GOLF BALLS WITH ELECTRONIC COMMUNICATION COMPONENTS AND METHODS FOR MAKING THEM

Abstract

A method for manufacturing a golf ball. The method includes creating a core with a cavity therein and positioning electronics in the cavity. The method further includes filing the cavity with a fill material while the electronics are positioned in the cavity such that the core, the electronics, and the fill material together form a spherical body, and such that when the fill material is cured the spherical body is balanced about a center thereof. The method further includes curing the fill material and covering the spherical body with an exterior cover.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/270,320, filed Oct. 21, 2021, which is incorporated herein by reference in its entirety.

FIELD

The present disclosure relates to golf balls and methods for making them, and particularly golf balls with electronic communication components.

BACKGROUND

This section includes discussion intended to help understand various aspects of the subject matter presently disclosed below. This discussion should not be interpreted as constituting an admission of prior art.

Golf balls are used by golfers while playing the game of golf, and most golfers tend to lose at least one golf ball per round of golf. The golf balls can be lost due to errant shots that cannot be located by the golfer. For example, the golf ball may come to rest in the water, under a bush, in a dense marsh area, or in tall grass. When the golf ball is lost, the golfer is assessed penalty strokes per the rules of golf and must use a second golf ball.

U.S. Pat. No. 7,691,009 entitled Apparatuses and Methods Relating to Findable Balls discloses golf balls for use with a system for finding golf balls and methods for making such golf balls. In the case of one exemplary golf ball, the ball includes a shell, a core material and a tag having a diode which is coupled to an antenna which has at least a portion formed from an elastic conductive material, such as an elastic conductive ink. The core material may include a void for receiving at least part of the diode. Other golf balls are described and methods for making balls are also described.

U.S. Pat. No. 10,213,646 entitled System for Locating a Golf Ball discloses a golf ball with an outer casing has an electronic device housed in a plastic core and includes at least one receiver, a microelectronic device for evaluating and forwarding the received signals and a transmitter and/or receiver. The transmitter or receiver can communicate with a separate electronic device worn by the user. The invention will enable a player to easily find and locate a ball that is not lying on the fairway that cannot be spotted or found with the naked eye.

U.S. Pat. No. 10,716,971 entitled Game Implements and System for Tracking or Locating Same discloses a system for locating an electronic game implement such as an electronic golf ball. The electronic game implement has an outer shell and internal core, with the core containing graphene coated electronics and a battery, wherein the associated electronics of the electronic game implement includes a processor and transceiver configured to measure data including acceleration, speed, travel trajectory and final location while also being configured to transmit the measured data via a communications protocol. The ball or sports game implement that includes the associated electronics are also an embodiment of the invention. The system includes a smart device having associated electronics to communicate with the electronic game implement ball, with the associated electronics of the smart device including a processor configured to receive the measured data from the electronics of the electronic game implement.

U.S. Pat. No. 11,167,180 entitled Smart Ball, Locator System and Method therefor discloses a wireless signal transmitting ball to be used in practice or gameplay of a sport and/or other entertainment activities. The ball of the disclosure comprises a microprocessor unit configured to record, process, and transmit data to a paired device. Further disclosed is a method of actuating the ball between different modes. The ball could be used by players during practice to record data about their performance. The ball could also be used by players or game officials or referees to keep score, adjudicate and decide the gameplay. For example, the information about location of the ball could be used to track balls that could potentially be lost. Additionally, data about spin, trajectory, speed, force applied, and the like could be used by players or broadcasters for gaining insights to add to viewing pleasure.

SUMMARY

This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

One embodiment of the present disclosure generally relates to a method for manufacturing a golf ball. The method includes creating a core with a cavity therein and positioning electronics in the cavity. The method further includes filing the cavity with a fill material while the electronics are positioned in the cavity such that the core, the electronics, and the fill material together form a spherical body, and such that when the fill material is cured the spherical body is balanced about a center thereof. The method further includes curing the fill material and covering the spherical body with an exterior cover.

