Golf ball with vapor barrier layer and method of making same

Abstract

A golf ball with at least one moisture vapor barrier layer is disclosed. In accordance to one aspect of the invention, the moisture vapor barrier layer may comprise butyl rubber. The butyl rubber may also be a halogenated butyl rubber such as bromobutyl rubber or chlorobutyl rubber. The butyl rubber may also be a sulfonated butyl rubber. The butyl rubber may be blended with other polymers. In accordance to another aspect of the invention, the moisture vapor barrier layer is placed on to a core subassembly and cured by infrared radiation (IR). IR-curable moisture vapor barrier materials include, but not limited to, butyl rubber, polysulfide rubber and single-pack castable polymers, among others. In accordance to another aspect of the invention, an outer layer of the golf ball may comprise a polymer that has a cured temperature greater than the softening temperature or melting temperature of the encased subassembly. Such outer layer may be cured by IR. The outer layer may be a cover, an intermediate layer or a moisture vapor barrier layer.

What is claimed is:  
     
         1 . A golf ball comprising a core, a moisture vapor barrier layer and a cover, wherein the moisture barrier layer has a moisture vapor transmission rate that is lower than that of the cover and wherein the moisture vapor barrier layer comprises butyl rubber.  
     
     
         2 . The golf ball of  claim 1 , wherein the butyl rubber comprises a halogenated butyl rubber.  
     
     
         3 . The golf ball of  claim 2 , wherein the halogenated butyl rubber is a bromobutyl rubber.  
     
     
         4 . The golf ball of  claim 2 , wherein the halogenated butyl rubber is a chlorobutyl rubber.  
     
     
         5 . The golf ball of  claim 1 , wherein the butyl rubber is a sulfonated butyl rubber.  
     
     
         6 . The golf ball of  claim 2 , wherein the halogenated butyl rubber is blended with a double bond-vulcanizable rubber.  
     
     
         7 . The golf ball of  claim 6 , wherein the core comprises a diene rubber.  
     
     
         8 . The golf ball of  claim 7 , wherein the core comprises a polybutadiene rubber.  
     
     
         9 . The golf ball of  claim 1 , wherein the moisture vapor transmission rate of the moisture vapor barrier layer is less than the moisture vapor transmission rate of ionomer resin.  
     
     
         10 . The golf ball of  claim 1 , wherein the moisture vapor transmission rate of the moisture vapor barrier layer is less than about 0.6 grams·mM/m 2 ·day.  
     
     
         11 . The golf ball of  claim 1 , wherein the moisture barrier layer comprises filler.  
     
     
         12 . The golf ball of  claim 11 , wherein the filler is selected from a group consisting of aluminum, mica, micaceous iron oxide, metal, ceramic and graphite.  
     
     
         13 . The golf ball of  claim 1 , wherein the butyl rubber is blended with ethylene propylene diene monomer rubber.  
     
     
         14 . The golf ball of  claim 1 , wherein the butyl rubber is blended with vinylidene chloride polymer.  
     
     
         15 . A golf ball comprising a core, a moisture vapor barrier layer and a cover, wherein the moisture barrier layer has a moisture vapor transmission rate that is lower than that of the cover and wherein the moisture vapor barrier comprises a brominated polymer, wherein the brominated polymer comprises a copolymer of isobutylene and p-methylstyrene.  
     
     
         16 . The golf ball of  claim 15 , wherein the brominated polymer is blended with a double bond-vulcanizable rubber.  
     
     
         17 . The golf ball of  claim 16 , wherein the core comprises a diene rubber.  
     
     
         18 . The golf ball of  claim 17 , wherein the core comprises a polybutadiene rubber.  
     
     
         19 . The golf ball of  claim 15 , wherein the moisture vapor transmission rate of the moisture vapor barrier layer is lower than the moisture vapor transmission rate of ionomer resin.  
     
     
         20 . The golf ball of  claim 1 , wherein the moisture vapor transmission rate of the moisture vapor barrier layer is less than about 0.6 grams·mm/m 2 ·day.  
     
     
         21 . The golf ball of  claim 1 , wherein the moisture barrier layer comprises filler.  
     
     
         22 . The golf ball of  claim 21 , wherein the filler is selected from a group consisting of aluminum, mica, micaceous iron oxide, metal, ceramic and graphite.  
     
     
         23 . A golf ball comprising a core, a moisture vapor barrier layer and a cover, wherein the moisture barrier layer has a moisture vapor transmission rate that is lower than that of the cover and wherein the moisture vapor barrier comprises polyisobutylene.  
     
     
         24 . A golf ball comprising a core subassembly, an outer layer encasing the core subassembly, wherein the outer layer comprises a polymer having a crosslinking temperature that is higher than the softening temperature of a portion of the core subassembly.  
     
