Patent ID: 7481956

Claim:
A method of forming a cosmetically defect-free golf ball component comprising the steps of: providing a golf ball precursor; mixing at least one of a saturated polyurea prepolymer, a saturated polyurethane prepolymer, or mixture thereof and at least one saturated curing agent to form a castable reactive liquid material; filling a first set of mold halves with a first amount of the material; cooling the golf ball precursor such that the golf ball precursor has a temperature of about 20° F. to about 50° F., lowering the cooled golf ball precursor into the first set of mold halves after a first predetermined time, wherein the precursor is held by vacuum for second predetermined time, and wherein the second predetermined time is sufficient for complete exothermic reaction of the first amount of material; releasing the golf ball precursor from the vacuum providing a partially covered golf ball precursor; filling a second set of mold halves with a second amount of the material, wherein the first and second amounts are substantially similar, and wherein an exothermic reaction of the second amount commences; and mating the second set of mold halves with the partially covered precursor after a third predetermined time, wherein the mold halves are mated for a fourth predetermined time that is sufficient for complete exothermic reaction of the second amount of material.