Another embodiment generally relates to another method for manufacturing a golf ball. The method includes providing a spherical core of a first material and providing electronics configured to provide wireless communication. The method further includes machining a cavity in the spherical core so as to accommodate the electronics and a fill material and filling the cavity with the fill material while the electronics are positioned in the cavity. The fill material is different than the first material of the spherical core. The method further includes curing the fill material, where the core, the electronics, and the fill material together form a spherical body, and covering the spherical body with an exterior cover. The fill material is selected such that when cured, the spherical body is balanced about a center thereof.

Another embodiment generally relates to a golf ball having a spherical core of a first material, whereby the spherical core has a cavity therein. Electronics are positioned in the cavity, whereby the electronics include a transmitter for wireless communication. A fill material is positioned in the cavity such that the cavity is entirely filled with the electronics and the fill material. The fill material is different than the first material. The spherical core, the electronics, and the fill material together form a spherical body. An exterior cover covers the spherical body.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a golf ball according to the present disclosure, which includes electronic communication components therein;

FIG. 2 is right side view of the golf ball of FIG. 1 with a 90-degree section removed to reveal an interior of the golf ball, including a core and the electronic communication components;

FIG. 3 is an isometric view of one example of electronic communication components such as may be incorporated within a golf ball according to the present disclosure;

FIG. 4 is an exploded isometric view showing a simplified depiction of electronic communication components as shown in FIGS. 1 and 2;

FIG. 5 is a schematic view of a control system including operating electronic communication components such as shown in FIGS. 3 and 4;

FIG. 6 is a flow chart depicting a method for making a golf ball according to the present disclosure;

FIG. 7 is a flow chart depicting another method for making a golf ball according to the present disclosure;

FIG. 8 is a right-side view of a core of a golf ball such as shown in FIG. 2, without electronic communication components within a cavity in the core;

FIG. 9 is a right-side view of the core of FIG. 8 with electronic communication components within the cavity in the core;

FIG. 10 is a right-side view of the core of FIG. 8 with fill material cured within the cavity in the core;

FIG. 11 is a front view of the core with the fill material cured within the cavity shown in FIG. 10; and

FIG. 12 is a front view of the core of FIG. 11 after contouring the fill material and covering the core with an exterior cover.

DETAILED DESCRIPTION

The present inventors have recognized that a golfer may lose one or more golf balls during a round of golf, and thus, it would be advantageous to develop a golf ball that can be electronically located by the golfer. Locating a golf ball that would otherwise be lost saves the golfer money as the golfer would lose fewer golf balls during a round of golf and thus would need to purchase less replacement golf balls. Likewise, an electronically located golf ball would reduce the time spent searching for the lost ball, saving the golfer's time and those behind golfer on the golf course. Moreover, having the ability to locate a missing golf ball would minimize or eliminate the lost ball penalty strokes assessed to the golfer, improving the golfer's score and game.

The present inventors have observed that conventional golf balls have been made with a variety of materials since the inception of the game of golf. For example, golf balls have been made with wood, rubber, and plastic. More recently, modern golf balls are made of urethane core and a plastic shell.

Modern golf balls typically have two or more components. In particular, a golf ball may include a urethane core and a plastic cover. These golf balls are generally referred to as two-part golf balls. The chemical makeup of urethane or polyurethane can be altered by golf ball designers that seek to change the physical properties of the urethane, and in the turn the golf ball, such as durometer (hardness) and density. For instance, foaming agents can be added to the urethane to change its chemical makeup. Note that it many instances, the urethanes used in modern golf balls are typically thermosets rather than thermoplastics which makes the urethane incompatible with standard conventional injection molding processes. Two-part urethane systems often require elevated temperatures to properly cure.