     
         25 . The golf ball of  claim 24 , wherein the crosslinking temperature is higher than the melting temperature of a portion of the core subassembly.  
     
     
         26 . The golf ball of  claim 24 , wherein the core subassembly comprises a core.  
     
     
         27 . The golf ball of  claim 26 , wherein the core subassembly further comprises at least an intermediate layer encasing the core.  
     
     
         28 . The golf ball of  claim 24 , wherein the outer layer is a cover layer.  
     
     
         29 . The golf ball of  claim 24 , wherein the outer layer is an intermediate layer.  
     
     
         30 . The golf ball of  claim 24 , wherein the outer layer is a moisture vapor barrier layer.  
     
     
         31 . The golf ball of  claim 24 , wherein the outer layer is cured by infrared radiation.  
     
     
         32 . A golf ball comprising a core and a moisture vapor barrier layer and a cover, wherein the moisture barrier layer has a moisture vapor transmission rate that is lower than that of the cover and wherein the moisture vapor barrier layer is cured by infrared radiation.  
     
     
         33 . The golf ball of  claim 32 , wherein the moisture vapor barrier layer comprises butyl rubber.  
     
     
         34 . The golf ball of  claim 33 , wherein the butyl rubber is a halogenated butyl rubber.  
     
     
         35 . The golf ball of  claim 33 , wherein the butyl rubber is a sulfonated butyl rubber.  
     
     
         36 . The golf ball of  claim 32 , wherein the moisture vapor barrier layer comprises polysulfide rubber.  
     
     
         37 . The golf ball of  claim 32 , wherein the moisture vapor barrier layer comprises a single-pack castable polymer.  
     
     
         38 . The golf ball of  claim 37 , wherein the single-pack castable isocyanate comprises uretdione moiety.  
     
     
         39 . The golf ball of  claim 38 , wherein the isocyanate is blended with an amine or polyol.  
     
     
         40 . The golf ball of  claim 37 , wherein the single-pack castable isocyanate comprises blocked isocyanate.  
     
     
         41 . The golf ball of  claim 40 , wherein the isocyanate is blended with an amine or polyol.  
     
     
         42 . The golf ball of  claim 37 , wherein the single-pack castable polymer comprises 3,5 dimethylpyrazole (DMP) blocked-IPDI.  
     
     
         43 . The golf ball of  claim 1 , wherein the cover has a Shore D hardness of less than about 65.  
     
     
         44 . The golf ball of  claim 43 , wherein the cover has a Shore D hardness between about 30 and about 60.  
     
     
         45 . The golf ball of  claim 44 , wherein the cover has a Shore D hardness between about 35 and about 50.  
     
     
         46 . The golf ball of  claim 45 , wherein the cover has a Shore D hardness between about 40 and about 45.  
     
     
         47 . The golf ball of  claim 1 , wherein the cover has a thickness between about 0.010 inch to about 0.050 inch.  
     
     
         48 . The golf ball of  claim 47 , wherein the cover has a thickness of about 0.030.  
     
     
         49 . The golf ball of  claim 1 , wherein the cover comprises a thermoset polymer.  
     
     
         50 . The golf ball of  claim 49 , wherein the thermoset polymer is thermoset polyrrethane.  
     
     
         51 . The golf ball of  claim 49 , wherein the thermoset polymer is thermoset polyurethane ionomer.  
     
     
         52 . The golf ball of  claim 49 , wherein the thermoset polymer is thermoset polyurethane epoxy.  
     
     
         53 . The golf ball of  claim 1 , wherein the cover comprises thermoplastic polyurethane.  
     
     
         54 . The golf ball of  claim 1 , wherein the core comprises polybutadiene.  
     
     
         55 . The golf ball of  claim 1 , wherein the core comprises a polymer, wherein the polymer is selected from a group consisting of natural rubber, polyisoprene, styrene-butadiene rubber, styrene-propylene-diene rubber, ionomer resin, polyamide, polyester, polyether amide copolymer, polyether ester copolymer, thermoplastic urethane, styrenic block copolymers elastomer, urethane, polyurea, epoxy, silicone, IPN, reaction injection molded polyurethane, and reaction injection molded polyurea.  
     
     
         56 . The golf ball of  claim 1 , wherein the moisture vapor barrier layer is formed by spraying.  
     
     
         57 . The golf ball of  claim 1 , wherein the moisture vapor barrier layer is formed by dipping.  
     
     
         58 . The golf ball of  claim 1 , wherein the moisture vapor barrier layer is formed by casting.  
     
     
         59 . The golf ball of  claim 1 , wherein the moisture vapor barrier layer is formed by compression molding.  
     
     
         60 . The golf ball of  claim 1 , wherein the moisture vapor barrier layer is formed by injection molding.