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Highly-neutralized acid polymer compositions having a low moisture vapor transmission rate and their use in golf ballsRelated Patent Categories: Games Using Tangible Projectile, Golf, Ball, Particular Unitary Or Layered Construction, Containing Metal, Diverse Layer Between Spherical Core And CoverHighly-neutralized acid polymer compositions having a low moisture vapor transmission rate and their use in golf balls description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070015608, Highly-neutralized acid polymer compositions having a low moisture vapor transmission rate and their use in golf balls. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation-in-part of U.S. application Ser. No. 11/270,066, filed Nov. 9, 2005, which is a continuation-in-part of U.S. application Ser. No. 10/959,751, filed Oct. 6, 2004, which is a continuation-in-part of U.S. application Ser. No. 10/360,233, filed Feb. 6, 2003, now U.S. Pat. No. 6,939,907, which is a continuation-in-part of U.S. application Ser. No. 10/118,719, filed Apr. 9, 2002, now U.S. Pat. No. 6,756,436, which claims priority to U.S. Provisional Application No. 60/301,046, filed Jun. 26, 2001, the entire disclosures of which are hereby incorporated herein by reference. FIELD OF THE INVENTION [0002] The present invention is directed to compositions having a moisture vapor transmission rate of 12.5 gmil/100 in.sup.2/day or less and comprising a highly neutralized acid polymer. The present invention is also directed to the use of such compositions in golf equipment, and particularly in two-piece and multi-layer golf balls having an overall core diameter of 1.00 inch or greater. The present invention is also directed to one-piece golf balls formed from such compositions. BACKGROUND OF THE INVENTION [0003] Conventional golf ball core materials, such as polybutadiene rubber, have a tendency to absorb moisture when exposed to atmospheric moisture for prolonged periods. Such moisture absorption can lead to undesirable golf ball properties and performance. Thus, in some golf ball constructions, a water vapor barrier layer is necessary to prevent exposure of the core to atmospheric moisture or water. [0004] Urethane is known to be useful as a golf ball cover layer material. However, urethane has a high moisture vapor transmission rate. Therefore, golf balls having a urethane cover typically require a layer underneath having a low moisture vapor transmission rate. [0005] A desire remains in the golf ball industry for core compositions having low moisture vapor transmission rates. The present invention describes such compositions and the use thereof in a variety of golf ball core layers. SUMMARY OF THE INVENTION [0006] In one embodiment, the present invention is directed to a two-piece golf ball consisting of a single layer core having a diameter of 1.58 inches or greater and a polyurethane or polyurea cover having a thickness of 0.05 inches or less. The core has a compression of from 50 to 85 and is formed from a composition having a moisture vapor transmission rate of 12.5 gmil/100 in.sup.2/day or less and comprising a highly neutralized acid polymer. [0007] In another embodiment, the present invention is directed to a multi-layer golf ball consisting of an inner core layer, an outer core layer, and a polyurethane or polyurea cover. The inner core layer has a diameter of 1.58 inches or greater, a compression of from 50 to 85, and is formed from a composition having a moisture vapor transmission rate of 12.5 gmil/100 in.sup.2/day or less and comprising a highly neutralized acid polymer. The outer core layer has a thickness of from 0.01 inches to 0.02 inches. The cover has a thickness of 0.04 inches or less. [0008] In yet another embodiment, the present invention is directed to a one-piece golf ball formed from a composition having a moisture vapor transmission rate of 2.5 gmil/100 in.sup.2/day or less and comprising a highly neutralized acid polymer. The ball has a diameter of from 1.62 inches to 1.74 inches, a compression of from 50 to 85, and a COR of 0.800 or greater. DETAILED DESCRIPTION OF THE INVENTION [0009] Conventional golf balls can be divided into two general classes: solid and wound. Solid golf balls include one-piece, two-piece (i.e., solid core and a cover), and multi-layer (i.e., solid core of one or more layers and/or a cover of one or more layers) golf balls. Wound golf balls typically include a solid, hollow, or fluid-filled center, surrounded by a tensioned elastomeric material, and a cover. [0010] Golf balls of the present invention include one-piece, two-piece, multi-layer, and wound golf balls having a variety of core structures, intermediate layers, covers, and coatings. Golf ball cores may consist of a single, unitary layer, comprising the entire core from the center of the core to its outer periphery, or they may consist of a center surrounded by at least one outer core layer. The center, innermost portion of the core is preferably solid, but may be hollow or liquid-, gel-, or gas-filled. The outer core layer may be solid, or it may be a wound layer formed of a tensioned elastomeric material. Golf ball covers may also contain one or more layers, such as a double cover having an inner and outer cover layer. Optionally, additional layers may be disposed between the core and cover. [0011] Golf balls of the present invention have at least one layer formed from a moisture resistant composition comprising a highly neutralized polymer as disclosed herein. In a preferred embodiment, the layer formed from the moisture resistant composition is the core of a two-piece golf ball. In another preferred embodiment, the layer formed from the moisture resistant