In addition, the two or more layers of a golf ball can have different durometers and/or densities relative to each other. In some constructions, these layers are formed by consecutive molding processes in which layers are molded over one another resulting in distinct transitions between the layers. Other golf balls, such as the Titleist ProV1, have a diffuse transition layer between larger layers that aims to eliminate sharp material changes between the larger layers when shockwaves waves propagate through the golf ball when struck with a club.

The evolution of the materials used to form golf balls indicates that prior golf ball designers often endeavored to improve the performance of the golf ball by changing the materials used to form the golf ball. The designers also may seek to optimize many factors and parameters such as how well the golf ball returns energy when hit with a driver (e.g., how far one can drive the golf ball), how well the golf ball is balanced, polar moment of inertia of the golf balls, responsiveness/predictability of putt hits, and the like.

The present inventors endeavored to develop the improved golf balls of the present disclosure (described herein below) that perform well in use while also being configured to be electronically located by the golfer. Additional details regarding the electronic components that facilitate electronic communications between the user and the golf ball are also provided below.

In view of this, the present inventors have recognized challenges in incorporating electronic components within the golf ball, which require several considerations to be considered when designing the golf ball. For example, while golf balls can be formed from many different materials (as illustrated by the different golf ball constructions briefly noted above), private organizations, such as the United States Golf Association (USGA), have rules that govern certain form factors of golf balls. The rules set forth by the USGA specify that the golf ball must have a minimum outside diameter of 1.680 inches and a maximum weight of 1.620 ounces. Only golf balls that conform to these rules may be used in USGA sanctioned competitions. Many local golf clubs and organization also follow the rules set forth by the USGA. Therefore, the USGA rules apply to many golfers at many different skill levels and are thereby important to consider when designing a golf ball.

Furthermore, the weight of the golf ball is preferably balanced about all axes to avoid weight inconsistences that could change the spin of the golf ball during flight (or when putting) and thus change the direction the ball travels. The golf ball may also have varying hardness along different radii. In this case, it is preferable that the rate of hardness change is consistent along all radii. Hardness rate non-homogeneity along one or more of the axes could cause inconsistencies between hits or prevent symmetrical shockwave propagation through the golf ball which could cause the golf ball to fly at an unexpected angle.

Accordingly, through research and experimentation, the present inventors developed the golf balls 2 described herein below. FIGS. 1 and 2 shows a completed golf ball 2 according to the present disclosure. The golf ball 2 extends from a center 4 to an outer surface 6 along an X-axis, a Y-axis, and a Z-axis that are each perpendicular to each other. FIG. 1 shows a front view in which the Z-axis extends into the page and FIG. 2 shows a side view in which the X-axis extends into the page. FIG. 2 also shows a section removed to reveal an interior of the golf ball 2. The golf ball 2 is also shown rotated slightly about the Z-axis to provide a perspective view of components inside the golf ball 2, discussed further below.

The golf ball 2 is generally spherical and includes a cover 10 that surrounds a generally spherical core 12. A center of the core 12 is coincident with the center 4 of the golf ball 2. The core 12 extends between the center 4 and an outer surface 14 that is radially inward of the outer surface 6 of the golf ball 2 as a whole. The core 12 comprise a urethane material. An inner surface 16 of the cover 10 surrounds the outer surface 14 of the core 12. A cavity 20 extends into the core 12 from the outer surface 14 to a position beyond the center 4. The cavity 20 has a top surface 22, a bottom surface 24, side surfaces 26, and an end surface 28. In the embodiment shown, the electronics assembly 30 (also referred to as electronics, discussed below) rest upon the bottom surface 24 and, in certain embodiments, abuts the end surface 28. The side surfaces 26 of the cavity 20 have a shelf 32 corresponding to a shape of the electronics assembly 30. The end surface 28 of the cavity 20 extends beyond the center 4 such that the electronics assembly 30 can be centered within the golf ball 2 along at least the X-axis and the Z-axis when positioned in the cavity 20. A fill material 40 is also provided within the cavity 20, which for clarity is omitted in FIG. 2.

