# US 9,433,831 B2 · Process for manufacturing golf balls having multi-layered covers > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,433,831 B2 - Document ID: US9433831B2 - Status: Granted - Kind: B2 - Application number: 14/277,837 - Filed: 2014-05-15 - Published: 2014-09-04 - Granted: 2016-09-06 - Earliest claimed: 2011-04-18 - Assignees: Acushnet Company - Applicants: Acushnet Company - Inventors: William E. Morgan; Michael J. Sullivan; Mark L. Binette; Brian Comeau - Web page: https://patentgrep.com/patent/US9433831B2 ## CPC - A63B 37/0074: {Two piece balls, i.e. cover and core} - A63B 37/0003: {Golf balls} - A63B 37/0019: {Specified dimple depth} - A63B 37/0031: {Hardness} - A63B 37/0033: {Thickness} - A63B 37/0043: {Hardness} - A63B 37/0045: {Thickness} - A63B 45/00: Apparatus or methods for manufacturing balls (working of plastics or substances in a plastic state B29) - B29C 43/027: {having an axis of symmetry (B29C43/102 takes precedence)} - B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} - B29C 65/483: {Reactive adhesives, e.g. chemically curing adhesives} - B29C 65/52: {characterised by the way of} applying the adhesive {(B29C65/50 takes precedence; apparatus for applying liquids in general B05C; processes for applying liquids in general B05D)} - B29C 65/7802: {Positioning the parts to be joined, e.g. aligning, indexing or centring} - B29C 65/7841: {Holding or clamping means for handling purposes (clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04)} - B29C 66/54: {Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles} - B29C 66/73921: {characterised by the materials of both parts being thermoplastics} - B29D 99/0042: {Producing plain balls (hollow balls B29D22/04)} - B29L 2031/546: {Golf balls} - Y10T 156/1041: Subsequent to lamination - A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Process for making golf ball having multi-layered cover having a very thin outermost cover layer comprising: providing first and second substantially hemispherical half shells comprising a thermoplastic composition; dispensing uncured liquid thermoset composition into a hemispherical cavity of first half shell; inserting first half of a core subassembly into hemispherical cavity and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer; dispensing the uncured liquid thermoset composition into hemispherical cavity of second half shell; inserting second half of core subassembly into hemispherical cavity of second half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer and thereby mating the first and second half shells; curing thermoset inner cover layer; and forming dimples in the outer surfaces of mated first and second half shells. ## Claims ### Claim 1 A process for manufacturing a golf ball, comprising: providing first and second substantially hemispherical half shells comprising a thermoplastic composition, each half shell further having an outer surface and an inner surface which forms an hemispherical cavity, dispensing an uncured liquid thermoset composition into the hemispherical cavity of the first half shell; providing a core subassembly; inserting a first half of the core subassembly into the hemispherical cavity of the first half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer; dispensing the uncured liquid thermoset composition into the hemispherical cavity of the second half shell; inserting a second half of the core subassembly into the hemispherical cavity of the second half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer and thereby mating the first and second half shells; curing the thermoset inner cover layer; and forming dimples in the outer surfaces of the mated first and second half shells. ### Claim 2 (depends on 1) The process of claim 1, wherein the step of mating the first and second hemispherical half shells forms an outer cover layer. ### Claim 3 (depends on 2) The process of claim 2, wherein the outer cover layer has a hardness of from about 50 Shore D or greater. ### Claim 4 (depends on 2) The process of claim 2, wherein the outer cover layer has a hardness of from about 55 Shore D or greater. ### Claim 5 (depends on 2) The process of claim 2, wherein the outer cover layer has a hardness of from about 60 Shore D or greater. ### Claim 6 (depends on 1) The process of claim 1, wherein the inner cover layer has a hardness of about 58 Shore D or lower. ### Claim 7 (depends on 1) The process of claim 1, wherein the inner cover layer has a hardness of about 54 Shore D or lower. ### Claim 8 (depends on 1) The process of claim 1, wherein the inner cover layer has a hardness of about 52 Shore D or lower. ### Claim 9 (depends on 1) The process of claim 1, wherein the inner cover layer has a hardness of from about 20 Shore D to about 50 Shore D. ### Claim 10 (depends on 1) The process of claim 1, wherein the outer surfaces of the first and second substantially hemispherical shells are non-uniformly contoured. ### Claim 11 (depends on 1) The process of claim 1, wherein the inner surfaces of the substantially hemispherical shells are uniformly contoured. ### Claim 12 (depends on 1) The process of claim 1, wherein dimples are formed within the non-uniform contour of the outer surface of the outer cover layer. ### Claim 13 (depends on 12) The process of claim 12, wherein the dimples have a maximum depth of from about 0.005 inches to about 0.015 inches. ### Claim 14 (depends on 12) The process of claim 12, wherein the dimples have a maximum depth of from about 0.0067 inches to about 0.0134 inches. ### Claim 15 (depends on 12) The process of claim 12, wherein the outer cover layer has a thickness of from about 0.003 inches to about 0.030 inches. ### Claim 16 (depends on 1) The process of claim 1, wherein the inner cover