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Multi-layer golf balls comprising ionomers with a percent neutralization gradientRelated Patent Categories: Games Using Tangible Projectile, Golf, Ball, Particular Unitary Or Layered Construction, Containing Metal, Diverse Layer Between Spherical Core And CoverMulti-layer golf balls comprising ionomers with a percent neutralization gradient description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060211518, Multi-layer golf balls comprising ionomers with a percent neutralization gradient. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS [0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/270,066, filed Nov. 9, 2005, which is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/959,751, filed Oct. 6, 2004, which is a continuation-in-part of co-pending U.S. patent 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. patent 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 Patent Application Ser. 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 multi-layer golf balls comprising at least two adjacent layers of neutralized polymers, of which at least one layer may be a highly neutralized moisture resistant polymer (HNMRP), whereby the at least two adjacent layers show a percent neutralization gradient that either increases or decreases from the center. [0003] The present invention is also directed to multi-layer golf balls comprising at least two adjacent layers of neutralized polymers, of which at least one layer may be an ionomer, whereby the at least two adjacent layers show a percent neutralization gradient that either increases or decreases from the center. BACKGROUND OF THE INVENTION [0004] 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 include a solid, hollow, or fluid-filled center, surrounded by a tensioned elastomeric material, and a cover. [0005] Golf ball core and cover layers are typically constructed with polymer compositions including, for example, polybutadiene rubber, polyurethanes, polyamides, ionomers, and blends thereof. Ionomers, particularly highly neutralized ionomers, are a preferred group of polymers for golf ball layers because of their toughness, durability, and wide range of hardness values. However, conventional highly neutralized polymers (RNP) are hydrophilic due to the use of magnesium ions to neutralize the ionomers. Therefore the conventional highly neutralized ionomers can absorb a significant amount of moisture that can lead to processing difficulties and reduction in golf ball performance such as decreased coefficient of restitution ("COR") and stiffness due to the plasticization of ionic aggregates by water molecules. [0006] Therefore, there remains a need for improved water or moisture resistant golf ball compositions and, in particular, highly neutralized or filly neutralized ionomers. The present invention exemplifies the use of these novel compositions in at least two adjacent layers of neutralized ionomeric polymers with a percent neutralization gradient that either increases or decreases from the center. At least one of the at least two adjacent layers can be a highly neutralized moisture resistant polymer, SUMMARY OF THE INVENTION [0007] The present invention is directed to a multilayer golf ball including a core, an intermediate layer, and a cover, the intermediate layer and cover bring adjacent to each other. At least one of the intermediate layer or cover includes a first highly neutralized moisture resistant acid polymer composition having a moisture vapor transmission rate of 8 g-mil/100 in2/day or less. The adjacent layer (intermediate layer or cover) not including the first highly neutralized moisture resistant acid polymer includes a second highly neutralized acid polymer. The two adjacent layers, in tandem, form a percent neutralization gradient. [0008] In one embodiment, the percent neutralization gradient progressively increases toward the outside of the golf ball. Alternatively, the percent neutralization gradient progressively decreases toward the outside of the golf ball. The first highly neutralized moisture resistant acid polymer preferably has a moisture vapor transmission rate of 5 g-mil/100 in2/day or less, more preferably 3 g-mil/100 in2/day or less. At least one of the first and second highly neutralized acid polymers comprise acid groups that are at least 90% neutralized, more preferably 100% neutralized. The first highly neutralized moisture resistant acid polymer is neutralized with less hydrophilic cation sources, such as metal ions and compounds of potassium, cesium, calcium, barium, manganese, copper, zinc, and tin. [0009] The total golf ball has a first volume and the two layers formed from the first and second highly neutralized acid polymers combine to have a second volume that is at least 40 percent of the first volume, more preferably at least 70 percent of the first volume, most preferably at least 90 percent of the first volume. [0010] The present invention is also directed to a multi-layer golf ball including a core and at least three adjacent layers comprising highly-neutralized acid polymers. The three adjacent layers include an innermost layer, an intermediate layer, and an outermost layer. The golf ball has a first volume and a combination of the innermost, intermediate, and outermost adjacent layers form a percent neutralization gradient and have a second volume that is at least about 40% of the first volume. More preferably, the second volume is at least 70% of the first volume, most preferably the second volume is at least 90% of the first volume. [0011] In one embodiment, the percent neutralization gradient progressively increases toward the outside of the golf ball. Preferably, the percent neutralization of the innermost layer is from about 20 to 70, the percent neutralization of the intermediate layer is from about 50 to 90, and the percent neutralization of the outermost layer is from about 70 to 100, and wherein the percent neutralization of the innermost layer is less than the percent neutralization of the intermediate layer, and the percent neutralization of the intermediate layer is less than the percent neutralization of the outermost layer. [0012] In an alternative embodiment, the percent neutralization gradient progressively decreases toward the outside of the golf ball. Preferably, the percent neutralization of the innermost layer is from about 70 to 100, the percent neutralization of the intermediate layer is from about 50 to 90, and the percent neutralization of the outermost layer is from about 20 to 70, and wherein the percent neutralization of the innermost layer is greater than the percent neutralization of the intermediate layer, and the percent neutralization of the intermediate layer is greater than the percent neutralization of the outermost layer. [0013] The present invention is further directed to a multi-layer golf ball including a core layer, an intermediate layer adjacent to the core layer, and an outermost layer adjacent to the intermediate layer. The golf ball has a first volume and at least two of the adjacent layers comprise a neutralized acid polymer, said two adjacent layers combining to form a percent neutralization gradient. Preferably, the combined adjacent layers have a second volume that is at least 40% of the first volume, more preferably at least 70% of the first volume, and most preferably at least 90% of the first volume. [0014] In one embodiment, the percent neutralization gradient progressively increases towards the outside of the golf ball. In an alternative embodiment, the percent neutralization gradient progressively decreases towards the outside of the golf ball. The neutralized acid polymer typically includes acid groups that are neutralized from about 80 to 100%. BRIEF DESCRIPTION OF THE DRAWINGS [0015] In the accompanying drawings which form a part of the specification and are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views: [0016] FIG. 1 is a front view of a golf ball in accordance to the present invention; [0017] FIG. 2 is a cross-sectional view of the golf ball in FIG. 1 showing a solid core, an intermediate layer and a cover; and [0018] FIG. 3 is a cross-sectional view of another golf ball in accordance to the present invention showing a solid core with multiple intermediate layers and a cover. DETAILED DESCRIPTION OF THE INVENTION Continue reading about Multi-layer golf balls comprising ionomers with a percent neutralization gradient... 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