Methods for manufacturing golf balls with protuberant interior interfaces

Abstract

A golf ball is disclosed comprising a core having a unique surface configuration and a cover disposed about the core. The unique surface configuration is preferably a protuberant surface. Protuberant surface configurations are preferably provided by a plurality of geometrical shaped projections, which extend outwardly from the surface. A protuberant surface provides a protuberant interface between the layer, i.e., the core, having the protuberant surface and a layer disposed immediately thereon. A protuberant interface is more efficient in terms of energy transfer compared to traditional smooth spherical golf ball layers. Additionally, a golf ball having desired performance characteristics may be formed by the incorporation of a unique protuberant interface.

What is claimed is:  
     
         1 . A method of forming a multi-layered golf ball comprising (i) a core having a protuberant surface defined by a plurality of projections that extend outwardly from the core; and (ii) a cover layer disposed around said core, said method comprising the steps of: 
 providing a thermoplastic polymeric material;    forming a tube of said thermoplastic polymeric material;    sealing one end of said tube, thereby providing a sealed end;    inserting said tube into a mold defining an interior molding chamber having protuberant interior walls such that the sealed end of said tube is generally disposed within said molding chamber;    inserting an injection component into said tube;    introducing an inflating medium through said injection component to the portion of said tube within said molding chamber such that said inflating medium causes said tube to expand outwardly to said protuberant interior walls of said molding chamber to form a golf ball layer having a protuberant surface;    hardening said golf ball layer; and    removing said golf ball layer from said mold.    
     
     
         2 . The method of  claim 1  wherein said sealing step is performed by crimping said one end of said tube.  
     
     
         3 . The method of  claim 1  wherein said injection component is a pin, needle or syringe.  
     
     
         4 . The method of  claim 1  wherein said inflating medium is pressurized or compressed air.  
     
     
         5 . The method of  claim 1  wherein said thermoplastic polymeric material is selected from the group consisting of metallocenes, metallocene polyolefins, polyurethanes, silicones, polyamides, polyureas, polyvinyl chlorides, acrylonitrile-butadiene-styrenes, acrylics, stryrene-acrylonitriles, styrene-maleic anhydrides, polycarbonates, polybutylene terephthalates, polyethylene terephthalates, polyphenylene ethers/polyphenylene oxides, reinforced polypropylenes, high-impact polystyrenes and combinations thereof.  
     
     
         6 . The method of  claim 1  further comprising: 
 removing excess thermoplastic polymeric material from an outer surface of said golf ball layer.  
 
     
     
         7 . The method of  claim 1  wherein said step of sealing said one end of said tube is performed to provide an unsealed end opposite from said sealed end and said step of inserting said tube into said mold is performed such that said unsealed end is disposed outside of said molding chamber.  
     
     
         8 . A method of forming a multi-layered golf ball comprising a core having (i) a protuberant surface defined by a plurality of projections that extend outwardly from the core and (ii) a cover layer disposed around said core, said method comprising the steps of: 
 providing a longitudinal hollow member defining a first end and a second end and an interior channel extending between said first end and said second end;    providing a mold defining an interior molding chamber having protuberant interior walls;    placing a thermoplastic polymeric material onto said first end of said longitudinal member;    positioning said first end of said longitudinal member and said thermoplastic material into said molding chamber;    introducing an inflating medium to said second end of said longitudinal member such that said inflating medium causes said thermoplastic material disposed on said first end of said longitudinal member to expand outwardly to said protuberant interior walls of said molding chamber to thereby form a golf ball layer;    removing said layer from said mold;    removing said longitudinal member from said layer thereby forming an opening in said layer; and    filling said opening.    
     
     
         9 . The method of  claim 8  wherein said inflating medium is pressurized or compressed air.  
     
     
         10 . The method of  claim 8  wherein said thermoplastic polymeric material is selected from the group consisting of metallocenes, metallocene polyolefins, polyurethanes, silicones, polyamides, polyureas, polyvinyl chlorides, acrylonitrile-butadiene-styrenes, acrylics, stryrene-acrylonitriles, styrene-maleic anhydrides, polycarbonates, polybutylene terephthalates, polyethylene terephthalates, polyphenylene ethers/polyphenylene oxides, reinforced polypropylenes, high-impact polystyrenes and combinations thereof.  
     
     
         11 . The method of  claim 8  wherein said step of filling said opening is performed by depositing an effective amount of an agent in said opening, said agent selected from the group consisting of a thermally curable adhesive, an ultra-violet curable adhesive, a paint, a hot melt adhesive, a polymeric material, and combinations thereof.  
     
     
         12 . The polymeric material of  claim 11  selected from the group consisting of thermoplastic polymeric materials including metallocenes, metallocene polyolefins, polyurethanes, silicones, polyamides, polyureas, polyvinyl chlorides, acrylonitrile-butadiene-styrenes, acrylics, stryrene-acrylonitriles, styrene-maleic anhydrides, polycarbonates, polybutylene terephthalates, polyethylene terephthalates, polyphenylene ethers/polyphenylene oxides, reinforced polypropylenes, high-impact polystyrenes and combinations thereof.  
     
     
         13 . The method of  claim 8  wherein said step of filling said opening is performed by: 
 placing a sufficient amount of a resin within a syringe or needle to fill said opening;  
 injecting said resin into said opening;  
 cauterizing said layer surrounding said opening by contacting said layer with a heated element;  
 allowing said resin to soften and flow into said opening such that the resulting surface between said opening and said layer is uniform; and  
 heating said layer and said resin such that crosslinking between said resin and said layer is promoted.  
 
     
     
         14 . The method of  claim 13  wherein said resin is selected from the group consisting of a thermally curable adhesive, an ultra-violet curable adhesive, a solvent or water-based paint, a hot melt adhesive, a polymeric material, and combinations thereof.  
     
     
         15 . The method of  claim 13  wherein said thermoplastic polymeric material is selected from the group consisting of metallocenes, metallocene polyolefins, polyurethanes, silicones, polyamides, polyureas, polyvinyl chlorides, acrylonitrile-butadiene-styrenes, acrylics, stryrene-acrylonitriles, styrene-maleic anhydrides, polycarbonates, polybutylene terephthalates, polyethylene terephthalates, polyphenylene ethers/polyphenylene oxides, reinforced polypropylenes, high-impact polystyrenes and combinations thereof.  
     
     
         16 . The method of  claim 8  wherein said opening is filled using spin bonding.  
     
     
         17 . A multi-layered golf ball comprising: 
 a core having a protuberant surface defined by a plurality of projections of the same geometrical shape and base diameter that extend outwardly from said core; and    a cover layer disposed around said core, wherein the base diameter of each projection as measured along the surface of the core is from about 0.0375 inches to about 0.420 inches.    
     
     
         18 . The golf ball of  claim 17  wherein the geometrical shape is selected from the group consisting of hemispherical, elliptical, conical, pyramidal, rectangular, hexagonal, pentagonal, trapezoidal, and cylindrical.  
     
     
         19 . The golf ball of  claim 17  wherein the geometrical shape is hemispherical.  
     
     
         20 . The golf ball of  claim 17  wherein each projection of the protuberant surface of the core extends outwardly a distance of from about 0.0125 inches to about 0.140 inches as measured from the surface of the core.  
     
     
         21 . The golf ball of  claim 17  further comprising: 
 one or more mantle layers disposed between said core and said cover layer.