Method of making a golf ball with lattice reinforced layer

Abstract

Methods of making a golf ball that includes a lattice reinforced layer, which is a layer made of at least two materials with different properties, includes various injection and compression molding steps. In some embodiments, the lattice reinforced layer is manufactured using a shutoff molding technique so that the entire lattice reinforced layer is molded in the same mold. In other embodiments, a grid for the lattice layer is formed first, then filled using an injection molding technique.

1 - 5 . (canceled) 
     
     
         6 . A method of making a golf ball comprising the steps of:
 making a core;   making a grid from a first material, the first material having at least one pore;   forming the grid into a cup;   positioning the cup on the core; and   overmolding a second material onto the grid, so that the second material at least partially fills the at least one pore of the grid.   
     
     
         7 . The method of  claim 6 , wherein the step of making the grid comprises cutting the first material. 
     
     
         8 . The method of  claim 7 , wherein the step of making the grid comprises die cutting the first material. 
     
     
         9 . The method of  claim 6 , wherein the step of forming the grid comprises compression molding the grid. 
     
     
         10 . The method of  claim 6  further comprising the step of cutting the grid prior to forming the grid into a cup. 
     
     
         11 . The method of  claim 6  further comprising the step of adhering the cup to the core. 
     
     
         12 . The method of  claim 6  further comprising the step of forming at least one additional layer on the core prior to positioning the cup on the core. 
     
     
         13 . The method of  claim 12  further comprising the step of adhering the cup to the at least one additional layer prior to positioning the cup on the core. 
     
     
         14 . The method of  claim 6 , wherein the step of overmolding the second material comprises injection molding the second material onto the grid. 
     
     
         15 . The method of  claim 6  further comprising forming a second cup from a second grid. 
     
     
         16 . The method of  claim 15 , wherein the cup and second cup are joined together to encompass the core. 
     
     
         17 - 20 . (canceled)