FIG. 3 shows an example of electronics assembly 30 separate from the golf ball 2, which as discussed above is configured for wirelessly communicating the location of the golf ball 2 to the user. The electronics assembly 30 include a battery 34, a printed circuit board (PCB) 36, and an integrated circuit (IC) 38. In one example, the battery 34 is a CR1025 coil cell battery manufactured by Digikey. The battery 34 may be rechargeable, such as by positioning the golf ball 2 within a cradle that charged the battery 34 via induction in a similar manner to modern smart phones and electric toothbrushes.

The electronics assembly 30 further includes a wireless transmitter or a wireless transceiver 35 configured to wirelessly communicate with a user interface device, such as a personal cellular phone or a handheld golf ball tracking unit. By way of example, the electronics assembly 30 may communicate wirelessly using a Bluetooth® low energy integrated circuit (BTLE) or another wireless communication device that communicate via Bluetooth®, near-field communication (NFC), Wi-Fi, and/or other wireless communication protocols known in the art. In certain configurations, NFC is used to initially connect to and configure the golf ball 2 to activate the golf ball 2 for use. In further embodiments, the golf ball 2 may be specifically configured for use for a particular round, such as a particular hole or golf course.

With continued reference to FIG. 3, the electronics assembly 30 further includes a GPS module 37 for determining the GPS location of the golf ball 2 in a manner known in the art. Other types of location detectors may be used in addition to, or as an alternative to, the GPS module 37 for determining the location of the golf ball 2 using techniques known in the art. The electronics assembly 30 of FIG. 3 further includes a sensor 39 (e.g., an accelerometer) that is configured to detect an impact of the golf ball 2, such as when the golf ball 2 is struck by a driver. Likewise, other conventionally known components may also be provided with the electronics assembly 30. A simplified version of the electronics assembly 30 is shown in FIG. 4 for showing in subsequent figures, particularly for being shown within the cavity 20 in the golf ball 2.

In certain embodiments, the electronics assembly 30 is configured such that when the sensor 39 detects an impact of the golf ball 2 (e.g., via a golf club), the wireless transceiver 35 is powered on or otherwise activated to begin transmitting the location of the golf ball 2. This preserves the power of the battery 34, extending the life of the golf ball 2. Similar power savings may also be provided for the GPS module 37, which also be powered on or awoken from a low power standby mode upon impact via detection by the sensor 39. The detected impact may also be used to record and/or report that a “hit” has occurred. In certain embodiments, metrics such as flight time may be calculated by detecting the first impact corresponding to the hit, then a subsequently impact when the golf ball 2 hits the ground again.

The wireless transceiver 35 and/or GPS module 37 may be configured to remain powered on for a pre-determined time following the detected impact, such as 5 minutes. Other power saving features may include sending at different communication rates after the impact is detected or sending at different rates as a function of how long ago the impact was detected. For example, the location of the golf ball 2 may communicated every 5 seconds within the first 5 minutes after detecting an impact, then every 10 seconds between 5 and 10 minutes after impact, every 30 seconds from 10 minutes to 15 minutes, and off after 15 minutes.

In general, the electronics assembly 30 may be configured like the control system 100 of FIG. 5. The control system 100 of FIG. 5 includes a processing system 110 (which may be generally equivalent to the IC 38), a memory system 120, and an I/O system 130 as discussed further below. The I/O system 130 may include the wireless transceiver 35 discussed above for wirelessly communicating with the golf ball 2. By way of example, a smart phone, smart watch, and/or tablet may function as an input device 99 and/or output device 101 communicating with the control system 100 (and the electronics assembly 30 more generally).

Additional information is now provided for control systems 100 and communication with the electronics assembly 30 and the golf ball 2 more generally. Certain aspects of the present disclosure are described or depicted as functional and/or logical block components or processing steps, which may be performed by any number of hardware, software, and/or firmware components configured to perform the specified functions. For example, certain embodiments employ integrated circuit components, such as memory elements, digital signal processing elements, logic elements, look-up tables, or the like, configured to carry out a variety of functions under the control of one or more processors or other control devices. The connections between functional and logical block components are merely exemplary, which may be direct or indirect, and may follow alternate pathways.

