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.

A rubber composition for a golf ball core includes (a) a conjugated diene polymer, (b) a multi-component copolymer having conjugated diene units, non-conjugated olefin units and aromatic vinyl units, and (c) an organic peroxide. The conjugated diene units include butadiene units, the non-conjugated olefin units include ethylene units, and the aromatic vinyl units include styrene units. The content of conjugated diene units with respect to the multi-component copolymer is at least 5 wt %. Golf balls having at least one core layer formed of such a rubber composition and a cover of one or more layers encasing the core exhibit improved durability to cracking on repeated impact while maintaining the basic properties required of golf balls, such as flight and spin controllability on approach shots.

The present invention provides methods for producing golf balls having polyurethane covers and the resultant balls. Multi-piece golf balls having an inner core and outer cover with one or more intermediate layers disposed between the core and cover can be formed. The methods involve producing hydroxyl-terminated adducts and isocyanate-terminated prepolymers. Thermoset and thermoplastic polyurethane compositions can be prepared. The resulting polyurethane compositions and golf ball covers have high thermal stability and good wear-resistance and durability.

A thermoplastic polyurethane composition includes a first elastomer, a second elastomer, and a third elastomer. The first elastomer includes a first material and a plurality of fiber elements. The second elastomer includes a second material. The third elastomer includes a third material and an additive. Each of the first, second, and third materials is one of polyester-based thermoplastic polyurethane, polyether-based thermoplastic polyurethane, polycarbonate-based thermoplastic polyurethane, or combinations thereof. A golf ball and a method for making the golf ball are also provided herein.

Methods of forming dual core golf ball constructions achieving consistent and repeatable concentricity by incorporating a pair of novel partially cured hemispherical shells produced using an inventive center plate button. The pair of resulting novel hemispherical shells may be collectively compression molded about and reliably center a spherical inner core there within due to the novel resulting centering features/structure provided on the inner surface of each partially cured hemispherical shell by the novel center plate button used to form same. Securing features/structure are thereby provided within/on inner surfaces of resulting partially cured hemispherical shells in order to prevent undesirable movement of the spherical inner core there within until the final compression molding step occurs.

The presently disclosed subject matter is directed to a golf ball providing improve play characteristics. The disclosed golf ball includes an outer cover comprising a plurality of divots. The disclosed golf ball further includes a central core comprising one or more lightweight materials, such as aerogel. The combination of the lightweight core and the unique divots enable the golf ball to go farther and straighter when hit by the golfer, thereby providing increased performance.

A golf ball comprising: (a) a core: (b) an outer cover layer; and (c) optionally, at least one intermediate layer, wherein at least the outer cover layer or the intermediate layer comprises a blend composition of: (i) a metallic coagent; and (ii)(a) at least one polyolefin or (ii)(b) at least one ionomer.

A method of producing a golf ball applies ultrasonic welding on two half shells to form at least one intermediate layer, at least one cover layer, or at least one intermediate layer and at least one cover layer. The ultrasonic welding may include pressing the two half shells together, delivering a high power electrical signal to a welding stack, and converting the high power electrical signal at the welding stack to ultrasonic energy. The converting may include converting the high power electrical signal into a mechanical vibration, modifying an amplitude of the mechanical vibration to generate a modified mechanical vibration, and applying the modified mechanical vibration to an interface of the two half shells to weld them together ultrasonically. Aspects also relate to golf balls, or one or more layers thereof, made using ultrasonic welding.

A method of producing a golf ball applies ultrasonic welding on two half shells to form at least one intermediate layer, at least one cover layer, or at least one intermediate layer and at least one cover layer. The ultrasonic welding may include pressing the two half shells together, delivering a high power electrical signal to a welding stack, and converting the high power electrical signal at the welding stack to ultrasonic energy. The converting may include converting the high power electrical signal into a mechanical vibration, modifying an amplitude of the mechanical vibration to generate a modified mechanical vibration, and applying the modified mechanical vibration to an interface of the two half shells to weld them together ultrasonically. Aspects also relate to golf balls, or one or more layers thereof, made using ultrasonic welding.

An object of the present invention is to provide a method for obtaining a golf ball having excellent impact durability. The present invention provides a method for producing a golf ball, comprising a first step of kneading (a) a base rubber, (b) an α,β-unsaturated carboxylic acid having 3 to 8 carbon atoms and/or a metal salt thereof as a co-crosslinking agent, (c) a crosslinkable compound having two or more polymerizable unsaturated bonds in a molecule thereof, and (d) a crosslinking initiator to prepare a core rubber composition; a second step of producing the spherical core from the core rubber composition at a molding temperature in a range from 100° C. to 150° C.; and a third step of molding the at least one cover layer covering the spherical core on the spherical core.