Patent Publication Number: US-6705463-B1

Title: Flip top golf ball container assembly provided with moisture barrier properties

Description:
RELATED APPLICATION 
     This application claims priority to provisional application Serial No. 60/210,113, filed Jun. 7, 2000. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an improved container assembly for golf balls, and more particularly, relates to a golf ball packaging that preserves the mechanical and physical characteristics of the ball during storage and transport. 
     2. Description of the Related Art 
     Golf balls generally come in two different varieties, solid golf balls and multi-piece golf balls. A solid golf ball consists of a polymeric sphere having a plurality of molded dimples which aid the flight characteristics of the golf ball. Solid golf balls are usually used for practicing, where high performance is not a priority, such as in driving ranges. Multi-piece golf balls exhibit better playing characteristics than solid golf balls and are consequently used on golf courses during play. A multipiece golf ball consists of either a wound or solid rubber core that is covered with a separate and distinct cover. The cover often comprises a single thermoplastic layer. Recently, new types of multi-piece golf balls have been introduced having a multilayered compound including a plastic mantle surrounding a solid polybutadiene rubber core and an external thermoplastic envelope. The solid core or the center of a wound core is generally made of an elastomer, such as a CIS content polybutadiene rubber which is combined with a zinc or other metal salt of unsaturated fatty acid. Often, small amounts of zinc oxide are also added to the core in order to achieve a higher performance in restitution, as described below. 
     The cover of a multi-piece golf ball is typically made from a material that contributes to the durability of the ball and also provides the particular “feel” characteristics of the ball when struck with a club. By way of example, a two-piece golf ball construction of a rubber core and an ionomer cover generally provides a very durable ball and also provides maximum traveling distance to the ball when struck with a club. 
     Golf ball manufacturers have recently introduced a new type of two-piece golf ball for use by tour players. The new golf balls provide a softer feeling to the ball when struck with a club. Manufacturers have achieved this characteristic by lowering the core compression and softening the cover of the golf ball. Golf ball manufacturers have also recently developed a three-layer golf ball having an intermediate mantle between the core and the cover. The three-layer golf ball provides a softer feel to the golf ball while also providing maximum distance and durability. 
     Unfortunately, multi-piece golf balls typically absorb moisture when they are subjected to prolonged storage under ambient conditions of temperature and humidity. A short period of moisture absorption can cause significant changes in the performance characteristics of the ball. Such moisture absorption may affect the weight of the ball, as well as the physical and mechanical characteristics of the various materials that make up the different pieces of the golf ball structure, including the cover, the core and the mantle. 
     One other characteristic that is affected by moisture absorption is the initial velocity of the golf ball. United States Golf Association (USGA) rules govern the allowable ranges of initial velocity values for golf balls. According to the USGA rules, the initial velocity must not exceed a value of 250 feet per second, with a maximum tolerance of 2%. Consequently, golf ball manufacturers have sought to manufacture golf balls that have an initial velocity as close as possible to the 255 feet per second limit, without exceeding this value. 
     As described in U.S. Pat. No. 5,875,891, moisture has been shown to adversely affect the initial velocity of a ball over a very short period of time. According to this reference, “the initial velocity loss is approximately 2.5 ft/sec. over twelve months for golf balls having a soft cover, between 50 to 60 shore D, in an environment of 72° F. and 50% of relative humidity (RH). Such a initial velocity loss of 2.5 ft/sec. corresponds to a loss of distance of approximately 6 to 10 yards when the ball is struck with a driver. For a golf ball having a hard cover, between 68-72 shore D in the same conditions, the initial velocity loss over 12 months is approximately 0.5 ft/sec.” 
     The problem of moisture absorption is particularly acute for soft cover balls because the soft cover is more permeable to moisture than a hard cover, so the moisture reaches the core more easily. Because it is made of a highly hygroscopic material, the core absorbs this moisture, which degrades the desired properties of the core. The degradation in performance characteristics is generally accelerated when the ambient storage temperature becomes higher. For a soft cover ball at a temperature around 110° F. and 50% RH, a velocity loss of 2.5 ft/sec may occur in only a few weeks, as opposed to twelve months for a soft cover ball in an environment of 72° F. and 50% RH. During transportation of the golf ball from the manufacturing facility to a retail store, actual storage conditions are closer to these conditions. Consequently, soft cover balls may experience a large reduction in performance characteristics when being transported from the manufacturing facilities to the retail store. 
