Callaway Golf Company

Gary G Marshall

Pijush K Dewanjee

David L Felker

Alan C Bettencourt

Donn A Wilber

A golf ball made by a process that prevents the cover from cracking due to thermal expansion of the core during the cover formation process. The method includes the forming a core. One or more optional boundary layers can be applied to the surface of the core. The core and any boundary layers are pre-heated such that the core and any boundary layer undergo volumetric thermal expansion. After the pre-heating, the cover of the ball is formed over the core and any boundary layer. The method of the present invention also decreases cover molding cycle times for golf balls.

Golf balls and methods of manufacturing the same

A method and system for casting a thermoset layer over a golf ball precursor product is disclosed herein. The system includes multiple stations connected by a conveyor system. The thermoset flowable material is dispensed into a plurality of cavities on each of the mold halves. A plurality of golf ball precursor products are then centered and inserted into the first mold half cavities. The mold halves are mated, heated and cooled. Then, at a de-molding station, the mold halves are separated and the thermoset layered golf balls are removed from the second mold half. A preferred thermoset material is a thermoset polyurethane.

System for forming a thermoset golf ball cover

A mold assembly designed for casting a layer for a golf ball is disclosed herein. The mold assembly has two halves that each hold a plurality of mold inserts. Each mold half is composed of a carrier base, a carrier plate, a retainer plate and a plurality of mold inserts. The multiple component aspect of each mold half allows for a more efficient transfer of heat during a casting process. Preferably, the mold assembly is utilized to mold a polyurethane cover on a golf ball precursor product.

Golf ball casting mold assembly

A method and system for inserting a golf ball precursor product into a cavity of a mold half for precision centering is disclosed herein. The precision centering allows for the concentricity of core in relation to the cover of a golf ball. The system includes an insertion mechanism that allows for the vertical movement of a plurality of vacuum cups along a longitudinal pathway. The vacuum cups retain the golf ball precursor products and insert each into a corresponding cavity on a mold half. As the vacuum cups are lowered along the longitudinal pathway, the mold half is elevated along the longitudinal pathway. The mold half and vacuum cups meet at an insertion position where the golf ball precursor products are released from the vacuum cups and set within a thermoset material contained in each of the cavities.

Cast molding insertion apparatus

Method for forming a thermoset golf ball cover

A method for determining the concentricity of a golf ball having a barium or bismuth doped boundary layer or cover is disclosed herein. The method uses an X-ray imaging machine to determine the thickness of the cover at various locations to ensure concentricity of the golf ball. The boundary layer may be an ionomer blend doped with barium or bismuth in an amount of five to fifteen parts per hundred of the ionomer material, and the cover may be composed of a thermoset polyurethane material. Alternatively, the cover may be doped with barium or bismuth, and the boundary layer may be undoped.

Method for verifying the concentricity of a multiple-layer golf ball

Method of casting a thermoset layer on a golf ball precursor product

A method and system for de-molding golf balls having a casted layer is disclosed herein. The invention includes exerting a first lateral force against a top mold half of a mold assembly and exerting a second lateral force against a bottom mold half of the mold assembly to separate the mold assembly and de-mold the golf balls from the top mold half. Preferably, the mold assembly is used to form a thermoset polyurethane cover over a core and boundary layer. The bottom mold half may have a double tapered pin, or a retractable pin with a single taper. The method and system allow for hot de-molding of golf balls from the mold assembly.

De-molding method and apparatus for a golf ball

Casting mold

A method of manufacturing golf balls is disclosed that prevents the cover from cracking due to thermal expansion of the core during the cover formation process. The method includes the forming a core. One or more optional boundary layers can be applied to the surface of the core. The core and any boundary layers are pre-heated such that the core and any boundary layer undergo volumetric thermal expansion. After the pre-heating, the cover of the ball is formed over the core and any boundary layer. The method of the present invention also decreases cover molding cycle times for golf balls.

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Soddy Daisy, TN, United States of America

Gary G Marshall