Abstract: The present invention is directed towards a method of forming a multilayer golf ball which comprises a core, an inner cover layer and an outer cover layer. The steps include forming a golf ball core; molding an inner cover layer around said golf ball core with a material having a first shore D hardness; and casting an outer cover layer around said inner cover layer and golf ball core with a thermoset material having a second shore D hardness less than the first. The core is comprised of a center made from a first rubber based material and an outer layer formed from a second rubber based material. Preferably, the first rubber based material has about 15 to 25 parts of a crosslinking agent per hundred parts of rubber and the second rubber based material has about 20 to 40 parts of a crosslinking agent per hundred parts of rubber.

Abstract: A casting system for a golf ball cover layer is disclosed. The system has a mix head that after dispensing the mixed material it is capable of pulling back any excess mixed material without the use of snuff-back valves. Alternatively, or additionally, the mix head of the present invention is capable of moving in one or more of directions x, y, and z. Furthermore, the system of the present invention is capable of adjusting the viscosity of the mixed material in the nozzle of the mix head. Additionally, the mix head is connected to a closed-loop flow controller that provides the mix head with accurate portions of precursors and curing agents.

Abstract: A nozzle for an injection molding machine is disclosed. The nozzle includes a nozzle body, an inner nozzle, and an outer nozzle. The nozzle defines two independent flow paths therethrough. The nozzle can simultaneously discharge two materials. A method of using the nozzle and a resulting golf ball product are also disclosed.

Abstract: A golf ball with relatively rigid inner core and soft intermediate layer is disclosed. The rigid inner core maintains the balls' high coefficient of restitution at high impact speeds, while the soft intermediate layer provides better feel for greenside play. The intermediate layer can be made from a highly neutralized polymer, which can be thermoset or thermoplastic. The highly neutralized polymer is foamed or otherwise has its specific gravity reduced. The intermediate layer can also be made from a castable reactive liquid polymer.

Abstract: The invention relates to a solid golf ball having a diameter of less than about 1.70 inches, including a core formed from a rubber base material having a resilience index of at least about 40 and an outer diameter of at least about 1.58 inches, and a cover disposed about the core formed of a material having a Shore D hardness of less than about 65.

Abstract: The present invention provides an apparatus and system for mixing castable polyurethanes for dispensing into a golf ball mold for application to a golf ball sub-assembly. The apparatus comprises a mixing block for merging together at least two polyurethane components, then a temperature control chamber to remove excess heat that is produced by the exothermic reaction resulting from the mixing of the urethane components. The mixing of the components is by passing the components through a tortuous mixing path created by a disposable static mixer element. The mixed components are dispensed into the golf ball mold by a multiple lead nozzle assembly.

Abstract: The present invention is directed to multi-layer golf balls having at least three core layers, at least one cover layer, and at least one intermediate layer between the core and the cover layer that acts as a vapor barrier. Advantageously, the at least three core layers have a hardness gradient that either increases or decreases toward the at least one intermediate vapor barrier layer.

Abstract: A golf ball having a core and a cover layer disposed about the core is disclosed. The core may further include a center and an outer core layer disposed about the center. The cover layer is formed from a composition having multiple reactive and/or non-reactive ingredients. At least one of these ingredients is a hydrogenated telechelic polycarbonate polyahl having a number average molecular weight of 2,000 to 10,000.

Abstract: A method for making a multilayer golf ball including a solid center having a center hardness, a plurality of laminates cut into a plurality of shapes formed around the center to create an inner ball, and a cover formed around the inner ball, wherein the plurality of layers can include at least a first layer having a hardness greater than the center hardness and a second layer having a hardness greater than the first layer hardness, and optionally a third layer disposed between the first and the second layers having a hardness greater than the first layer hardness.

Abstract: A golf ball having a core, a harder non-ionomer inner layer, and a cover layer. The inner layer having a material hardness of 50 Shore D to 80 Shore D, a flexural modulus of 30 to 175 kpsi, and comprising a composition that comprises a polyester elastomer. The cover layer is formed from a composition having multiple reactive and/or non-reactive ingredients, and having a material hardness of 25 Shore D to 70 Shore D and a flexural modulus of 2,000 psi to 100,000 psi. The cast cover includes a composition that comprises a hydrogenated telechelic polyhydrocarbon polyahl having a number average molecular weight of 1,500 to 10,000. The cover is a cast urethane or urea material.

Abstract: An improved mold frame for making a fast thermal response mold is disclosed. The mold frame has a plurality of rows with each row having a plurality of cavities. The mold frame is constructed of two half-molds, each half-mold containing an upper and lower plate vacuum brazed together to form flow channels that allow thermal mediums to pass in close proximity to the cavity. Without any direct contact between the flow mediums and the cavities the necessity for O-rings is eliminated. Without O-rings the compression molding of thermoplastic materials may be at temperatures greater than 300° F.

