Method of making a golf ball with a multi-layer core
View Patent ↗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.
1. A method of making a golf ball comprising the steps of:
forming a core having a core hardness;
providing a roll stock comprising a first layer having a first hardness, a second layer having a second hardness, and a third layer having a third hardness, wherein at least one of the first, second, and third layers is formed of a thermoset material, wherein the thermoset material comprises a thermoset polybutadiene material and wherein at least one of the first, second, and third layers is formed from a thermoplastic material, and wherein the first, second, and third hardnesses differ by about 3 Shore D to about 20 Shore D, and wherein the first hardness is greater than the core hardness;
heating the roll stock to a softening point;
forcing the roll stock against a plurality of molds;
cooling the plurality of molds;
removing the roll stock from the plurality of molds to form a plurality of shells;
positioning two of the plurality of shells to surround the core; and
forming a cover from a castable reactive liquid material.
2. The method according to claim 1 , wherein the step of forcing comprises forcing the roll stock against each of the plurality of molds by vacuum or pressure.
3. The method of claim 1 , wherein a mold cycle occurs from the step of forcing to the step of removing, and wherein the mold cycle is about 30 seconds or less.
4. The method of claim 1 , wherein the formed cover has a thickness of about 0.05 inches or less.
5. The method of claim 1 , wherein the golf ball has a compression of about 85 or less.
6. The method of claim 1 , wherein the step of forming a cover comprises casting the cover around the golf ball.
7. A method of making a golf ball comprising the steps of:
forming a core;
providing a roll stock comprising at least two layers wherein at least one of the two layers is formed of a thermoset material, wherein the thermoset material is polybutadiene;
wherein the roll stock further comprises at least one sheet of material formed from a thermoplastic material;
heating the roll stock to a softening point;
engaging in a mold cycle comprising the steps of:
forcing the roll stock against a plurality of molds;
cooling the plurality of molds;
removing the roll stock from the plurality of molds to form a plurality of shells, wherein the mold cycle is about 30 seconds or less;
positioning two of the plurality of shells to surround the core; and
forming a cover disposed about the shells comprising a castable reactive liquid material having a hardness of less than 60 Shore D.
8. The method of claim 7 , wherein the cover comprises an inner layer and an outer layer.
9. The method of claim 8 , wherein the outer layer is cast.
10. The method of claim 7 , wherein the cover has a thickness of 0.05 inches or less.
11. The method of claim 8 , wherein the inner layer comprises an ionomer resin.