Patent ID: 7314587

Claim:
A method of forming a golf ball comprising the steps of (a) forming a golf ball core; (b) forming an inner cover layer around said golf ball core with a material having a first shore D hardness, wherein forming the inner cover layer comprises molding the inner cover material; and (c) casting an outer cover layer of less than about 0.05 inches around said inner cover layer and golf ball core with a thermoset material having a second shore D hardness less than the first, wherein casting the outer cover layer comprises: (i) placing the golf ball core in core holder; (ii) gelling the thermoset material to a viscosity of between 2,000 cps to 30,000 cps in the first mold half; (iii) placing the golf ball core in to the gelling thermoset material in the first mold half; (iv) disengaging the golf ball core from the core holder after a selected period of time; (v) placing the golf ball core, while still in said first mold half with the thermoset material against a second mold half having additional thermoset material and mating the two mold halves together; and (vi) curing the thermoset material in the mated mold halves.