초록 ▼

Embodiments provide systems and methods for manufacturing a multilayer golf ball having strong inter-layer bonding and desired structural characteristics, provided by including temporary, removable particles in a golf ball substrate and then removing the particles to form voids in the substrate, inc

Embodiments provide systems and methods for manufacturing a multilayer golf ball having strong inter-layer bonding and desired structural characteristics, provided by including temporary, removable particles in a golf ball substrate and then removing the particles to form voids in the substrate, including the outer surface and interior of the substrate. Golf balls having the resulting strong inter-layer bonding and structural characteristics are also disclosed.

대표청구항 ▼

1. A method for manufacturing a golf ball comprising: forming a substrate of the golf ball, the substrate having an outer surface;disposing removable substrate particles at the outer surface of the substrate such that at least a portion of each of the removable substrate particles is exposed at the

1. A method for manufacturing a golf ball comprising: forming a substrate of the golf ball, the substrate having an outer surface;disposing removable substrate particles at the outer surface of the substrate such that at least a portion of each of the removable substrate particles is exposed at the outer surface of the substrate;wherein forming the substrate and disposing the removable substrate particles at the outer surface of the substrate comprises: mixing particles with a substrate material to form a mixture;injecting the mixture into a mold with the particles suspended throughout the mixture, wherein a first plurality of the particles is disposed against the mold and comprises the removable substrate particles, and wherein a second plurality of the particles is encased within the substrate and comprises non-exposed removable substrate particles; andsolidifying the mixture to form the substrate, with the removable substrate particles exposed at the outer surface of the substrate;removing the removable substrate particles from the outer surface of the substrate to form voids in the outer surface of the substrate;leaving the non-exposed removable substrate particles encased within the substrate to provide the substrate with structural support that is at least equal to the structural support provided by the substrate material, wherein the non-exposed removable substrate particles are made of material capable of withstanding impact by a golf club;applying dimple-shaped removable particles to a cover mold, wherein each dimple-shaped removable particle has a substantially flat side and a spherical side, wherein the dimple-shaped removable particles are applied with their flat sides against the cover mold in a uniform distribution corresponding to a desired dimple pattern;injecting a cover material in liquid form into the cover mold, over the dimple-shaped removable particles, and into the voids of the substrate;solidifying the liquid cover material to form a cover of the golf ball, with the dimple-shaped removable particles embedded in the cover with the flat sides of the dimple-shaped removable particles exposed at the outer surface of the cover;removing the golf ball from the cover mold with the dimple-shaped removable particles embedded in the cover of the golf ball; andremoving the dimple-shaped removable particles from the outer surface of the cover to form the desired dimple pattern in the cover of the golf ball. 2. The method of claim 1, wherein the removable substrate particles comprise soluble material, wherein removing the removable substrate particles comprises applying a solvent to the substrate, and wherein the solvent comprises a substance that dissolves the soluble material. 3. The method of claim 2, wherein the removable substrate particles comprise water-soluble particles, and the solvent comprises water. 4. The method of claim 1, wherein before mixing the particles with the substrate material to form the mixture, the method further comprises selecting a material for the particles that is both conducive to removal by a desired removal means and is conducive to providing the structural support to the substrate. 5. The method of claim 4, wherein the desired removal means comprises dissolving by a solvent. 6. The method of claim 1, wherein removing the removable substrate particles from the outer surface of the substrate and leaving the non-exposed removable substrate particles encased within the substrate comprise applying a solvent to the outer surface of the substrate such that the solvent dissolves the removable substrate particles at the outer surface of the substrate but does not reach the non-exposed removable substrate particles encased within the substrate to leave the non-exposed removable substrate particles intact. 7. The method of claim 1, wherein the particles mixed with the substrate to form the mixture comprise soluble particles dissolvable in a solvent, and wherein removing the removable substrate particles from the outer surface of the substrate comprises applying the solvent to the substrate. 8. The method of claim 1, wherein applying the dimple-shaped removable particles comprises applying the dimple-shaped removable particles to a concave spherical surface of the cover mold by dispensing the dimple-shaped removable particles through a dispensing head having a shape complementary to the concave spherical surface of the cover mold, wherein the dimple-shaped removable particles are dispensed through outlets of the dispensing head positioned at locations at which the dimple-shaped removable particles are desired on the concave spherical surface of the cover mold. 9. The method of claim 1, wherein the substrate comprises one of an intermediate layer and a core of the golf ball. 10. The method of claim 1, wherein the substrate comprises a first substrate layer, and wherein the method further comprises forming a second substrate layer under the first substrate layer such that material of the first substrate layer occupies voids in an outer surface of the second substrate layer. 