The present invention is directed to a golf ball having a cover in which the dimples have two distinct hardness regions. The cover of the present invention is formed from a castable formulation including at least one prepolymer that incorporates some degree of unsaturation in the backbone of the polymer, at least one curative, and at least one free radical initiator. The present invention also explores the methods of making such golf balls. The methods of the present invention allow for the production of a golf ball dimple with two distinct hardnesses to be formed using a single castable formulation.

Improved injection molding methods and molds, for forming TPU layers, especially thin TPU covers, into golf ball constructions, and having improved number, shape and placement of both the injection gates and the cold slugs within the mold in order to minimize/eliminate damage to dimples strategically positioned close to the parting line of a mold in order to maximize aerodynamic properties of the resulting golf ball.

Golf ball comprising a core, an outer layer and at least one adhesion promoting coating disposed between each of the core and the outer layer; the core comprising a rubber composition comprising at least one zinc-containing and/or magnesium-containing component; the outer layer comprising at least one ionomer; and the adhesion promoting coating comprising a waterborne dispersion comprised of at least one ethylene acid copolymer having an acid content of at least 15% by weight wherein the copolymer is at least partially neutralized with one or more neutralizing agent; wherein at least one neutralizing agent is selected from ammonia compounds and/or amine compounds. In a specific embodiment, the at least one neutralizing agent comprises i) mono and/or divalent metal compounds and ii) ammonia compounds and/or amine compounds.

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

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.

Golf ball molds and methods for molding golf balls, particularly golf balls having thermoplastic polyurethane covers, are provided. The molds and methods are particularly suitable for manufacturing covers for golf balls. Multi-piece golf balls having inner cores, outer cores, inner covers, and intermediate layers can be made. Retractable pins are used for holding the golf ball within the mold, wherein each retractable pin has a primary vent section, secondary vent section, and tertiary vent section for removing air and other gasses from the interior spherical cavity of the mold.

A golf ball material contains (i) fine particles that have an average particle size of less than 300 μm and are composed of a crosslinked multi-component copolymer having conjugated diene units, non-conjugated olefin units and aromatic vinyl units; and (ii) a thermoplastic resin. The conjugated diene units include butadiene units, the non-conjugated olefin units include units selected from the group consisting of ethylene, propylene and 1-butene units, the aromatic vinyl units include styrene units, and the content of the conjugated diene units in the multi-component copolymer is 5 wt % or more. This golf ball material is soft, has an excellent rebound resilience and also has a good processability.

In an aspect, a sports ball includes a core including a negative Poisson's ratio (NPR) foam material, in which the core has a Poisson's ratio of between 0 and −1, and in which the NPR foam material includes an NPR polymer foam; and a cover layer surrounding the core. In an aspect, a golf club includes an elongated shaft; a grip disposed at a first end of the elongated shaft; and a head connected to a second end of the elongated shaft, the head having a flat face configured for contact with a golf ball, in which the flat face is formed of a negative Poisson's ratio (NPR) foam material, in which the head has a Poisson's ratio of between 0 and −1, and in which the NPR foam material includes an NPR metal foam, an NPR ceramic foam, or an NPR-PPR composite foam.

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.

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.