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

• US 6,387,316 B1
• Filed: 02/01/2000
• Issued: 05/14/2002
• Est. Priority Date: 02/01/2000
• Status: Expired due to Fees

• Current Assignee: Callaway Golf Company (Topgolf Callaway Brands Corp.)
• Original Assignee: Callaway Golf Company (Topgolf Callaway Brands Corp.)
• Inventors: Marshall, Gary G.
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): Lee, Edmund H.
• Application Number:
  US09/495,588
• Time in Patent Office: 833 Days
• Field of Search: 264/510, 264/248, 264/251, 264/254, 264/279.1, 264/275, 264/511
• US Class Current: 264/511
• CPC Class Codes: B29C 31/008 Handling preformed parts, e.g. inserts B29C37/001 takes precedence; for injection moulding B29C45/14008; for blow moulding B29C49/2408; for thermoforming B29C51/165
• CPC Class Codes: B29C 33/0022 Multi-cavity moulds B29C33/301 takes precedence
• CPC Class Codes: B29C 33/34 movable, e.g. to or from the moulding station
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 39/22 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29C 39/36 Removing moulded articles
• CPC Class Codes: B29L 2031/54 Balls

Abstract

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.

Claims

1. A method for simultaneously casting a thermoset layer on each of a plurality of golf ball precursor products, the method comprising:

providing a first mold half having a plurality of mold cavities, a second mold half having a plurality of mold cavities, a dispensing station, an insertion station, a holding platen, a hopper and a mold assembly station;

introducing a flowable material into each of a plurality of cavities disposed on the first mold half and the second mold half, at the dispensing station;

the flowable material comprising a thermoset polymer material, precursor thermoset polymer materials, or a mixture thereof;

transferring the first mold half from the dispensing station to the insertion station and the second mold half to the mold assembly station, wherein the first mold half at the insertion station is in a conveyor position;

suctioning each of the plurality of golf ball precursor products from a holding platen using a vacuum cup for each, the holding platen movable from a hopper position to a suctioning position, each vacuum cup connected to a locating plate;

lifting the first mold half in a vertical plane from the conveyor position to an insert position, the locating plate lying in the vertical plane;

lowering the locating plate with each of the plurality of golf ball precursor products retained in corresponding vacuum cups toward the first mold half at the insert position;

extending the vacuum cups from a retracted position to an extended position toward the plurality of cavities located in the first mold half;

inserting each of the plurality of golf ball precursor products into a corresponding cavity of the plurality of cavities of the first mold half, wherein the extended vacuum cup centers the golf ball precursor products within the cavities to 0.005 inch precision;

releasing each of the plurality of golf ball precursor products from each of the vacuum cups after one to twenty seconds wherein the flowable material in the plurality of cavities of the first mold half is firm enough to prevent further movement of the golf ball precursor product;

lowering the first mold half with the plurality of golf ball precursor products therein from the insert position to the conveyor position;

transferring the first mold half to the mold assembly station; and

mating the first mold half with the second mold half to form a mold assembly to enclose each of the plurality of golf ball precursor products within a spherical cavity to form a thermoset layer on each of the plurality of golf ball precursor products, wherein the entire insertion process is completed within sixty seconds.

2. The method according to claim 1 further comprising heating the mold assembly to cure the thermoset layer on each of the golf ball precursor products.

3. The method according to claim 1 wherein the plurality of golf ball precursor products suctioned from the holding platen is ten, and the plurality of cavities of the first mold half is ten.

4. The method according to claim 1 further comprising elevating each of the golf ball precursor products above the holding platen through flowing of air into each of a plurality of platen cavities that hold each of the golf ball precursor products.

5. The method according to claim 1 wherein each of the plurality of golf ball precursor products is selected from the group consisting of a core and a core with a boundary layer thereon.

6. The method according to claim 1 wherein the insert position is defined by a spacer plate having an aperture therein for allowing the insertion of each of the plurality of golf ball precursor products therethrough and into each of the plurality of cavities of the first mold half.

7. The method according to claim 1 wherein the flowable material is a thermoset polyurethane material and precursors therefor.

8. The method according to claim 1 wherein the first mold half is inverted prior to mating with the second mold half.