In certain examples, communication amongst and between components within the control system 100, as well as with input device 99 and output device 101, is provided via a communication link CL. The communication links CL may be wired (e.g., within the electronics assembly 30) or wireless (e.g., communication with output devices 101 such as smart phones). The control system 100 is capable of receiving information and/or controlling one or more operational characteristics of the electronics assembly 30 and its various sub-systems by sending and receiving control signals via the communication links CL. It will be recognized that the extent of connections and the communication links CL may in fact be one or more shared connections, or links, among some or all of the components in the electronics assembly 30. Moreover, the communication link CL lines are meant only to demonstrate that the various control elements are capable of communicating with one another, and do not represent actual wiring connections between the various elements, nor do they represent the only paths of communication between the elements. Additionally, the electronics assembly 30 may incorporate various types of communication devices and systems, and thus the illustrated communication links CL may in fact represent various different types of wireless and/or wired data communication systems.

The control system 100 may be a computing system that includes a processing system 110, memory system 120, and input/output (I/O) system 130 for communicating with other devices, such as input devices 99 and output devices 101, either of which may also or alternatively be stored in a cloud 102. The processing system 110 loads and executes an executable program 122 from the memory system 120, accesses data 124 stored within the memory system 120, and directs the electronics assembly 30 to operate as described in further detail below.

The processing system 110 may be implemented as a single microprocessor or other circuitry or be distributed across multiple processing devices or sub-systems that cooperate to execute the executable program 122 from the memory system 120. Non-limiting examples of the processing system include general purpose central processing units, application specific processors, and logic devices.

The memory system 120 may comprise any storage media readable by the processing system 110 and capable of storing the executable program 122 and/or data 124. The memory system 120 may be implemented as a single storage device or be distributed across multiple storage devices or sub-systems that cooperate to store computer readable instructions, data structures, program modules, or other data. The memory system 120 may include volatile and/or non-volatile systems and may include removable and/or non-removable media implemented in any method or technology for storage of information. The storage media may include non-transitory and/or transitory storage media, including random access memory, read only memory, magnetic discs, optical discs, flash memory, virtual memory, and non-virtual memory, magnetic storage devices, or any other medium which can be used to store information and be accessed by an instruction execution system, for example.

As discussed above, the electronics assembly 30 together provide the functions of the golf ball 2 described herein. Based on the USGA's rules related to the minimum outside diameter and maximum weight, the outside diameter of the golf ball 2 is 4.3 cm (1.68 in) and the weight of the golf ball 2 is 45.9 g (1.62 oz). Thus, the average density of the golf ball 2 will be 1.13 grams per cubic centimeter (g/cc). However, the present inventors recognized that the inclusion of the electronics assembly 30 within the golf ball 2 requires the core 12 of the golf ball 2 to be modified further in order to meet the USGA rules and also maintain a weight balance within the golf ball 2. As such, the densities of the core 12, the electronic assembly 30, and the fill material 40 may all be different, for example with the density of the core 12 equaling the sum of the densities of the electronic assembly 30 and the fill material 40 (when cured).

In one example, the electronics assembly 30 has a volume of 1.31 cubic centimeter (cc) and a mass of 3.61 grams (g). Table 1 below lists the components of the electronics assembly 30 and corresponding volumes and weights.

TABLE 1
Component of the
electronics assembly 30	Volume (cc)	Mass (g)	Density (g/cc)
IC	0.03	0.07	2.00
Battery	0.79	2.60	3.31
PCB	0.49	0.94	1.90
Electronics assembly	1.31	3.61	2.75
30 total=

It will be recognized that golf ball design can and does include varying materials, hardness, or density along a radius through the golf ball. However, performance is often related to the consistency of these changes about all radii of the golf ball. Looking to FIG. 1, it is noted that while the radii of the X-axis and the Z-axis are similar, the radii of the Y-axis is different, both from the X-axis and the Z-axis, but also in opposite directions along the Y-axis. Therefore, still further examples of the golf ball 2 as disclosed herein create an insert comprising the electronics assembly 30 and ballast of fill material 40 that provides symmetrical physical properties (e.g., one or more of mass, volume, density, hardness) along not only the X-axis, Y-axis, and Z-axis, but along intermediate radii as well.

