A process for producing golf ball including a core and a cover layer, wherein the cover layer provides one or more deep dimples that extend through the cover layer and/or into a layer or component underneath is disclosed. The cover may be a single layer or it may include multiple layers. If the cover is a multi-layer cover, the dimples extend to or into at least the first inner cover layer, and may extend into two or more inner cover layers. If the cover is a single layer, the dimples extend into the core. The dimples may be spherical or non-spherical, and the portion of the dimple that extends to or into the next inner layer may be the same or different shape as the outer portion of the dimple.
1. A process for forming a golf ball having a plurality of deep dimples, said process comprising the steps of:
providing an intermediate ball comprising at least a core;
providing a molding apparatus having a generally spherical molding chamber with a molding surface defined by (i) a first plurality of raised regions for forming a plurality of dimples on said cover layer, and (ii) a second plurality of raised regions, each of said second plurality of raised regions extending beyond said first plurality of raised regions, for concentrically positioning an object within said molding chamber and for forming deep dimples, and an assembly for administering a flowable material into said molding chamber;
providing to said molding apparatus a flowable material suitable for use as said cover layer for said golf ball;
positioning said intermediate ball within said molding chamber such that said second plurality of raised regions of said molding surface contacts and retains said intermediate ball within said molding chamber;
administering said flowable material into said molding chamber and generally between said intemiediate ball and said molding surface; and,
upon curing, removing the molded ball from said molding apparatus.
2. The process of claim 1 , wherein said flowable material comprises an ionomeric material.
3. The process of claim 1 , wherein said flowable material comprises polyurethane.
4. The process of claim 1 , wherein said flowable material comprises a (i) polymer having an active hydrogen group selected from the group consisting of polyol, —OH, amine, —NH 2 , and combinations thereof, and (ii) a polyisocyanate.
5. The process of claim 1 , further comprising a step of:
adding a barrier coating to said core prior to molding.
6. The process of claim 1 , wherein said step of providing to said molding apparatus said flowable material is performed by:
providing a polyol material to said molding apparatus;
providing a polyisocyanate material to said molding apparatus; and
reacting said polyol material and said polyisocyanate material to form a polyurethane material.
7. The process of claim 6 , wherein said reacting step is performed in said molding chamber.
8. A process for forming a cover layer having a plurality of deep dimples on a golf ball core, said process comprising the steps of:
providing a golf ball core;
providing a flowable material adapted for forming said layer on said golf ball core;
providing a mold including (i) a generally spherical molding chamber having outer surface including a plurality of raised protrusions that form a plurality of deep dimples in said layer, wherein the height of said raised protrusions is greater than the thickness of said layer, and (ii) provisions for introducing said flowable material into said molding chamber;
concentrically positioning said golf ball core in said molding chamber such that said plurality of raised protrusions contact said golf ball core; and
introducing said flowable material into said molding chamber whereby said flowable material flows between said golf ball core and said outer surface of said molding chamber to thereby form said layer.
9. The process of claim 8 , wherein said flowable material is a polyurethane material.
10. The process of claim 8 , wherein said flowable material includes (i) a polyol component and (ii) a polyisocyanate component.
11. The process of claim 8 , wherein said step of introducing said flowable material into said molding chamber includes chemically reacting said polyol component with said polyisocyanate component.
12. The process of claim 8 , further comprising the step of adding a moisture barrier coating to the core prior to molding.
13. A process for forming a golf ball having at least one dimple that extends through an outer layer of said ball, said process comprising:
providing an intermediate golf ball assembly comprising at least a core;
providing a molding apparatus including a generally spherical molding chamber having a first population of raised regions for forming a plurality of dimples on an outer layer of said golf ball, and at least one other raised region having a height that is greater than the thickness of said outer layer;
positioning said intermediate golf ball assembly in said molding chamber; and
administering a flowable material adapted to form said outer layer, to said molding apparatus.
14. The process of claim 13 , further comprising a step of hardening said flowable material to thereby form said outer layer.
15. The process of claim 13 , wherein upon positioning said intermediate golf ball assembly in said molding chamber, said other raised region of said molding chamber contacts said intermediate golf ball assembly.