11. The method of claim 10, wherein the voids in the outer surface of the second substrate layer are formed by: applying second removable substrate particles to a surface of a second mold;injecting second substrate layer material in liquid form into the second mold over the second removable particles; andsolidifying the liquid second substrate layer material with the second removable particles embedded in the second substrate layer material. 12. The method of claim 1, wherein removing the removable substrate particles comprises one of physically contacting the removable substrate particles with force and pneumatically contacting the removable substrate particles with air. 13. The method of claim 1, wherein the removable substrate particles comprise one of fluid-filled microcapsules, gas-filled microcapsules, and gel microbeads, and wherein removing the removable substrate particles comprises heating the removable substrate particles. 14. The method of claim 1, wherein removing the removable substrate particles comprises selectively heating the removable substrate particles without appreciably heating the substrate. 15. A method for manufacturing golf ball comprising: forming a substrate of the golf ball, the substrate having an outer surface;disposing removable substrate particles at the outer surface of the substrate such that at least a portion of each of the removable substrate particles is exposed at the outer surface of the substrate;wherein forming the substrate and disposing the removable substrate particles at the outer surface of the substrate comprises: mixing particles with a substrate material to form a mixture;injecting the mixture into a mold with the particles suspended throughout the mixture, wherein a first plurality of the particles is disposed against the mold and comprises the removable substrate particles, and wherein a second plurality of the particles is encased within the substrate and comprises non-exposed removable substrate particles; andsolidifying the mixture to form the substrate, with the removable substrate particles exposed at the outer surface of the substrate;removing the removable substrate particles from the outer surface of the substrate to form voids in the outer surface of the substrate;leaving the non-exposed removable substrate particles encased within the substrate to provide the substrate with structural support that is at least equal to the structural support provided by the substrate material, wherein the non-exposed removable substrate particles are made of material capable of withstanding impact by a golf club;applying dimple-shaped removable particles to a cover mold, wherein each dimple-shaped removable particle has a substantially flat side and a spherical side, wherein the dimple-shaped removable particles are applied with their flat sides against the cover mold in a uniform distribution corresponding to a desired dimple pattern;injecting a cover material in liquid form into the cover mold, over the dimple-shaped removable particles, and into the voids of the substrate;solidifying the liquid cover material to form a cover of the golf ball, with the dimple-shaped removable particles embedded in the cover with the flat sides of the dimple-shaped removable particles exposed at the outer surface of the cover; andremoving the golf ball from the cover mold with the dimple-shaped removable particles embedded in the cover of the golf ball,wherein the dimple-shaped removable particles are removable from the outer surface of the cover to form the desired dimple pattern in the cover of the golf ball. 16. The method of claim 15, wherein each void has an opening at the outer surface of the substrate that is narrower than an interior dimension of the each void. 17. A method for manufacturing a golf ball comprising: applying removable particles to a mold, wherein each removable particle has a substantially flat side and a spherical side, wherein the removable particles are applied with their flat sides against the mold in a uniform distribution corresponding to a desired dimple pattern;injecting a cover material in liquid form into the mold and over the removable particles;solidifying the liquid cover material to form a cover of the golf ball, with the removable particles embedded in the cover with the flat sides of the removable particles exposed at the outer surface of the cover;removing the golf ball from the mold with the removable particles embedded in the cover of the golf ball; andremoving the removable particles from the outer surface of the cover to form the desired dimple pattern in the cover of the golf ball. 18. The method of claim 17, wherein applying the removable particles comprises applying the removable particles to a concave spherical surface of the mold by dispensing the removable particles through a dispensing head having a shape complementary to the concave spherical surface of the mold, wherein the removable particles are dispensed through outlets of the dispensing head positioned at locations at which the removable particles are desired on the concave spherical surface of the mold. 19. The method of claim 18, wherein the complementary shape is a convex hemispherical shape. 20. The method of claim 17, wherein the removable particles comprise soluble material, wherein removing the removable particles comprises applying a solvent to the outer surface of the cover, and wherein the solvent comprises a substance that dissolves the soluble material. 21. The method of claim 20, wherein the removable particles comprise water-soluble particles, and the solvent comprises water. 22. The method of claim 17, wherein removing the removable particles comprises one of physically contacting the removable particles with force and pneumatically contacting the removable particles with air. 23. The method of claim 17, wherein the removable particles comprise one of fluid-filled microcapsules, gas-filled microcapsules, and gel microbeads, and wherein removing the removable particles comprises heating the removable particles. 24. The method of claim 17, wherein removing the removable particles comprises selectively heating the removable particles without appreciably heating the cover.