     U.S. Pat. No. 5,875,891 discloses a packaging for golf balls that acts as a barrier inhibiting moisture absorption by a golf ball during storage. In one embodiment, the packaging includes a sealing member that defines an internal closed volume that is configured to receive golf ball(s). The sealing member preferably has a laminate structure that includes a moisture barrier layer, a sealing layer and a structural layer. According to the reference, “There is therefore a need for a packaging that may be used to store golf balls prior to first use and prevent the damage associated with difficult storage and shipping conditions, such as temperature and moisture. Such a packaging should sufficiently protect the golf ball to ensure the freshness of the golf ball and preserve the optimum properties of the golf ball prior to first use, while also preserving and protecting the structure of the ball. The packaging should be both capable of protecting single or multiple golf balls and retaining the physical and mechanical properties of the ball, such as the initial velocity value, until the packaging is opened.” The reference purports to satisfy these needs. U.S. Pat. No. 5,875,981 at col. 3 lines 49-65. 
     U.S. Pat. Nos. 4,783,056 and 4,812,116, the latter being a divisional of the former, disclose a mold and a process for making an aseptic vial and cap. The teachings of these references are incorporated herein by reference. 
     Co-pending U.S. application Ser. No. 09/386,702 filed on Aug. 31, 1999, and assigned to the same assignee as the present application, discloses a leakproof, resealable container and cap assembly which comprises a cap and container attached by a hinge. The container has an upper portion and an outer surface, and at the upper portion, the container has a rim. The cap has a circular base portion with an outer periphery and a cylindrical tubular skirt extending perpendicularly and outwardly around said outer periphery of the base; the skirt has an inner wall which includes at least one recess. In another embodiment, the cap has opposing ends; the cap has a thumb tab for facilitating the opening and closing of the container and the hinge attached to the container. The thumb tab and hinge are positioned on opposing ends of the cap and extend perpendicularly and outwardly from the skirt of the cap. In a further embodiment, the skirt of the cap overlies the container and the rim of the container is situated within the recess of the inner wall of the skirt of the cap during a closed position. The container may also be provided with a flange projecting radially outwardly from the outer surface of the container. The hinge may be attached to the container flange and the skirt of the cap is designed to overlie the rim of the container and be in uniform close proximity to the container flange during the closed position. The cap and container assembly, when in the closed position, form a leakproof, air tight seal. The cap and container may be integrally molded of plastic, forming a hinge therebetween. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a resealable container and cap assembly for storing and packaging golf balls. The container substantially prohibits the ingress of moisture into the container through the lid when the container is sealed. In other words, it is substantially moisture-proof. In another aspect of the invention, the container assembly is provided with a desiccant or similar material which reduces the moisture present within the container when it is sealed. That is, after the container has been sealed, the desiccant absorbs moisture present in the cavity. Likewise, after the container has been opened and then resealed, the desiccant absorbs moisture that entered the cavity when the container was opened. 
     In one embodiment of the present invention, the assembly comprises a cap and container that may be attached by a hinge. The container has an upper portion and an outer surface, and at the upper portion, the container has a rim. The cap has a base portion with an outer periphery and a skirt extending perpendicularly and outwardly around said outer periphery of the base; the skirt has an inner wall. The cap sealingly engages with the upper portion of the container which provides a seal between the interior of the container and the outside environment. 
     The container and cap may be non-circular in shape. For instance, the container and cap may be provided with corners, either squared or rounded. The container and cap may be any non-circular shape, such as a triangle or an ellipse, without regard to whether the shape is symmetrical or not. Although the container and cap may take a circular shape, non-circular shapes may be preferable since it permits the user to insert a finger or object into the container and remove a ball, rendering the inversion of the container to remove a ball unnecessary. 
     In another embodiment, the cap has a thumb tab for facilitating the opening and closing of the container, and a hinge is attached to the container. The thumb tab and hinge are positioned on opposing ends of the cap and extend perpendicularly from the skirt of the cap. In a further embodiment, the skirt of the cap overlies the rim of the container and the rim of the container is situated within a recess of the inner wall of the skirt of the cap during the closed position. 