layer has a thickness that is equal to or greater than the thickness of the hemispherical shells. ### Claim 17 (depends on 1) The process of claim 1, wherein the inner cover layer has a thickness of from about 0.010 inches to about 0.110 inches. ### Claim 18 (depends on 1) The process of claim 1, wherein the inner cover layer has a thickness of from about 0.015 inches to about 0.060 inches. ### Claim 19 (depends on 1) The process of claim 1, wherein the inner cover layer has a thickness of from about 0.020 inches to about 0.040 inches. ### Claim 20 (depends on 1) The process of claim 1, wherein the thermoplastic material is an ionomer. ### Claim 21 (depends on 1) The process of claim 1, wherein the thermoplastic material is an ionomer blend. ### Claim 22 A process for manufacturing a golf ball, comprising: a first step of forming first and second substantially hemispherical half shells having a uniform thickness comprising a thermoplastic composition, each half shell further having an outer surface and a non-uniformly contoured inner surface, the inner surface forming an hemispherical inner cavity; a second step of securing the first half shell in a golf ball mold; a third step of securing a core subassembly in a subassembly holder; a fourth step of dispensing an uncured liquid thermoset composition into the hemispherical cavity of the first half shell; a fifth step of inserting a first half of the core subassembly into the hemispherical cavity of the first half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms a non-uniformly contoured inner cover layer having a non-uniform thickness; a sixth step of disengaging the core assembly from the subassembly holder when the thermoset composition has gelled to a point of rigidity; a seventh step of securing the second half shell in a golf ball mold; an eighth step of dispensing the uncured liquid thermoset composition into the hemispherical cavity of the second half shell; a ninth step of inserting a second half of the core subassembly into the hemispherical cavity of the second half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms a non-uniformly contoured inner cover layer having a non-uniform thickness and thereby mating the first and second half shells; a tenth step of curing the thermoset inner cover layer to complete the golf ball and then removing the resulting golf ball from the golf ball mold. ### Claim 23 A process for manufacturing a golf ball, comprising: a first step of forming first and second substantially hemispherical half shells having a uniform thickness comprising a thermoplastic composition, each half shell further having an outer surface and a non-uniformly contoured inner surface, the inner surface forming an hemispherical inner cavity; a second step of securing the first half shell in a golf ball mold; a third step of securing a core subassembly in a subassembly holder; a fourth step of dispensing an uncured liquid thermoset composition into the hemispherical cavity of the first half shell; a fifth step of inserting a first half of the core subassembly into the hemispherical cavity of the first half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms a non-uniformly contoured inner cover layer having a uniform thickness; a sixth step of disengaging the core assembly from the subassembly holder when the thermoset composition has gelled to a point of rigidity; a seventh step of securing the second half shell in a golf ball mold; an eighth step of dispensing the uncured liquid thermoset composition into the hemispherical cavity of the second half shell; a ninth step of inserting a second half of the core subassembly into the hemispherical cavity of the second half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms a non-uniformly contoured inner cover layer having a uniform thickness and thereby mating the first and second half shells; a tenth step of curing the thermoset inner cover layer to complete the golf ball and then removing the resulting golf ball from the golf ball mold. ### Claim 24 A process for manufacturing a golf ball, comprising: a first step of forming first and second substantially hemispherical half shells having a uniform thickness comprising a thermoplastic composition, each half shell further having a uniformly contoured outer surface and an inner surface which forms an hemispherical cavity, a second step of securing the first half shell in a golf ball mold; a third step of securing a core subassembly in a subassembly holder; a fourth step of dispensing an uncured liquid thermoset composition into the hemispherical cavity of the first half shell; a fifth step of inserting a first half of the core subassembly into the hemispherical cavity of the first half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer having a uniform thickness; a sixth step of disengaging the core assembly from the subassembly holder when the thermoset composition has gelled to a point of rigidity; a seventh step of securing the second half shell in a golf ball mold; an eighth step of dispensing the uncured liquid thermoset composition into the hemispherical cavity of the second half shell; a ninth step of inserting a second half of the core subassembly into the hemispherical cavity of the second half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms a inner cover layer having a uniform thickness, and thereby mating the first and second half shells; a tenth step of curing the thermoset inner cover layer; an eleventh step of forming dimples in the outer surface of the mated first and second half shells, thereby eliminating the uniformity of the contour of the outer surface of the mated first and second half shells; and a twelfth step of removing the resulting golf ball from the golf ball mold.