Abstract: A golf ball comprising a core; an intermediate layer having a flexural modulus of between about 65,000 psi and about 120,000 psi and being formed from a polymer blend comprising a first material selected from the group consisting of thermoset polyurethanes, thermoset polyetheresters, and thermoset polyetheramides and a second material comprising a grafted-metallocene polymer; and a cover layer comprising a castable reactive liquid thermoset polyurea.

Abstract: A multilayer golf ball including a solid center having a center hardness, a plurality of laminates cut into a plurality of shapes formed around the center to create an inner ball, and a cover formed around the inner ball, wherein the plurality of layers can include at least a first layer having a hardness greater than the center hardness and a second layer having a hardness greater than the first layer hardness, and optionally a third layer disposed between the first and the second layers having a hardness greater than the first layer hardness.

Abstract: A method for making a multilayer golf ball including a solid center having a center hardness, a plurality of laminates cut into a plurality of shapes formed around the center to create an inner ball, and a cover formed around the inner ball, wherein the plurality of layers can include at least a first layer having a hardness greater than the center hardness and a second layer having a hardness greater than the first layer hardness, and optionally a third layer disposed between the first and the second layers having a hardness greater than the first layer hardness.

Abstract: A method for reliably forming golf balls using solid cores is described. The method includes using a freezing apparatus to freeze a core. The core may be frozen at any desired temperature, for any desired duration. The time and duration may be chosen in order to achieve a desired size or effective modulus. When a core is sufficiently frozen, it may be placed in a molding apparatus. In order to minimize condensation or frost that may form on a frozen core, a dehumidifying method or apparatus may be included and a layer is preferably molded around the core soon after it is removed from the freezing apparatus.

Abstract: A multilayer golf ball including a solid center having a center hardness, a plurality of laminates cut into a plurality of shapes formed around the center to create an inner ball, and a cover formed around the inner ball, wherein the plurality of layers can include at least a first layer having a hardness greater than the center hardness and a second layer having a hardness greater than the first layer hardness, and optionally a third layer disposed between the first and the second layers having a hardness greater than the first layer hardness.

Abstract: A golf ball comprising a core and a cover disposed about the core, wherein the core comprises a center and at least one outer core layer adjacent the center, and the cover comprises at least one inner cover layer and an outer cover layer; wherein the center has an outer diameter of 0.375 inches to 1.4 inches; the outer core layer has an outer diameter of 1.4 inches to 1.62 inches; the inner cover layer has an outer diameter of 1.58 inches or greater and a material hardness of 72 Shore D or less; and the outer cover layer has a material hardness of 55 Shore D or less; and wherein the center has a first hardness, the outer core layer has a second hardness greater than the first, and the inner cover layer has a third hardness greater than the second.

Abstract: The present invention is directed to a golf ball with a core and a cover layer surrounding the core. The golf ball preferably has a weight between about 1.45 ounces and about 1.57 ounces and the core preferably has a diameter of greater than about 1.58 inches. Thus, forming a lightweight golf ball with an oversize core. In a ball with a thermoplastic cover, the core preferably has a diameter of greater than 1.61 inches. In a ball with a thermoset cover, the core preferably has a diameter of greater than 1.58 inches. This golf ball is specifically designed to optimize its play characteristics for low swing speed players. The golf ball may further include an intermediate layer disposed between the core and the cover.

Abstract: The present invention is directed towards a method of forming a multilayer golf ball which comprises a core, an inner cover layer and an outer cover layer. The steps include forming a golf ball core; molding an inner cover layer around said golf ball core with a material having a first shore D hardness; and casting an outer cover layer around said inner cover layer and golf ball core with a thermoset material having a second shore D hardness less than the first. The core is comprised of a center made from a first rubber based material and an outer layer formed from a second rubber based material. Preferably, the first rubber based material has about 15 to 25 parts of a crosslinking agent per hundred parts of rubber and the second rubber based material has about 20 to 40 parts of a crosslinking agent per hundred parts of rubber.

Abstract: The present invention is directed to a golf ball with a core and a cover layer surrounding the core. The golf ball preferably has a weight between about 1.45 ounces and about 1.57 ounces and the core preferably has a diameter of greater than about 1.58 inches. Thus, forming a lightweight golf ball with an oversize core. In a ball with a thermoplastic cover, the core preferably has a diameter of greater than 1.61 inches. In a ball with a thermoset cover, the core preferably has a diameter of greater than 1.58 inches. This golf ball is specifically designed to optimize its play characteristics for low swing speed players. The golf ball may further include an intermediate layer disposed between the core and the cover.