However, as noted above, the total volume and mass of the golf ball 2 must also meet the USGA (or other) specifications and also must be balanced about the center of the ball to provide desired performance. In examples, the electronics assembly 30 may have a greater density due to the battery 34 and other components compared to the urethane materials of core 12. Thus, the mass of the core 12 may need to be adjusted and or balanced, including the use of a ballast, also referred to as fill material 40, to either increase or decrease the mass of the combined core 12 and fill material 40 and to balance the combination of the core 12, fill material 40, and electronics assembly 30 about the center of the core 12 (and thus, about the center 4 of the golf ball 2). The fill material 40 thus may be a void or low-density urethane material, while in other examples, the fill material 40 may be a high-density urethane material or further include weights (not depicted) to balance the mass of the electronics assembly 30.

In the example of FIGS. 1 and 2, a void 42 remains within the cavity 20 in the core 12 of the golf ball 2 after the electronics assembly 30 is positioned within the cavity. The electronics assembly 30 may be positioned in the cavity 20 so as to be balanced in one, two, or all three axes when the void 42 has not yet been filled by the filling material 40. The core 12 is configured such that volume of the void 42 corresponds to a volume of the material forming the core 12 that equals the mass of the electronics (in this example, 3.61 grams). The void 42 is exemplarily filled with fill material 40 of an associated density to achieve the overall physical requirements noted above. example, if the fill material 40 is the same volume as the electronics (e.g., 1.31 cc), then a mass of 2.96 g will produce the same average density of the combined ballast (fill material 40) and the electronics assembly 30 as the overall ball specification (e.g., 1.13 g/cc). In this manner, the golf ball 2 as a whole is balanced about its center 4 along all three axes when the electronics assembly 30 is positioned in the cavity and the electronics assembly 30 and the fill material 40 together entirely fill the cavity 20.

It will be recognized that in a further example, the core 12 of the golf ball 2 may be more or less dense, and therefore, the ballast may be adjusted to balance the physical properties of the electronics assembly relative to specified physical properties of a portion of the golf ball instead of the golf ball as a whole. Moreover, it should be recognized that the present disclosure also contemplates configurations in which the fill material 40 and the electronics assembly 30 are together balanced about the center 4 of the golf ball 2 along fewer than all three axes, including being balanced along one axes or two axes.

Additional information is now provided for how to make golf balls 2 according to the present disclosure. Known techniques manufacturing golf balls involve an automated multiple-step manufacturing process that builds layers around a hard spherical molded core of natural rubber or synthetic rubber, collectively rubber. The core of the golf ball is typically the densest layer in the construction and therefore the portion of the manufacturing process to create the core uses the most heat and pressure. The present inventors have discovered that such conditions limit manufacturing achievement of the ball construction described above, particularly as these known techniques would damage or destroy the electronics assembly 30 described above. In other words, the presently disclosed golf ball 2 cannot be made via methods presently known in the art.

Therefore, a new manufacturing process has been developed and will be described herein. FIG. 6 depicts a method 200 for making a golf ball 2 according to the present, which can be viewed with reference to the elements described above and shown in FIGS. 1 and 2. Step 202 provides for creating a core 12 with a cavity 20 therein, the result of which is exemplified in FIG. 8. By way of example, the core 12 may be manufactured by heating a fixed amount of the rubber material and molding it under pressure to form the core 12. In the method 200 of FIG. 6, instead of progressing to the manufacture of the additional layers, the core 12 is removed and cooled. A pocket or cavity 20 is then machined into the core 12, whereby the cavity 20 is of a volume configured to receive the electronics assembly 30 and the ballast or fill material 40 as previously described. The present disclosure also contemplates methods in which the cavity 20 is formed with the formation of the core 12, rather than the cavity 20 being subsequently machined. By way of example, this may be achieved by 3D printing a core 12 so as to include the cavity 20 from the onset.

