System And Method For Making A Golf Ball With One Or More Patterned Film Layers

• US 20130165272A1
• Filed: 12/27/2011
• Published: 06/27/2013
• Est. Priority Date: 12/27/2011
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Cheng, Chia-Chyi, Tutmark, Bradley C.
• Granted Patent: US 9,474,939 B2
• Time in Patent Office: Days
• US Class Current: 473/378
• CPC Class Codes: A63B 37/0003 Golf balls
• CPC Class Codes: A63B 37/0004 Surface depressions or protrusions
• CPC Class Codes: A63B 37/0022 Coatings, e.g. paint films; Markings
• CPC Class Codes: A63B 37/0074 Two piece balls, i.e. cover and core
• CPC Class Codes: A63B 37/0092 Hardness distribution amongst different ball layers
• CPC Class Codes: A63B 45/00 Apparatus or methods for manufacturing balls working of plastics or substances in a plastic state B29
• CPC Class Codes: B29C 2063/485 the liquid being an adhesive
• CPC Class Codes: B29C 49/46 characterised by using particular environment or blow fluids other than air
• CPC Class Codes: B29C 63/22 using layers or sheathings having a shape adapted to the shape of the article B29C63/26 and B29C63/38 take precedence
• CPC Class Codes: B29L 2031/546 Golf balls

Abstract

A system and method for manufacturing a golf ball with one or more patterned film layers is disclosed. The system and method may involve creating a patterned film layer and applying the patterned film layer to the surface of a golf ball. The patterned film layer may include a layer of film having cutouts leaving the remaining portions of film in a pattern. The pattern may include a net pattern. The patterned film layer may include a material that is relatively harder or relatively softer than the surface of the golf ball. The method may include removing portions of film from a film material to create a patterned film material, cutting the patterned film material into sheets, molding two patterned film sheets into substantially hemispherical cups, and applying the two substantially hemispherical cups to a golf ball.

Claims

9. A method of manufacturing a golf ball with a patterned layer, comprising:

forming a pattern on a film material by removing portions of film from the film material in a pattern;

molding the film material into substantially hemispherical cups by placing film material between a first set of mold halves; and

applying the substantially hemispherical cups to the outer surface of a golf ball.

10. The method according to claim 9, further comprising heating the first set of mold halves.

11. The method according to claim 9, further comprising disposing adhesive between the substantially hemispherical cups and the outer surface of the golf ball.

12. The method according to claim 9, further comprising applying the substantially hemispherical cups to the outer surface of the golf ball by positioning the substantially hemispherical cups into a second set of mold halves, positioning the golf ball between the substantially hemispherical cups, and pressing the second set of mold halves together.

13. The method according to claim 12, further comprising heating the second set of mold halves.

14. The method according to claim 9, further comprising unrolling the film material from a roll of film material.

15. The method according to claim 14, further comprising cutting sheets of film material.

16. A method of manufacturing a golf ball with a patterned layer, comprising:

forming a pattern on a film material by removing portions of film from the film material in a pattern;

molding the film material into substantially hemispherical cups by placing film material between a first set of mold halves, pressing the first set of mold halves together, and inflating a bladder between the first set of mold halves; and

applying the substantially hemispherical cups to the outer surface of a golf ball.

17. The method according to claim 16, further comprising removing the portions of film with a die cutter.

18. The method according to claim 17, further comprising feeding the film material through a rotary a die cutter.

19. The method according to claim 16, further comprising applying the substantially hemispherical cups to the outer surface of the golf ball by positioning the substantially hemispherical cups into a second set of mold halves, positioning the golf ball between the substantially hemispherical cups, and pressing the second set of mold halves together.

20. The method according to claim 19, wherein the first set of mold halves and the second set of mold halves include substantially hemispherical shapes.

21. A golf ball comprising:

a core;

a cover layer, the cover layer substantially surrounding the core and including a plurality of dimples and at least one land area separating the dimples;

a patterned film layer substantially surrounding the cover layer; and

wherein the cover layer has a first hardness and the patterned film layer has a second hardness different from the first hardness.

1. A method of manufacturing a golf ball with a patterned layer, comprising:

forming a pattern on a film material by removing portions of film from the film material;

molding the film material into substantially hemispherical cups; and

applying the substantially hemispherical cups to the outer surface of a golf ball.

2. The method according to claim 1, further comprising removing the portions of film with a die cutter.

3. The method according to claim 2, further comprising feeding the film material through a rotary a die cutter.

4. The method according to claim 1, further comprising cutting sheets from the film material.

5. The method according to claim 4, further comprising positioning the sheets of film material between mold halves.

6. The method according to claim 5, further comprising positioning a bladder between the sheets of film material while the sheets of film material are positioned between the mold halves.

7. The method according to claim 6, further comprising molding the film material into substantially hemispherical cups by pressing the mold halves together and inflating the bladder between the sheets of film material so that the bladder presses the sheets against mold portions of the mold halves.

8. The method according to claim 1, further comprising applying the substantially hemispherical cups to the outer surface of a golf ball by positioning the substantially hemispherical cups into mold halves and pressing a golf ball between the mold halves.

22. The golf ball according to claim 21, wherein the first hardness is harder than the second hardness.

23. The golf ball according to claim 21, wherein the first hardness is softer than the second hardness.

24. The golf ball according to claim 21, wherein the patterned film layer covers substantially all of the land area.

25. The golf ball according to claim 21, wherein the patterned film layer includes a net pattern defined by cutout portions.

26. The golf ball according to claim 21, wherein a solid film layer substantially surrounds the patterned film layer.

23-1. The golf ball according to claim 21, wherein the patterned film layer covers substantially all of the plurality of dimples.