Abstract: A method of molding a layer of a thermoset or thermoplastic material around a golf ball component within a mold, in which the component is positioned within a mold cavity defined by opposing mold portions of the mold, to leave a cavity space between the component and the mold portions. A reaction mixture comprising at least two reactants is injected under a hydraulic pressure into the cavity space. The pressurized reaction mixture pushes the mold portions apart from each other to a partially open position with an opening therebetween. The reaction mixture is allowed to react partially within the cavity space, and then the mold portions are compressed toward each other to the closed position. The reaction mixture further reacts to form the layer of the thermoset or thermoplastic material immediately about the component.

Abstract: A method of making molds for the production of golf balls is disclosed. A hob is made having an imperfectly spherical arcuate surface that is composed of at least two different arcs in continuous arrangement to each other. A mold half is formed using the hob so that the imperfectly spherical hob creates an imperfectly spherical golf ball cavity within the mold half. When used to make golf balls, the imperfectly spherical cavity results in golf balls having a higher degree of sphericity than golf balls made by spherical hobs and mold half cavities.

Abstract: A golf ball comprising a core of one or more layers, a cover layer of one or more layers and a mantle layer disposed between the core and the cover. The mantle layer comprises a thermoplastic material, preferably having a hardness of greater than 60 Shore D and a Bashore resilience of greater than 34 and a vicat point of greater than 350° F.

Abstract: The disclosed invention provides a golf ball including a core and a cover of at least two layers, wherein the at least one cover layer includes an inner cover layer of at least one ionomer resin and an outer cover formed from a polymer blend including at least one grafted metallocene-catalyzed polymer and at least one ionomer neutralized with a metal cation, and optionally, a non-grafted metallocene-catalyzed polymer.

Abstract: A golf ball including a core; an intermediate layer formed from a polymer blend including a first material having a flexural modulus of between about 65,000 psi and about 120,000 psi and a second material including a grafted-metallocene polymer; and a cover layer formed from a castable reactive liquid material.

Abstract: A golf ball comprising a core, a barrier layer enveloping the core, and a cover enveloping the barrier layer, wherein the barrier layer has a moisture vapor transmission rate less than that of the cover, and the barrier layer comprises a thermoplastic or thermoset composition of microparticles dispersed in a binder.

Abstract: The present invention is directed towards a method of manufacturing a multi-layered golf ball, with at least an inner cover having multiple layers formed by a sandwich injection molding process. The multi-layered inner cover comprises an inner layer and an outer layer of a first material and an intermediate layer therebetween of a second material. The materials having different properties.

Abstract: The present invention is directed to a golf ball with a core and a polymeric layer reinforced with relatively long fibers. Such layer can be the cover, a portion of the cover, an intermediate layer, a portion of the intermediate layer, or any layer in the golf ball. Preferably, this layer comprises relatively long fibers embedded in a thermoplastic matrix to increase the flexural modulus and the impact resistance of the thermoplastic. The fibers may be arranged in random or non-random pattern in the layer.

Abstract: This invention is directed to golf balls including one or more foamed, microcellular materials. The invention also encompasses methods of controlling or adjusting one or more material properties or the weight distribution of a golf ball, and methods of forming golf balls including such microcellular materials.

Abstract: The present invention is directed towards a multi-layered golf ball, at least the inner cover having multiple layers formed by a sandwich injection molding process, wherein each multi-layered cover comprises an inner layer and an outer layer of a first material and an intermediate layer therebetween of a second material. The materials having different properties. An embodiment of the invention includes both covers being multi-layered formed by the sandwich injection molding process.

Abstract: A golf ball comprising a core, an intermediate layer, and a cover layer; wherein the intermediate layer is formed of a polymer blend comprising an ionomer having at least about 16% acid groups and a grafted-metallocene polymer; and the cover layer comprises a castable reactive liquid material. Optionally, a non-ionomer may be blended with the polymer blend or, in an alternative, the high acid ionomer may be blended solely with the non-ionomer.

Abstract: The present invention is directed towards a multi-layer golf ball which comprises a core, a cover layer and at least one intermediate layer disposed between the core and cover, wherein the intermediate layer comprises a polyether-type polyurethane and optionally, a second thermoplastic component such as polyetherester block copolymer, polyesterester block copolymer, polyetheramide block copolymer, dynamically vulcanized thermoplastic elastomer, functionalized styrene-butadiene elastomer, thermoplastic polyurethane, thermoplastic polyesters, metallocene polymer or blends thereof and a density-modifying filler such as zinc oxide, titanium dioxide or blends thereof.

Abstract: The disclosed invention provides a golf ball including a core and a cover of at least two layers, wherein the at least one cover layer includes an inner cover layer of at least one ionomer resin and an outer cover formed from a polymer blend including at least one grafted metallocene-catalyzed polymer and at least one ionomer neutralized with a metal cation, and optionally, a non-grafted metallocene-catalyzed polymer.

Abstract: The present invention is directed towards a multilayer golf ball which comprises a core, an inner cover layer and an outer cover layer, wherein the outer cover layer comprises a castable reactive liquid material having a shore D hardness less than the shore D hardness of the material forming the inner cover layer. The present invention also relates to golf balls having improved adhesion between adjacent layers, as well as method for making golf balls having such improved adhesion. In particular, the outer surface of the core, an intermediate layer(s) or both the core and the intermediate layer(s) has a textured surface profile integrally molded in the outer surface thereof so that the surface profile promotes interfacial adhesion.

Abstract: The invention provides a method for making a golf ball. Two cups are molded from an elastomer separately from an inner sphere. In one embodiment of the method, the cups are molded on both sides of a single mold part with hemispherical protrusions that form cavities in the cups. An inner sphere is placed within the cavities, and the cups are joined, by preferably crosslinking the cups together or applying adhesive there between. To retain the characteristics of the cup material where the cups meet, an embodiment of the cups can be formed with nonplanar mating surfaces that mesh with each other. The nonplanar mating surfaces preferably have a pattern that is symmetrical about the inner sphere, such as concentric ridges, for example a tongue and a groove.

Abstract: A golf ball comprising a core and a cover layer, wherein the core has an outer diameter of no greater than about 1.62 inches; the cover layer comprises an inner cover layer and an outer cover layer having a material hardness of less than about 60 Shore D; and at least one of the core or the cover comprises high-Mooney-viscosity rubber, high-Mooney-viscosity rubber regrind, or a mixture thereof.

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 comprising a core, an intermediate layer and a cover, wherein the intermediate layer has a moisture vapor transmission rate that is lower than that of the cover and, additionally, a primary ingredient of the intermediate layer is made from a material including polybutadiene, natural rubber, butyl-based rubber, acrylics, trans-polyisoprene, neoprene, chlorinated polyethylene, balata, multi-layer thermoplastic films, blends of ionomers, polyvinyl alcohol copolymer and polyamides, and dispersions of acid salts of polyetheramines.

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: A golf ball including a solid core having an outer diameter of less than about 1.59 inches; an outer cover layer having a first material hardness and including a urethane elastomer formed from a castable reactive liquid material; and a casing disposed between the core and the cover layer, the casing including polyurea and having an outer diameter of between about 1.59 inches and about 1.64 inches and a second material hardness of between about 30 and about 70 Shore D; wherein a ratio of the second material hardness to the first material hardness is greater than 1.5.