weight of a carrier polymer.

A golf ball can include a core, a mid layer, and a cover. The golf ball can satisfy the following mathematical formulas (1) and (2),

(Fa/Fan)≤0.90  (1),

(Fa/Fan).sup.2/(Fp/Fpn)≤0.90  (2),

wherein Fa represents a maximum vertical force of the golf ball measured under a first condition. Fan represents a maximum vertical force of a standard ball measured under the first condition, Fp represents a maximum vertical force of the golf ball measured under a second condition, and Fpn represents a maximum vertical force of the standard ball measured under the second condition.

A method for forming a golf ball core with a nanofiller masterbatch is disclosed herein. The method includes mixing the nanofiller masterbatch, a graphene masterbatch material with other materials to form a core mixture, wherein the masterbatch preferably comprises 1-80% by weight of nanofillers and 20-99% by weight of a carrier polymer.

In a golf ball having a core, envelope layer, intermediate layer and cover, the (core diameter)/(ball diameter) value falls within a particular range, the core has a specific hardness profile, and the Shore C hardness relationships among the core center and surface hardnesses and the surface hardnesses of the envelope layer-encased sphere, intermediate layer-encased sphere and ball satisfy the following conditions:
core surface hardness<surface hardness of envelope layer-encased sphere<surface hardness of intermediate layer-encased sphere>ball surface hardness,  (1)
(surface hardness of envelope layer-encased sphere)−(core center hardness)≥28.  (2)
Also, the envelope layer, intermediate layer and cover have respective thicknesses which satisfy the condition:
cover thickness<intermediate layer thickness  (3)
cover thickness<envelope layer thickness  (4)
envelope layer thickness≥0.8 mm.  (5)
This ball enables mid-level and skilled amateur golfers to achieve superior distances on driver shots and on iron shots, and moreover has a soft yet good feel at impact.

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

A golf ball 2 includes a core 4, a mid layer 6, a cover 8, and dimples 10. A difference DH in hardness between a surface and a central point of the core 4, a thickness Tm and a hardness Hm of the mid layer 6, a thickness Tc and a hardness Hc of the cover 8, and an amount of compressive deformation Sb meet the following mathematical formulas.

(DH*Hm)/(Hc*Tc)>80

((Sb*Tc)/(Hc* Hm*Tm))*1000>0.75

An area ratio So of dimples 10 and a ratio Rs of a number of the dimples 10 each having a diameter of equal to or greater than 9.60% but equal to or less than 10.37% of a diameter of the golf ball 2 meet the following mathematical formula (3).

Rs≧−2.5*So+273   (3)

An object of the present invention is to provide a golf ball traveling a great distance on driver shots. The present invention provides a golf ball comprising a spherical core including an inner layer and an outer layer, wherein a difference (H.sub.X+1−H.sub.X−1) between a hardness (H.sub.X+1) at a point outwardly away in a radial direction from a boundary between the inner layer and the outer layer of the spherical core by 1 mm and a hardness (H.sub.X−1) at a point inwardly away in the radial direction from the boundary between the inner layer and the outer layer of the spherical core by 1 mm is 0 or more in Shore C hardness, a surface hardness (H.sub.X+Y) of the spherical core is more than 70 in Shore C hardness, an angle α of a hardness gradient of the inner layer is 0° or more, a difference (α−β) between the angle α and an angle β of a hardness gradient of the outer layer is 0° or more, and the intermediate layer has a highest hardness among the constituent members of the golf ball.

A golf ball 2 includes a spherical core 4, an inner mid layer 6 positioned outside the core 4, an outer mid layer 8 positioned outside the inner mid layer 6, a reinforcing layer 10 positioned outside the outer mid layer 8, and a cover 12 positioned outside the reinforcing layer 10. When distances (%) from a central point of the core 4 to nine points and JIS-C hardnesses at the nine points, which nine points are obtained by dividing a region from the central point of the core 4 to a surface of the core 4 at intervals of 12.5% of a radius of the core 4, are plotted in a graph, R.sup.2 of a linear approximation curve obtained by a least-square method is equal to or greater than 0.95.

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 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.