Multilayer golf ball with a thin thermoset outer layer
First Claim
1. A method for forming a multilayer golf ball having improved interfacial adhesion, said method comprising:
- (a) forming a core;
(b) forming an intermediate layer over the core, wherein the intermediate layer has an integrally molded textured outer surface, wherein said textured outer surface comprises a plurality of peaks having draft angles of less than about 10 degrees and heights of between about 2 to about 15 mils. (c) casting a cover layer over the intermediate layer with a castable liquid reactive material or reaction products thereof.
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Accused Products
Abstract
The present invention is directed towards a multilayer golf ball which comprises a core, an inner cover layer and an outer cover layer, wherein the outer cover layer comprises a castable reactive liquid material having a shore D hardness less than the shore D hardness of the material forming the inner cover layer. The present invention also relates to golf balls having improved adhesion between adjacent layers, as well as method for making golf balls having such improved adhesion. In particular, the outer surface of the core, an intermediate layer(s) or both the core and the intermediate layer(s) has a textured surface profile integrally molded in the outer surface thereof so that the surface profile promotes interfacial adhesion.
93 Citations
23 Claims
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1. A method for forming a multilayer golf ball having improved interfacial adhesion, said method comprising:
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(a) forming a core;
(b) forming an intermediate layer over the core, wherein the intermediate layer has an integrally molded textured outer surface, wherein said textured outer surface comprises a plurality of peaks having draft angles of less than about 10 degrees and heights of between about 2 to about 15 mils. (c) casting a cover layer over the intermediate layer with a castable liquid reactive material or reaction products thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of forming a multilayer golf ball comprising a cover, a core and at least one intermediate layer interposed between said cover and core, said multilayer ball having improved interfacial adhesion between its layers, wherein the method comprises:
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(a) forming a golf ball core;
(b) forming a textured pattern on the interior surface of a mold cavity, wherein said pattern comprises a plurality of depressions having depths of about 2 to about 15 mils and draft angles less than about 10 degrees;
(c) placing the core in said mold cavity;
(d) forming an intermediate layer having a first shore D hardness on said core in said mold cavity, said intermediate layer having a textured surface profile integrally molded in the outer surface thereof, wherein said surface profile is a corresponding image of said pattern and comprises a plurality of peaks having heights of about 2 to about 15 mils; and
(e) casting an outer cover layer with a castable liquid reactive material or reaction products thereof having a second shore D hardness less than the first shore D hardness and a thickness of less than 0.05 inches.
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- 15. A golf ball having improved interfacial adhesion comprising a cover, a core and at least one intermediate layer therebetween, wherein said intermediate layer has a textured surface profile integrally molded in an outermost surface thereof, wherein said textured surface profile comprises a plurality of peaks extending from said outermost surface, said peaks having heights of about 3 to about 7 mils.
- 20. A golf ball having improved interfacial adhesion comprising a cover, a core and at least one intermediate layer therebetween, wherein said intermediate layer has a textured surface profile integrally molded in an outermost surface thereof, wherein said textured surface profile comprises a plurality of peaks extending from said outermost surface, said peaks having a draft angle less than about 10 degrees.
Specification