     The container may also be provided with a flange projecting radially outwardly from the outer surface of the container. The hinge may be attached to the container flange and the skirt of the cap is designed to overlie the rim of the container and be in uniform close proximity to the container flange during the closed position. The cap and container assembly, when in the closed position, form a leakproof, moisture proof seal. The cap and container may be integrally molded of plastic, with the hinge formed therebetween. 
     In a further embodiment, the hinge of the assembly has a recess positioned between two elements, the first element being attached to the skirt of the cap and the second element being attached to the container. The recess may be a piece of thermoplastic integral with the two elements, the recess being relatively thinner than the two elements. In still a further embodiment, the recess functions as a bending point during the opening and closing of the container. 
     In a further embodiment a ridge is provided on the base of the cap and extends perpendicularly in the direction of the skirt. The ridge is positioned a distance away from the skirt which approximately corresponds to the thickness of the rim and/or upper portion of the container. This arrangement creates a gap between the ridge and the skirt. When the cap is closed onto the container, the rim of the container resides within the gap. Together, the ridge, skirt, and rim forming a substantially moisture proof seal. 
     While the present invention is described in terms of providing a moisture proof container for the packaging and storing of golf balls, is it evident that this container can be used to store any of a number of other items that would benefit from being packaged and stored in a dry environment. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side view of one embodiment of the present invention; 
     FIG. 2 is an top plan view of the embodiment of FIG. 1; 
     FIG. 3 is a side elevational view of an embodiment of the container and cap assembly of the present invention in a closed position; 
     FIG. 4 is a cross-sectional side view of an embodiment of the assembly in a closed position; 
     FIG. 5 is a perspective view of an embodiment of the hinge which connects the cap and container; 
     FIG. 6 is a side elevational view of an embodiment of the container and cap assembly of the present invention sized to hold three golf balls; 
     FIG. 7 is a side elevational view of another embodiment of the present invention; 
     FIG. 8 is a plot of moisture ingress through the seal over a 50 day period (measured in hours); 
     FIG. 9 is a plot of shelf life of golf balls stored in container with desiccant. 
    
    
     DETAILED DESCRIPTION OF THE PRESENT INVENTION 
     The present invention relates to a moisture proof, resealable container and lid assembly. The term “resealable” means that the closure can be closed at least once after the container is opened for the first time. Preferably, the closure can be opened and closed additional times after the initial opening. 
     In another embodiment, the cap and container assembly, in a closed position, forms a moisture proof seal. The term “moisture proof” refers to a rate of ingress of moisture into a sealed container of about 500 μg/day or less determined by the test method of the example. 
     Referring now to FIGS. 1 and 2, where one embodiment of the resealable cap and container assembly  10  of the present invention is illustrated, the assembly  10  includes a container  20  having a base  28 , an internal cavity  27 , an outer surface  25 , an upper portion  21  and lower portion  26 . The container  20  has a rim  22  at the upper portion  21 . The assembly  10  also has a cap  30  which has a base  31  and a skirt  33  extending perpendicularly around the outer periphery of the base  31 . The cap  30  is provided with a thumb tab  36  for facilitating the opening and closing of the container, and is attached to the container  20  by hinge  40 . The tab  36  and hinge  40  are preferably positioned on opposing ends of the cap and extend perpendicularly from the skirt  33  of the cap  30 . A desiccant puck  3  can be seen sitting at the bottom of the container in FIG.  2 . 
     The container may also have a flange  24  projecting radially outwardly from the outer surface  25  of the container  20 . The hinge  40  may also be attached to the container flange  24 . The hinge  40  also has a recess  42  that functions as a bending point during the opening and closing of the container. The hinge  40  has two elements,  40 A and  40 B, respectively, formed on either side of the recess. One element  40 A is attached to the flange  24  of the container  20  and the second element  40 B is attached to the cap  30 . 
     As illustrated in FIG. 2, the cap and container are non-circular in shape. The cap and container each have curved sides  50  and flat sides  52 , joined by rounded corners  54 . A non-circular shape can facilitate the removal of a golf ball without the need to invert the container, as discussed above. Any kind of non-circular shape can be used in this invention, without regard to whether the shape is symmetrical or asymmetrical. Suitable shapes include the square, triangle, ellipse, rectangle, trapezoid, and numerous others. If the assembly is provided with corners, as is the case with the embodiment of FIGS. 1 and 2, they may be squared or rounded. Furthermore, the skilled artisan would understand that the assembly could be circular in its shape. 