composition is the inner core layer of a multi-layer golf ball. In yet another preferred embodiment, the present invention provides a one-piece golf ball formed from the moisture resistant composition. [0012] For purposes of the present disclosure, a composition is "moisture resistant" if it has a moisture vapor transmission rate ("MVTR") of 12.5 gmil/100 in.sup.2/day or less. Preferably, the moisture resistant compositions of the present invention have an MVTR of 8.0 gmil/100 in.sup.2/day or less, or 6.5 gmil/100 in.sup.2/day or less, or 5.0 gmil/100 in.sup.2/day or less, or 4.0 gmil/100 in.sup.2/day or less, or 2.5 gmil/100 in.sup.2/day or less, or 2.0 gmil/100 in.sup.2/day or less. As used herein, moisture vapor transmission rate (MVTR) is given in gmil/100 in.sup.2/day, and is measured at 20.degree. C., and according to ASTM F1249-99. [0013] Moisture resistant compositions of the present invention comprise a highly neutralized acid polymer ("HNP") and optionally one or more additional materials including, but not limited to, organic acids and salts thereof, fillers, additives, and non-fatty acid melt flow modifiers. In a preferred embodiment, the moisture resistant compositions consist essentially of an HNP and optionally one or more additional materials selected from the group consisting of organic acids and salts thereof fillers, additives, and non-fatty acid melt flow modifiers. Consisting essentially of, as used herein, means that the recited components are essential, while smaller amounts of other components may be present to the extent that they do not detract from the operability of the present invention. [0014] As used herein, "highly neutralized" refers to the acid polymer after at least 70%, preferably at least 80%, more preferably at least 90%, even more preferably at least 95%, and even more preferably 100%, of the acid groups thereof are neutralized. The HNP may be neutralized by a cation, a salt of an organic acid, a suitable base of an organic acid, or any combination of two or more thereof. [0015] Suitable HNPs are salts of homopolymers and copolymers of .alpha.,.beta.-ethylenically unsaturated mono- or dicarboxylic acids, and combinations thereof The term "copolymer," as used herein, includes polymers having two types of monomers, those having three types of monomers, and those having more than three types of monomers. Preferred acids are (meth) acrylic acid, ethacrylic acid, maleic acid, crotonic acid, fumaric acid, itaconic acid. (Meth) acrylic acid is particularly preferred. As used herein, "(meth) acrylic acid" means methacrylic acid and/or acrylic acid. Likewise, "(meth) acrylate" means methacrylate and/or acrylate. Preferred acid polymers are copolymers of a C.sub.3 to C.sub.8 .alpha.,.beta.-ethylenically unsaturated mono- or dicarboxylic acid and ethylene or a C.sub.3 to C.sub.6 .alpha.-olefin, optionally including a softening monomer. Particularly preferred acid polymers are copolymers of ethylene and (meth) acrylic acid. [0016] When a softening monomer is included, the acid polymer is referred to herein as an E/X/Y-type copolymer, wherein E is ethylene, X is a C.sub.3 to C.sub.8 .alpha.,.beta.-ethylenically unsaturated mono- or dicarboxylic acid, and Y is a softening monomer. The softening monomer is typically an alkyl (meth) acrylate, wherein the alkyl groups have from 1 to 8 carbon atoms. Preferred E/X/Y-type copolymers are those wherein X is (meth) acrylic acid and/or Y is selected from (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, methyl (meth) acrylate, and ethyl (meth) acrylate. More preferred E/X/Y-type copolymers are ethylene/(meth) acrylic acid/n-butyl acrylate, ethylene/(meth) acrylic acid/methyl acrylate, and ethylene/(meth) acrylic acid/ethyl acrylate. [0017] The amount of ethylene or C.sub.3 to C.sub.6 .alpha.-olefin in the acid copolymer is typically at least 15 wt %, preferably at least 25 wt %, more preferably at least 40 wt %, and even more preferably at least 60 wt %, based on the total weight of the copolymer. The amount of C.sub.3 to C.sub.8 .alpha.,.beta.-ethylenically unsaturated mono- or dicarboxylic acid in the acid copolymer is typically within a range having a lower limit of 1 wt %, or 3 wt %, or 4 wt %, or 5 wt %, and an upper limit of 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, based on the total weight of the copolymer. The amount of optional softening comonomer in the acid copolymer is typically within a range having a lower limit of 0 wt %, or 5 wt %, 10 wt %, 15 wt %, and an upper limit of 20 wt %, or 30 wt %, or 35 wt %, or 40 wt %, or 50 wt %, based on the total weight of the copolymer. [0018] The acid polymer may be partially neutralized prior to being neutralized to 70% and higher. Suitable partially neutralized acid polymers include, but are not limited to, Surlyn.RTM. ionomers, commercially available from E. I. du Pont de Nemours and Company; AClyn.RTM. ionomers, commercially available from Honeywell International Inc.; and Iotek.RTM. ionomers, commercially available from ExxonMobil Chemical Company. [0019] In a particular embodiment, the acid polymer is selected from Nucrel.RTM. acid copolymers, commercially available from E. I. du Pont de Nemours and Company (such as Nucrel.RTM. 960, an ethylene/methacrylic acid copolyiner); Primacor.RTM. polymers, commercially available from Dow Chemical Company (such as Primacor.RTM. XUS 60758.08L and XUS60751.18, ethylene/acrylic acid copolymers containing 13.5 wt % and 15.0 wt % acid, respectively); and partially neutralized ionomers thereof. Continue reading about Highly-neutralized acid polymer compositions having a low moisture vapor transmission rate and their use in golf balls... 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