Self-aligning core body for forming golf ball sub-assembly with foamed casing layer

A method of forming a golf ball sub-assembly, the method comprising:

• (i) forming a plurality of protrusions on a core body such that the plurality of protrusions project from an outer surface of the core body;
• (ii) depositing a foamed casing material on an interior surface of at least one first casting mold;
• (iii) plunging the core body into the at least one first casting mold including the foamed casing material such that at least a subset of the plurality of protrusions contacts the interior surface of the at least one first casting mold to center the core body relative to the at least one first casting mold;
• (iv) engaging the at least one first casting mold with at least one second casting mold to form a molding assembly that defines a void between the core body, the at least one first casting mold, and the at least one second casting mold;
• and
• (v) curing the foamed casing material such that the foamed casing material expands and fills the void to form a casing layer around the core body.

A method of forming a golf ball sub-assembly, the method comprising:

• (i) depositing a foamed casing material on an interior surface of at least one first casting mold, wherein the foamed casing material is formed from polyurethane foam;
• (ii) plunging a core body including plurality of protrusions into the at least one first casting mold including the foamed casing material such that at least a subset of the plurality of protrusions contacts the interior surface of the at least one first casting mold to center the core body relative to the at least one first casting mold,
• wherein plunging the core body occurs no later than 30 seconds after step (i) and while the polyurethane foam has a viscosity of 5,000 cp-50,000 cp;
• (iii) engaging the at least one first casting mold with at least one second casting mold to form a molding assembly that defines a void between the core body, the at least one first casting mold, and the at least one second casting mold;
• and
• (iv) curing the foamed casing material such that the foamed casing material expands and fills the void to form a casing layer around the core body.