     The container is sized to hold at least one golf ball. It can be sized to hold one ball, or a plurality of balls (i.e.—two, three, four, five, or any other possible number). In an exemplary depiction shown in FIG. 6, the container is sized to hold three golf balls. 
     Suitable material for assembly  10  includes plastic (e.g. thermoplastics such as polypropylene and polyethylene). In one embodiment, the cap  30  and container  20  may be integrally molded of the plastic to form a hinge  40  therebetween. In one embodiment, the cap  30  and container  20  may be produced in a molding process and, in another embodiment, may be molded in accordance with the mold similar to that disclosed in U.S. Pat. Nos. 4,783,056 and 4,812,116, respectively or, in another embodiment, may be produced in accordance with U.S. Pat. No. 5,723,085. The disclosure of these patents are incorporated by reference herein. 
     Turning to FIG. 5, which shows the hinge  40  of one embodiment of the present invention, the recess  42  is characterized by a relatively thinner section of plastic material which bridges thicker sections  40 A,  40 B of the hinge  40  . The recess  42  is a location which bends relatively easily and acts as the location where the hinge folds when the lid is closed, and as the location where the hinge opens when the lid is opened. 
     In another embodiment, the thumb tab  36  has a length from about 0.125 inches to about 0.325 inches, preferably 0.235 inches, measured from the outside perimeter of the cap to the end of the tab. In still another embodiment, the assembly  10  can be sealed and/or resealed by applying, in a singular motion, downward pressure upon the thumb tab or base of the cap  31  to obtain a leakproof seal. As an example a user places his or her thumb parallel or on top of the thumb tab (i.e. the frontal portion of the container) and applies a downward pressure until an audible snap is heard and then verified by visual inspection of uniform cap position around the flange. The same effect can be obtained if the user presses down upon the base of the cap  31 . 
     FIG. 3 depicts a side elevational view of the present invention in a closed position. The cap and container assembly  10  comprises the cap  30  and the container  20  connected by the hinge  40 . The container  20  has a flange  24  extending from the outer surface  25  and a base  28 . The cap  30  has a skirt  33  and the thumb tab  36  extending perpendicular from the skirt  33 . In a closed position, the skirt  33  of the cap  30  overlies the container  20  and lies upon the flange  24  of the container  20 . 
     FIG. 4 illustrates a cross-sectional view of the assembly  10  in a closed position. The skirt  33  of the cap  30  overlies the container  20  and lies upon the flange  24  of the container  30  while the rim  22  of the container  20  is situated within the recess  32  of the inner wall  35  of the skirt  33  of the cap  30 . The container  20  can be sealed and/or resealed by applying, in a singular motion, downward pressure upon the thumb tab  36  or the base of the cap  31  to obtain a moisture proof seal. 
     FIG. 7 illustrates another embodiment of the present invention. Container  12  is provided with wall  13 , which defines an internal cavity  15 . The upper region of the container wall  13  is provided with a rim  63  extending around the periphery of the container  12 . Rim  63  and the smooth transition surface at upper edge  62  of the container  12  form an annular region for interlocking with the cap  14 . In one embodiment, the outer diameter at the rim  63  is greater than the outer wall diameter of wall  13 . In one embodiment, it is about 0.025″ greater. The outer diameter of the rim  63  is constant for about 0.033″ at a first rim surface  65 . Adjacent the first rim surface  65 , a second rim surface  67  tapers down to the outer wall  13  of the container  12  over a distance of about 0.030″ at an oblique angle, suitably about 21°. 
     The container  12  may be integrally connected to the cap  14  by means of a tab or flange  16 . Cap  14  has a base  85 , and a skirt  87  extending therefrom. Extending perpendicular to the skirt  87  is a thumb tab  88  for facilitating the opening and closing of the container. Ridge  74  is positioned on the interior  70  of the base  85 , and extends perpendicularly therefrom. The outer wall  77  of the ridge  74  and the wall surfaces  87  of the cap rim define a gap  81  into which rim  63  is fitted to form a moisterproof seal when the cap is in the closed position. An end surface  79  of the ridge  74  interconnects the inner edge  75  with the outer edge  77 . 
