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  Multi-layer golf ball having a cover layer with increased moisture resistanceUSPTO Application #: 20070060417Title: Multi-layer golf ball having a cover layer with increased moisture resistance Abstract: A golf ball having a core, a harder non-ionomer inner layer, and a cover layer. The inner layer having a material hardness of 50 Shore D to 80 Shore D, a flexural modulus of 30 to 175 kpsi, and comprising a composition that comprises a polyester elastomer. The cover layer is formed from a composition having multiple reactive and/or non-reactive ingredients, and having a material hardness of 25 Shore D to 70 Shore D and a flexural modulus of 2,000 psi to 100,000 psi. The cast cover includes a composition that comprises a hydrogenated telechelic polyhydrocarbon polyahl having a number average molecular weight of 1,500 to 10,000. The cover is a cast urethane or urea material. (end of abstract)
Agent: Acushnet Company - Fairhaven, MA, US Inventor: Christopher Cavallaro USPTO Applicaton #: 20070060417 - Class: 473371000 (USPTO) Related Patent Categories: Games Using Tangible Projectile, Golf, Ball, Particular Unitary Or Layered Construction The Patent Description & Claims data below is from USPTO Patent Application 20070060417. 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. 11/243,850, filed Oct. 5, 2005, which is a continuation-in-part of U.S. application Ser. No. 11/162,538, filed Sep. 14, 2005, which is a continuation-in-part of U.S. application Ser. No. 10/656,704, filed Sep. 5, 2003, now U.S. Pat. No. 6,989,422. These applications and patent are entirely incorporated herein by reference. FIELD OF THE INVENTION [0002] The present disclosure is directed to a golf ball that has a polyester elastomer intermediate layer covered by a cover layer having increased resistance to water and moisture vapor in comparison to conventional golf ball cover layers. BACKGROUND OF THE INVENTION [0003] One conventional material used to form golf ball covers is balata, a natural or synthetic trans-polyisoprene rubber. The softness of the balata cover allows the player to achieve spin rates sufficient to more precisely control ball direction and distance, particularly on shorter shots. However, balata covers lack the durability required by the average golfer, and are easily damaged. Accordingly, alternative cover compositions have been developed in an attempt to provide balls with spin rates and a feel approaching those of balata covered balls, while also providing a golf ball with a higher durability and overall distance. [0004] Ionomer resins (e.g., copolymers of olefin, such as ethylene, and ethylenically unsaturated carboxylic acids, such as (meth)acrylic acids, wherein the acid groups are partially or fully neutralized by metal ions) have also been used as golf ball cover materials. Ionomer covers may be virtually cut-proof, but in comparison to balata covers, they display inferior spin and feel properties. [0005] Polyurethanes and polyureas, by providing soft "feel," have also been recognized as useful materials for golf ball covers. However, conventional polyurethane covers do not match ionomer covers with respect to resilience or rebound. Unsaturated components (such as aromatic diisocyanate, aromatic polyol, and/or aromatic polyamine) used in a polyurethane or polyurea composition may at least in part attribute to the composition's susceptibility to discoloration and degradation upon exposure to thermal and actinic radiation, such as ultraviolet (UV) light. Conventional polyurethane covers can be prone to absorption of moisture, which is another mechanism through which desirable physical properties in the cover may be compromised. Moisture passed through the cover may further deteriorate physical and performance properties of the core. [0006] Therefore, a continuing need remains for novel golf ball construction, and particularly for a golf ball cover that has the desirable and/or optimal combination of physical and performance characteristics, and still be hydrophobic and thus resistant to moisture absorption. The golf ball disclosed herein has superior and desirable hydrophobicity and resistance to moisture absorption without sacrificing playability. SUMMARY [0007] This disclosure is directed to a multi-layered golf ball having a core, at least one intermediate layer disposed about the core, and a cover disposed about the intermediate layer. The core may have a diameter of 1.65 inches or less, preferably 1.64 or less, a compression of 100 or less, a deflection at 100 kg force of 1.0 mm or greater, preferably 1.5 mm or greater, and a CoR of 0.77 or greater, preferably 0.78 or greater. The intermediate layer may have material hardness in Shore D of 50-80, and a flexural modulus that ranges from 30 to 175 kpsi. The golf ball may have a CoR of 0.78 or greater, preferably 0.79 or greater, a compression of 110 or less, a deflection at 100 kg force of 1.0 mm or greater, a diameter of 1.68 inches or greater, a MOI of 87 or less, and a dimple pattern having 250-450 dimples. [0008] The core may have a specific gravity of 1.4 g/cm.sup.3 or less, and a center hardness that is less than a surface hardness by 3 Shore C