In step 204, the electronics assembly 30 is positioned within the cavity 20, which may be centered along one, two, or three axes within the core 12, as exemplified in FIG. 9. With continued reference to FIG. 6, step 206 provides for filling the cavity 20 with the fill material 40 (e.g., urethane that cures at the density needed to serve as the ballast) while the electronic assembly 30 is positioned in the cavity 20. The fill material 40 may be injected into the cavity 20 so as to surround the electronics assembly 30, and such that the core 12, the electronics assembly 30, and the fill material 40 together form a spherical body 13 that when cured will be balanced about the center of the spherical body 13.

With continued reference to FIG. 6, step 208 provides for curing the fill material 40, which may be performed by the passage of time, using heat, ultra-violet light, or other techniques known in the art (exemplified in FIG. 10). It should be recognized that the fill material 40 may be more than one material, for example with a first material being injected to fill the cavity 20 in the region balanced about the center 4 of the golf ball 2, with a second material used to fill the remainder of the cavity 20 (i.e., from the portion of the cavity 20 radially outwardly from the electronics assembly 30). Likewise, other ballasts may be included within the cavity 20 in addition to the fill material, such as an additional weight positioned at a determined location within the cavity 20 and effectively sealed therein via the fill material 40.

In certain embodiments, the fill material 40 when cured expands and thus extends outwardly from the outer surface 14 of the core 12. In this case, the method may further include the step of removing the excess material 44 (e.g., via a blade 46) such that the fill material 40 is contoured to match the outer surface 14 of the core 12. The core 12 and the fill material 40 therefore together form the spherical body 13 (as exemplified in FIG. 11).

Returning to the method 200 of FIG. 6, step 210 provides for covering the spherical body with the cover 10, which may be dimpled like a conventional golf ball. The cover 10 may be provided around the spherical body 13 of the core 12 and the fill material 40 via injection molding or compression molding in a conventional manner without the heat and/or pressure damaging the electronic assembly 30. The completed golf ball 2 produced according to method 200 is exemplified by FIG. 12.

Another method 300 is provided in FIG. 7. In step 302, a spherical core is provided as the core 12, which comprises a first material. In step 304, the electronics assembly 30 is provided, the electronics assembly 30 being configured to provide wireless communication via the techniques described above. The core 12 is machined in step 306 to create a cavity 20 therein. In particular, the cavity 20 is machined so as to accommodate the electronics assembly 30 and the volume of fill material 40 needed to (when cured) provide for a balance combination of the core 12, the electronics assembly 30, and the fill material 40.

In step 308, the cavity 20 is filled with the fill material 40, which is different than the first material of the core 12, while the electronics assembly 30 is positioned in the cavity 20. As discussed above, the fill material 40 is selected such that when cured, the volume of the fill material 40, the core 12, and the electronics assembly 30 form a spherical body 13 that are balanced about a center of the spherical body 13. As also discussed above, the balance about the center of the spherical body 13 may be only after excess fill material extending beyond the outer surface 14 of the core 12 is trimmed and contoured to match the curved outer surface 14 of the core 12. The fill material 40 is cured in step 310, followed by covering the spherical body 13 with the cover 10 in step 12.

In this manner, the presently disclosed golf balls provide for electronic communication of their locations with a user, but without sacrificing homogeneity and balance from incorporating the electronic assemblies within the golf balls. In particular, the presently disclosed golf balls and methods for making them provide for restoring balance and recreating the correct spring-force response through the golf ball, despite the addition of the electronics assembly, via the proper positioning and combination of carefully selected materials.