     The ridge  74 , the gap  81  and the cylindrical skirt  87  combine to form an annular region for interlocking with the rim  63  on the container  12 . The rim  63  is adapted to sealingly fit within the gap  81  formed between the seal  74  and the outer cap rim. The top surface  76  forms a smooth transition surface to further guide the seal  74  around the container wall. 
     In one embodiment, to insure that the moisture which may is enter the container assembly is absorbed so it does not adversely affect golf ball performance, a desiccant, in the shape of a disc (e.g. puck), sleeve, or other shapes, either conforms to a part of the container or is placed within the container. U.S. Pat. No. 5,911,937 discloses a process and resulting structure for producing a desiccant insert. The method of making the desiccant insert is incorporated by reference herein as an embodiment of one method of making the desiccant insert. In addition, U.S. Pat. No. 5,911,937 discloses various structures and positions in the container for the desiccant insert including a plug and a liner in the container. These structures and positions are also incorporated by reference herein as embodiments of various structures and positions of the desiccant insert. 
     In another embodiment, a suitable puck is constructed as follows: (a) 35% Polypropylene (Aristech manufacturer); (b) 5% Polyethylene Glycol (Dow manufacturer “E4500”); and (c) 60% Molecular Sieve (Elf AtoChem manufacturer “MS4A”). The above percentages are on a weight/weight basis. The components are blended and extruded into pellets. The pellets are injection molded into the desiccant puck. All sample components are in the solid phase. The total weight of the molded puck can be approximately 4.5 grams. In another embodiment, a desiccant may be blended with a thermoplastic material to form a suitable shape. 
     EXAMPLE 
     The moisture ingress through the flip-top seal of the container described in FIGS. 1-4 was determined over a fifty (50) day period. A total of six (6) vials were used for the study. Two vials, referred to as CONTROL A and CONTROL B, do not contain desiccant. Four other vials, referred to as Samples C, D, E, F, have 2.0 grams of loose molecular sieve (MS) powder placed inside, plus or minus 0.25 grams. The dimensions of the containers are approximately 1.8″ in diameter×5.3″ tall. The test method can be described as follows: (a) placing two grams plus or minus 0.25 grams of molecular sieve (“MS”) into four (4) containers 1.8″ in diameter×5.3″ tall and recording the weight; (b) recording the weight of two of the same containers which do not contain any MS material, which containers are maintained as controls; (c) closing the containers by applying, in a singular motion, a downward pressure upon the container lids or thumb tabs until the rim portions, adjacent to the thumb tabs, contact the inside flat part of the caps also adjacent to the thumb tabs; (d) weighing the six (6) containers and recording their respective weights; (e) placing the closed containers in an environmental chamber maintained at conditions of 80% relative humidity and 72□F; (f) weighing the containers on a daily basis for fifty (50) days, recording the weights of the respective containers, and returning them to the chamber; (g) subtracting the weights recorded in steps (a) and (b) from the current day weight of the respective containers to calculate the moisture ingress of the container in units of micrograms of water; and (h) determining the moisture ingress through the seal by discounting the moisture ingress through the vial, according to the following methodology, calculated on a daily basis: 
     n—Sample Type (A-F) 
     Sn—Sample Weight Gain=(Current Vial Weight—Initial Vial Weight at Start of Study) 
     Ctrl—Average Weight Gain of Control Samples=(SA+SB)/2 
     TS—Average Weight Gain of Test Samples=(SC+SD+SE+SF)/4 
     MI—Moisture Ingress through Seal=(TS−Ctrl). 
     A relative humidity transducer is mounted in the environmental chamber. The transducer measures the relative humidity inside the chamber. The transducer is a capacitive type, composed of a thin polymer film, with a 0-100% relative humidity operating range, accuracy +3%RH from 10-90% at (−20-40□C), resolution: &gt;0.04% between (25-60% RH). 
     Results 
     The data collected shows that the average moisture ingress through the flip-top seal is 318 μg per day over the test period. The rate of moisture ingress is relatively constant over the test period, as shown by the plot in FIG.  8 . The data is presented in Table 1. The MS absorbed approximately 5% of its total capacity. 
     FIG. 9 shows the relationship between shelf life and moisture ingress rate of a 4.5 gram desiccant puck containing 60% (w/w) desiccant material.