points or more. [0009] The intermediate layer is formed from a polyester elastomer (Hytrel), and may possess Shore D hardness in the range of 50-80 and flex modulii that ranges from 30 to 175 kpsi. The hardness of the intermediate layer is greater than the outer cover by at least 5 Shore D points [0010] The cover layer may be formed from a composition comprising a hydrogenated telechelic polyhydrocarbon polyahl having a M.sub.n of 1,500 to 1 0,000, preferably 3,000 to 5,000, and a functionality of 1.8 to 2.0, preferably 1.9, a saturated polyisocyanate (e.g., bis(isocyanatocyclohexyl)-methane), and a saturated secondary polyamine (e.g., bis(sec-butylamino)-dicyclohexylmethane). Preferably, the telechelic polyahl forms soft segment in the resulting reaction product. The cover may be a thermoplastic or thermoset polyurethane or polyurea, preferably a cast thermoset. The cover may have a water vapor permeability of 0.1 gmm/(m.sup.2daymm Hg) or less. The golf ball may display a low weight gain, when subjected to total water submersion at ambient temperature for 3 weeks, of 0.003 oz/wk or less. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0011] Broadly, the present disclosure is directed to golf balls and compositions used to form such golf balls. The golf balls may have a compression of 110 or less, a deflection at 100 kg force of 1.0 mm or greater, a coefficient of restitution ("CoR") of 0.79 or more, preferably 0.825 or less, a moment of inertia ("MOI") of 87 or less, an overall diameter of 1.68 inches or greater, and/or a dimple pattern having 250 to 450 dimples. When subjected to a total submersion test in tap water at ambient temperature, the golf balls display a low weight gain, with a 3-week averaged weight gain of preferably 0.003 oz/wk or less, more preferably 0.002 oz/wk or less, most preferably 0.001 oz/wk or less. The MOI is typically measured on model number MOI-005-104 Moment of Inertia Instrument manufactured by Inertia Dynamics of Collinsville, Conn. The instrument is plugged into a COMM port of a PC and is driven by MOI Instrument Software version #1.2. [0012] An embodiment of the golf ball may have a 3-piece construction comprising of a core, an intermediate layer and a cover. Optionally, the golf ball has a coating layer disposed about the cover. The cover may be formed from a thermoplastic or thermoset material having urethane and/or urea linkages (e.g., polyurethane, polyurea), having a material hardness of 25-65 Shore D, a flexural modulus of 2,000 psi or greater, and/or a water vapor transmission rate ("WVTR") less than or equal to that of Surlyn.RTM.. The material may have a water vapor permeability, in unit of gmm/(m.sup.2daymm Hg), of 0.1 or less, preferably 0.05 or less, more preferably 0.03 or less, most preferably 0.02 or less. Polyurethanes and polyureas, by providing soft "feel," have been recognized as useful materials for golf ball covers. However, conventional polyurethane covers do not match ionomer covers with respect to resilience or rebound. Unsaturated components (such as aromatic diisocyanate, aromatic polyol, and/or aromatic polyamine) used in a polyurethane or polyurea composition may at least in part attribute to the composition's susceptibility to discoloration and degradation upon exposure to thermal and actinic radiation, such as ultraviolet (UV) light. Conventional polyurethane covers can be prone to absorption of moisture, which is another mechanism through which desirable physical properties in the cover may be compromised. Moisture passed through the cover may further deteriorate physical performance. The present invention incorporates the use of a polyester elastomer (such as in the Hytrel family) for the intermediate layer, which provides an inventive aspect in that this layer may be at least 5 Shore D hardness points higher than the cover. This type of construction provides the hardness necessary for distance but still provides the "feel" of the soft polyester elastomer cover. When such a soft cover has been utilized in the prior art, it was necessary to provide moisture protection in the intermediate layer by using an ionomer. The present invention provides the moisture protection in the cover composition. [0013] The core of the 2-piece balls may have a diameter of 1.64 inches or less, a compression of 100 or less, a deflection at 100 kg force of 1.5 mm or greater, a CoR of 0.78 or greater, a specific gravity of 1.4 g/cm.sup.3 or less, and/or a center hardness less than a surface hardness by 3 Shore C points or more, preferably by 5 Shore C points or more. The core may be formed from a free radical initiator cured rubber composition comprising a rubber or a blend thereof having a Mooney viscosity of 30 or greater, a crosslinking agent at a level of 15 phr or greater by weight of the rubber, a rubber regrind, a filler, and/or optionally a CoR enhancer. Suitable rubbers, free radical initiators, crosslinking agents, and CoR enhancers include high cis polybutadiene rubbers, dicumyl peroxide, zinc diacrylate, and zinc pentachlorothiophenol, respectively, as well as any and all of those disclosed in the parent applications and in U.S. application Ser. Nos. 11/173,282 and 60/689,901, the disclosures of which are