Process and apparatus for producing a golf ball with deep dimples

A molding apparatus for forming a golf ball having a cover with a thickness and a plurality of dimples along its outer surface, said molding apparatus comprising:

• a first molding component defining a hemispherical first mold surface, said first mold surface having at least two populations of outwardly extending projections that form said dimples, said populations differing from each other by the height of said projections;
• a second molding component defining a hemispherical second mold surface, said second mold surface having at least two populations of outwardly extending projections that form said dimples, said populations differing from each other by the height of said projections, said second molding component adapted such that upon engagement with said first molding component, a generally spherical molding chamber results from said first mold surface and said second mold surface;
• and
• provisions for receiving one or more flowable materials used for forming said golf ball and administering such materials into said molding chamber;
• wherein said at least one population of outwardly extending projections of said first mold surface and said at least one population of outwardly extending projections of said second mold surface have a projection height in the range of from about 0.005 inches to about 0.050 inches.

A reaction injection molding apparatus for forming a golf ball core or intermediate ball assembly and an outer cover layer disposed about said core or ball assembly, said molding apparatus comprising:

• a first mold defining a hemispherical first mold surface;
• a second mold defining a hemispherical second mold surface, said first and said second mold surfaces having a first population of raised regions that form dimples along said cover layer, and a second population of raised regions each having a height greater than the thickness of said outer cover layer;
• provisions for receiving two or more flowable reactants utilized for forming said outer cover layer;
• wherein said second population of raised regions constitutes a minority proportion of the total number of dimples along said cover layer.

A process for producing a golf ball having a particular proportion of deep dimples along an outer surface of said ball, said process comprising:

• providing a molding apparatus that defines a generally spherical molding chamber resulting from a molding surface having a first population of raised regions that form dimples in a golf ball, and a second population of raised regions that form deep dimples in a golf ball,
• providing a flowable molding material;
• positioning a core or intermediate ball assembly in said molding chamber;
• introducing said flowable molding material into molding chamber between said core or intermediate ball assembly and said molding surface;
• and
• hardening said flowable molding material to thereby form said golf ball;
• wherein said second population of said raised regions constitutes at least 5% of the total number of dimples along said outer surface of said ball.