Molding processes and equipment for forming golf balls with deep dimples

Abstract

Molding equipment and related techniques for forming a golf ball are disclosed. The golf ball comprises a core and a cover layer, wherein the cover layer provides one or more deep dimples that extend through the cover layer to and/or into a layer or component underneath are disclosed. The molding equipment provides one or more selectively positionable knock-out pins along the surface of the molding chamber. These pins are specially tailored such that after their retraction subsequent to molding, the resulting voids are deep dimples. The molding equipment and related processes are particularly useful when forming the various layers by reaction injection molding.

1 - 8 . (CANCELED)  
     
     
         9 . A process for forming a golf ball having a plurality of deep dimples, said process comprising: 
 providing a molding apparatus having (i) an upper mold including a first molding surface that defines at least one aperture, said upper mold further including a selectively positionable pin in each of said apertures, and (ii) a lower mold including a second molding surface that defines at least one aperture, said lower mold further including a selectively positionable pin in each of said apertures, said pins of said upper and lower molds having a distal end that may be extended past said respective first and second molding surface, said upper and lower molds adapted to engage each other such that said first molding surface and said second molding surface form a generally spherical molding chamber;    positioning a golf ball core or intermediate ball assembly within said molding chamber;    extending at least one of said pins within said molding chamber so that said distal end of said extended pin contacts said golf ball core or intermediate ball assembly;    introducing a molding material within said molding chamber and around said golf ball core or intermediate ball assembly to thereby form a layer of said material around said golf ball core or intermediate ball assembly;    at least partially hardening said molding material;    retracting said pins to thereby form deep dimples in said resulting layered core or ball assembly.    
     
     
         10 . The process of  claim 9 , wherein said pins are extended into said molding chamber a distance of from about 0.002 inches to about 0.140 inches as measured from said respective first and second molding surface.  
     
     
         11 . The process of  claim 10 , wherein said distance is from about 0.002 inches to about 0.050 inches.  
     
     
         12 . The process of  claim 9 , further comprising: 
 providing on at least one of said first and second molding surfaces, a raised protuberance that upon said steps of introducing and at least partially hardening said molding material, forms a deep dimple in said resulting layered core or ball assembly.    
     
     
         13 . The process of  claim 9 , further comprising; 
 removing said resulting layered core or ball assembly from said molding chamber.    
     
     
         14 . The layered core or ball assembly resulting from the process of  claim 13 .  
     
     
         15 . A process for forming a golf ball having a plurality of deep dimples, said process comprising: 
 providing a molding apparatus having (i) an upper mold including a first molding surface that defines a first raised protuberance adapted to form a deep dimple and at least one aperture, said upper mold further including a selectively positionable pin in each of said apertures, and (ii) a lower mold including a second molding surface that defines a second raised protuberance adapted to form a deep dimple and at least one aperture, said lower mold further including a selectively positionable pin in each of said apertures, said pins of said upper and lower molds having a distal end that may be extended past said respective first and second molding surface, said upper and lower molds adapted to engage each other such that said first molding surface and said second molding surface form a generally spherical molding chamber;    positioning a golf ball core or intermediate ball assembly within said molding chamber;    extending at least one of said pins within said molding chamber so that said distal end of said extended pin contacts said golf ball core or intermediate ball assembly;    introducing a molding material within said molding chamber and around said golf ball core or intermediate ball assembly to thereby form a layer of said material around said golf ball core or intermediate ball assembly;    at least partially hardening said molding material.    
     
     
         16 . The process of  claim 15  wherein upon positioning said golf ball core or intermediate ball assembly within said molding chamber, said core or ball assembly contacts said first and second raised protuberances defined in said first and second molding surfaces.  
     
     
         17 . The process of  claim 15 , wherein said first and second raised protuberances have a height of from about 0.002 inches to about 0.140 inches.  
     
     
         18 . The process of  claim 15 , wherein said pins are extended into said molding chamber a distance of from about 0.002 inches to about 0.140 inches as measured from said respective first and second molding surface.  
     
     
         19 . The process of  claim 15 , further comprising: 
 removing said resulting golf ball having deep dimples from said molding chamber.    
     
     
         20 . The process of  claim 15 , further comprising: 
 extending said pins to displace said resulting layered core or ball assembly from said molding chamber.    
     
     
         21 . The process of  claim 17 , further comprising: 
 retracting said pins to thereby form additional deep dimples in said resulting layered core or ball assembly.    
     
     
         22 . The process of  claim 15 , further comprising: 
 retracting said pins to thereby form additional deep dimples in said resulting layered core or ball assembly.    
     
     
         23 . The ball formed from the process of  claim 15.