incorporated by reference in their entirety. [0014] The center of the 3-piece balls may have a diameter of 0.375 inches to 1.6 inches, a compression of 10 to 60, and/or a deflection at 100 kg force of 1.0 mm or greater. The center may be formed from free radical initiator cured rubber composition comprising a rubber or a blend thereof having a Mooney viscosity of 30 or greater, a cross-linking agent at a level of 10 phr to 40 phr, a rubber regrind, a filler, and/or optionally a CoR enhancer. The core having the center and the outer core layer of the 3-piece balls may have a diameter of 1.64 inches or less, a compression of 100 or less, a deflection at 100 kg force of 1.0 mm or greater, a CoR of 0.78 or greater, and/or a surface hardness of 60 Shore C or greater. The outer core layer may be formed from a free radical initiator cured rubber composition comprising a rubber or a blend thereof having a Mooney viscosity of 30 or greater, a crosslinking agent at a level of 25 phr to 55 phr, a rubber regrind, trans polyisoprene, a filler, and/or optionally a CoR enhancer. [0015] Golf balls of the present disclosure comprise compositions formed at least in part from one or more telechelic polyahls having a hydrophobic polyhydrocarbon backbone. In one example, suitable telechelic polyahls have a polydispersity of 1.35 or less, preferably 1.3 or less (e.g., 1.26 to 1.23, or less), more preferably 1.2 or less, and most preferably 1.1 or less, with 1.0 being the theoretical minimum. In another example, the polyhydrocarbon backbone of the telechelic polyahl may be partially, substantially, or fully hydrogenated. In a further example, the telechelic polyahls may be liquid at ambient temperatures. In a further example, the telechelic polyahls may have a functionality (e.g., hydroxyl, primary or secondary amine) of 2.1 or less, preferably 2.0 or less, but 1.8 or greater, preferably 1.9 or greater. In a further example, the telechelic polyahls may have a M.sub.n of 2,000 or greater, preferably 3,000 or greater, but 5,000 or less. [0016] In homotelechelic polyahls, the reactive end-groups may be hydroxyl groups (secondary, tertiary, preferably primary, or combination thereof) or amine groups (primary, preferably secondary, or combination thereof). In heterotelechelic polyahls, at least one of the reactive end-groups is amine or hydroxyl group (e.g., one being amine group and another being hydroxyl group). The telechelic polyahls may have an average hydroxyl or amine functionality of 1.6 or greater, preferably 1.8 or greater. The telechelic polyahls may further have additional hydroxyl and/or amine groups at the terminals, directly on the polymer backbone, on the branched side chains off the backbone, if any, and/or at the terminals of the branched side chains, if any. Any one or more of the secondary amine groups may in part form a single-ring or multi-ring heterocyclic structure. Preferred homotelechelic polyahls include .alpha.,.omega.-dihydroxy telechelics and .alpha.,.omega.-diamino telechelics; preferred heterotelechelic polyahls include .alpha.-amino-.omega.-hydroxy telechelics. [0017] Amine or hydroxyl functionalities of suitable telechelic polyahls may be chosen specifically for certain chemical reactivity and/or physical properties. In one example, the telechelic polyahls may have a low amine or hydroxyl functionality of 1.6 or greater, preferably 1.8 or greater, more preferably 1.9 or greater, further preferably 2.3 or less, further preferably 2.15 or less, further preferably 2.0 or less. In another example, the telechelic polyahls may have a mid-range amine or hydroxyl functionality of 2.4 or greater, preferably 2.9 or less, more preferably 2.6 or less. Telechelic polyahls having different amine or hydroxyl functionalities may be used singly or in combinations of two or more thereof. In one example, one, two, or more telechelic polyahls of low amine or hydroxyl functionalities may be used in a composition together with one, two, or more telechelic polyahls of mid-range amine or hydroxyl functionalities. [0018] In one example, the compositions may further include at least one isocyanate (including any and all of those disclosed in the parent applications, preferably saturated, like bis(isocyanatocyclohexyl)-methane) and one or more additional reactants, and form thermoplastic, thermoset, castable, millable, or foamable (intumescent or swellable) reaction products that have urethane and/or urea linkages (e.g., polyurethanes, polyureas, poly(urethane-urea)s). In a further example, the one or more telechelic polyahls may form soft segments in the reaction products, such as by reacting with the at least one isocyanate to form a prepolymer, which is then chain-extended by one or more additional reactants (including any and all curatives disclosed in the parent applications, preferably saturated, like secondary polyamines such as 4,4'-bis(sec-butylamino)-dicyclohexylmethane) to form the reaction products. [0019] In a further example, the one or more telechelic polyahls may form hard segments in the reaction products, such as by reacting with an NCO-containing prepolymer to form the reaction products. Continue reading... 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