In the present description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different apparatuses, systems, and method steps described herein may be used alone or in combination with other apparatuses, systems, and methods. It is to be expected that various equivalents, alternatives, and modifications are possible within the scope of the appended claims.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A method for manufacturing a golf ball, the method comprising:

creating a core with a cavity therein;

positioning electronics in the cavity;

filing the cavity with a fill material while the electronics are positioned in the cavity such that the core, the electronics, and the fill material together form a spherical body, and such that when the fill material is cured the spherical body is balanced about a center thereof;

curing the fill material; and

covering the spherical body with an exterior cover.

2. The method according to claim 1, wherein creating the core comprises machining the cavity into a solid base material.

3. The method according to claim 1, wherein three axes intersect through a center of the golf ball, each of the three axes being perpendicular to the others, wherein the electronics are positioned in the cavity so as to be unbalanced about the center along one of the three axes, and wherein the cavity is filled with the fill material such that the golf ball is balanced about the center thereof along each of the three axes.

4. The method according to claim 1, wherein the core, the electronics, and the fill material each have a density, respectively, and wherein the fill material is selected such that the density of the core equals a sum of the densities of the electronics and the fill material.

5. The method according to claim 1, wherein the fill material is selected as two materials having differing densities.

6. A method for manufacturing a golf ball, the method comprising:

providing a spherical core of a first material;

providing electronics configured to provide wireless communication;

machining a cavity in the spherical core, the cavity being machined to accommodate the electronics and a fill material;

filling the cavity with the fill material while the electronics are positioned in the cavity, the fill material being different than the first material of the spherical core;

curing the fill material, wherein the core, the electronics, and the fill material together form a spherical body; and

covering the spherical body with an exterior cover;

wherein the fill material is selected such that when cured, the spherical body is balanced about a center thereof.

7. The method according to claim 6, wherein the spherical core is molded of melted rubber as the first material.

8. The method according to claim 7, further comprising cooling the spherical core before machining the cavity therein.

9. The method according to claim 8, further comprising curing the spherical core before machining the cavity therein.

10. The method according to claim 6, further comprising contouring the fill material once cured such that the core and the fill material together form the spherical body.

11. The method according to claim 6, wherein the spherical core, the electronics, and the fill material each have a density, respectively, and wherein the fill material is selected such that the density of the spherical core equals the sum of the densities of the electronics and the fill material.

12. A golf ball comprising:

a spherical core of a first material, the spherical core having a cavity therein;

electronics positioned in the cavity, the electronics comprising a transmitter for wireless communication;

a fill material positioned in the cavity such that the cavity is entirely filled with the electronics and the fill material, the fill material being different than the first material, and wherein the spherical core, the electronics, and the fill material together form a spherical body; and

an exterior cover covering the spherical body.

13. The golf ball according to claim 12, wherein the first material is a thermoset.

14. The golf ball according to claim 12, wherein the fill material entirely surrounds the electronics within the cavity.

15. The golf ball according to claim 12, wherein the golf ball is spherical and balanced about a center thereof, wherein three axes intersect through the center, each of the three axes being perpendicular to the others, and wherein the electrics are unbalanced about the center along at least one of the three axes.

16. The golf ball according to claim 15, wherein the fill material and the electronics are together balanced about the center along the at least one of the three axes.

17. The golf ball according to claim 12, wherein the first material, the electronics, and the fill material each have a density, respectively, and wherein the density of the fill material is equal to a sum of the densities of the electronics and the fill material.

18. The golf ball according to claim 12, the electronics further comprising a sensor configured to detect an impact on the golf ball.

19. The golf ball according to claim 18, wherein the electronics are configured such that the transmitter starts communicating wirelessly when the sensor detects an impact on the golf ball.

20. The golf ball according to claim 12, the electronics further comprising a receiver configured for close-range communication with an external device, and wherein electronics are configured to activate the transmitter so as to be able communicate wirelessly when the receiver receives an activation signal from the external device.