Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Reexamination Certificate
1999-08-17
2001-10-16
Silbaugh, Jan H. (Department: 1732)
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
C264S250000, C264S255000, C264S279100, C264S297700, C264S297800, C425S451000, C425S515000, C425S517000
Reexamination Certificate
active
06303065
ABSTRACT:
TECHNICAL FIELD OF THE INVENTION
The present invention is directed to a method and apparatus for making golf balls. More particularly, the invention is directed to a method and apparatus for forming multi-layered cores or golf balls that are substantially automated.
BACKGROUND OF THE INVENTION
Generally, golf balls have been classified as solid balls or wound balls. Solid balls are generally comprised of a solid polymeric core and a cover. These balls are generally easy to manufacture, but are regarded as having limited playing characteristics. Wound balls are comprised of a solid or liquid-filled center surrounded by tensioned elastomeric material and a cover. Wound balls generally have good playing characteristics, but are more difficult to manufacture than solid balls.
The prior art is comprised of various golf balls that have been designed to provide optimal playing characteristics. These characteristics are generally the initial velocity and spin of the golf ball, which can be optimized for various players. For instance, certain players prefer to play a ball that has a high spin rate for playability. Other players prefer to play a ball that has a low spin rate to maximize distance. However, these balls tend to be hard feeling and difficult to control around the greens.
Manufacturers have molded layers around a solid center by placing a preformed center between two blocks of core material in a spherical compression mold, and closing the mold. This process, however, provides little control over the ultimate placement of the center within the golf ball core. Large variations in the location of the center can result.
The prior art also provides for the manufacture of double cover golf balls. This is generally accomplished by injection molding a first and then a second cover layer around a core. This system, however, requires complex injection molds, usually with retractable pins within the mold to properly position the core. Moreover, this system generally works better with thermoplastic materials.
Therefore, what is desired is a method and apparatus for molding multi-layer cores or multi-layer covers that ensures properly centered balls.
SUMMARY OF THE INVENTION
According to the present invention a method and an apparatus for making a core and/or golf ball are disclosed. The method for forming cores comprises the steps of providing center, providing a plurality of mold plates, and forming a plurality of core hemispherical shells from elastomeric material. The mold plates include a bottom mold plate defining a plurality of cavities, a top mold plate defining a plurality of corresponding cavities, and a center mold plate including a plurality of corresponding protrusions.
The step of forming the hemispherical shells further includes placing elastomeric material in the cavities of the bottom mold plate and the top mold plate, locating the top mold plate between the center and bottom mold plates so that the cavities in the top mold plate are adjacent to the center mold plate and the three mold plates are vertically aligned, rotating the center mold plate and the top mold plate together until the center mold plate is between the top and bottom mold plates, and applying heat and pressure to the three mold plates to form the elastomeric material into the shells in the bottom and top mold plate cavities.
The method further includes rotating the center mold plate and the top mold plate together until the top mold plate is between the center and bottom mold plates, placing the centers in the shells in the bottom mold plate, rotating the top mold plate with the shells therein until the cavities in the top mold plate are adjacent to the centers in the bottom mold plate, and applying heat and pressure to the top and bottom mold plates to join the shells around the centers to form the cores.
In one embodiment, the method includes moving the top and center mold plates vertically before and after rotating.
The method of making a ball, comprises providing cores and the top, bottom and center mold plates. Then a plurality of cover hemispherical shells are formed from a first cover material. The cover shells are formed by placing the first cover material in the cavities of the bottom mold plate and the top mold plate; locating the top mold plate between the center and bottom mold plates so that the cavities in the top mold plate are adjacent to the center mold plate and the top, center and bottom mold plates are vertically aligned; rotating the center mold plate and the top mold plate together until the center mold plate is between the top and bottom mold plates; and applying heat and pressure to the three mold plates to form the first cover material into the shells in the bottom and top mold plate cavities. Next, the center mold plate and the top mold plate are rotated together until the top mold plate is between the center and bottom mold plates. The cores are placed in the shells in the bottom mold plate, the top mold plate is rotated until the cavities in the top mold plate are adjacent to the centers in the bottom mold plate, heat and pressure are applied to the top and bottom mold plates to join the shells around the cores to form an assembly, and a second cover material is molded around the assembly.
The apparatus for molding the golf balls includes the bottom, top, and center mold plates. The apparatus further includes first, second, and third frames. The first frame extends substantially horizontally, defines a lower position, and has the bottom and top mold plates slidably and releasably coupled thereto. The second frame extends substantially vertically and is aligned with the first frame. The second frame also defines a rotate position spaced above the lower position and an elevated position spaced above the rotate position. The third or rotating frame is rotatably connected to the second frame at the rotate position. At least one of the top and center mold plates are releasably coupled to the third frame to rotate the associated mold plate.
In another embodiment, the apparatus further includes a lower elevator and an upper elevator. The lower elevator moves at least one plate between the lower position and the rotate position. The upper elevator moves the center mold plate between the elevated position and the rotate position.
In yet another embodiment, the apparatus also includes a mold press disposed adjacent to the first frame for applying heat and pressure to at least two of the mold plates.
REFERENCES:
patent: 3933967 (1976-01-01), Taylor
patent: 4744741 (1988-05-01), Glover et al.
patent: 5683312 (1997-11-01), Boehm et al.
patent: 6096255 (2000-08-01), Brown et al.
Ditzel Daniel
Earle Steven
Kennedy John W.
Moore Thomas E.
Reid, Jr. Walter L.
Acushnet Company
Lee Edmund H.
Pennie & Edmonds LLP
Silbaugh Jan H.
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