MOLDING PROCESSES AND EQUIPMENT FOR FORMING GOLF BALLS`
Molding equipment and related techniques for forming a golf ball are disclosed. The golf ball comprises a core and a cover layer, wherein the cover layer provides one or more deep dimples that extend through the cover layer to and/or into a layer or component underneath are disclosed. The cover may be a single layer or include multiple layers. The cover layer(s) may be formed from any material suitable for use as a cover, including, but not limited to, ionomers, non-ionomers and blends of ionomers and non-ionomers. The molding equipment and related processes are particularly useful when forming the various layers by reaction injection molding.
1 . A process for forming a cover layer for a golf ball, said process comprising the steps of:
providing a molding apparatus having a generally spherical molding chamber with a molding surface defined by (i) a plurality of first raised regions for forming a plurality of depressions on the cover layer for the golf ball, each of the first raised regions having a first height, and (ii) a plurality of second raised regions, each of the second raised regions having a second height at least twice the height of the first height of the first raised regions, and an assembly for administering a flowable material into said molding chamber;
positioning the core within the generally spherical molding chamber such that the plurality of second raised regions of the molding surface contact and retain the core within the generally spherical molding chamber;
administering a flowable material into the generally spherical molding chamber and generally between the core and the molding surface for forming the cover layer over the core, the cover layer comprising an ionomer material.
2 . A process for forming a layer on a golfball core, the method comprising the steps of:
providing a multi-piece golf ball core;
providing a flowable material adapted for forming the layer on the golf ball core, the flowable material comprising an ionomer material;
providing a mold including (i) a generally spherical molding chamber having a molding surface including a plurality of raised protrusions that form a plurality of deep depressions in the layer, and (ii) provisions for introducing the flowable material into the molding chamber;
concentrically positioning the golf ball core in the molding chamber such that the plurality of raised protrusions contact the golf ball core; and
introducing the flowable material into the molding chamber whereby said flowable material flows between the golf ball core and the outer surface of the molding chamber to thereby form the layer.
3 . A process for forming a layer on a golf ball core, the method comprising the steps of:
providing a mandrel having a medially disposed spherical portion and laterally extending projection and a circumferential belt extending about an equator of the medially disposed spherical portion;
placing the mandrel within a molding chamber;
introducing a first flowable material into the molding chamber to form a cover layer comprising two hemispherical shells;
removing the mandrel from the molding chamber;
placing a core or intermediate ball within the molding chamber between the two hemispherical shells of the cover layer; and
introducing a second flowable material into the molding chamber to form a cover layer over the core or intermediate ball.
4 . The method according to claim 3 wherein the first flowable material and the second flowable material are the same.
5 . The method according to claim 3 wherein the first flowable material and the second flowable material are the polyurethane.