Patent Grant
11472085
The present disclosure relates to polymeric materials, and particularly to polymeric films. More particularly, the present disclosure relates to gas-permeable barrier films formed from polymeric material and filler.
According to the present disclosure, a gas-permeable barrier film is made using a manufacturing process. The manufacturing process comprises the steps of extruding a composition to form a molten web, casting the molten web to form a quenched film, and stretching the quenched film to form the gas-permeable barrier film.
In illustrative embodiments, the composition extruded to form the molten web comprises a polyolefin and an inorganic filler. The quenched film is formed by casting the molten web against a surface of a chill roll, and the quenched film is then stretched.
In illustrative embodiments, a gas-permeable barrier film comprising a polyolefin and an inorganic filler dispersed in the polyolefin has a basis weight of less than about 100 gsm. The gas-permeable barrier film also has a Gurley porosity of less than about 330 seconds.
In illustrative embodiments, a multi-layer gas-permeable barrier film comprises at least one gas-permeable barrier film according to the present disclosure and at least one additional layer.
In illustrative embodiments, a sterilizable package, a garment, and a building material each comprise a gas-permeable barrier film in accordance with the present disclosure.
Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
The detailed description particularly refers to the accompanying figures in which:
A first embodiment of a gas-permeable barrier film 2 in accordance with the present disclosure is shown, for example, in
A precursor film containing a thermoplastic polymer 4 and a solid filler 6 dispersed in the thermoplastic polymer 4 may be produced by either a cast film process or a blown film process. The film thus produced may then be stretched by one or more stretching processes. The stretching process moves (e.g., pulls) polymeric material away from the surface of solid filler dispersed therein, thereby forming the micropores 8.
In one example, stretching may be achieved via machine direction (MD) stretch by a process analogous to that shown in simplified schematic form in
In another example, stretching may be achieved via transverse or cross-directional (CD) stretching by a process analogous to that shown in simplified schematic form in
In a further example, stretching may be achieved via intermeshing gears (IMG) stretching by a process analogous to the one shown in simplified schematic form in
A precursor film containing a thermoplastic polymer 4 and a solid filler 6 dispersed in the polymer 4 that is stretched to form a gas-permeable barrier film 2 in accordance with the present disclosure may be prepared by mixing together the thermoplastic polymer 4 (or a combination of thermoplastic polymers 4), the solid filler 6, and any optional components until blended, heating the mixture, and then extruding the mixture to form a molten web. A suitable film-forming process may be used to form a precursor film en route to forming a gas-permeable barrier film. For example, the precursor film may be manufactured by casting or extrusion using blown-film, co-extrusion, or single-layer extrusion techniques and/or the like. In one example, the precursor film may be wound onto a winder roll for subsequent stretching in accordance with the present disclosure. In another example, the precursor film may be manufactured in-line with a film stretching apparatus such as shown in one or more of
In addition to containing one or more thermoplastic polymers and solid filler, the precursor film may also contain other optional components to improve the film properties or processing of the film. Representative optional components include, but are not limited to, anti-oxidants (e.g., added to prevent polymer degradation and/or to reduce the tendency of the film to discolor over time) and processing aids (e.g., added to facilitate extrusion of the precursor film). In one example, the amount of one or more anti-oxidants in the precursor film is less than about 1% by weight of the film and the amount of one or more processing aids is less than about 5% by weight of the film. Additional optional additives include but are not limited to whitening agents (e.g., titanium dioxide), which may be added to increase the opacity of the film. In one example, the amount of one or more whitening agents is less than about 10% by weight of the film. Further optional components include but are not limited to antiblocking agents (e.g., diatomaceous earth) and slip agents (e.g. erucamide a.k.a. erucylamide), which may be added to allow film rolls to unwind properly and to facilitate secondary processing. In one example, the amount of one or more antiblocking agents and/or one or more slip agents is less than about 5% by weight of the film. Further additional optional additives include but are not limited to scents, deodorizers, pigments other than white, noise reducing agents, and/or the like, and combinations thereof. In one example, the amount of one or more scents, deodorizers, pigments other than white, and/or noise reducing agents is less than about 10% by weight of the film.
Prior to stretching, the precursor film may have an initial basis weight of less than about 400 grams per square meter (gsm). In one example, the precursor film has an initial basis weight of less than about 350 gsm. The precursor film may be a monolayer film, in which case the entire precursor film comprises the thermoplastic polymer (or combination of thermoplastic polymers) and solid filler (or combination of solid fillers). In another example, the precursor film may be a multilayer film as shown in
In one example, a gas-permeable barrier film 2 in accordance with the present disclosure is formed via a blown film process. In another example, a gas-permeable barrier film 2 in accordance with the present disclosure is formed via a cast film process. The cast film process involves the extrusion of molten polymers through an extrusion die to form a thin film. The film is pinned to the surface of a chill roll with an air knife, an air blanket, and/or a vacuum box. Alternatively, the film is subjected to an embossing process on a patterned chill roll.
In illustrative embodiments, a process for making a gas-permeable barrier film 2 in accordance with the present disclosure includes (a) extruding a composition containing a thermoplastic polymer 4 and a solid filler 6 to form a molten web, (b) casting the molten web against a surface of a chill roll to form a quenched film, and (c) stretching the quenched film to form the gas-permeable barrier film 2.
It has been discovered that by extruding a composition containing a thermoplastic polymer and an inorganic filler, and then subjecting the quenched film to a stretching process as described herein, gas-permeable barrier films 2 exhibiting surprisingly and unexpectedly improved properties as compared to other gas-permeable barrier films may be prepared. As further described below, these properties may include high gas transmission rate (e.g., high porosity) in combination with moisture and microbial barrier protection. The combination of high gas transmission rate and barrier protection is desirable for applications ranging from medical/pharmaceutical packaging to house wraps, and was heretofore achieved using flashspun high-density polyethylene of the type sold under the trade name TYVEK by Dupont. Since TYVEK is formed from a loose fibril structure that is subsequently compacted to achieve a desired degree of microbial barrier, gas-permeable barrier films 2 in accordance with the present disclosure, which are not based on the intermediacy of a loose fibril structure, may provide greater control over the uniformity of the porosity of a film.
In accordance with the present disclosure, the casting of the molten web against a surface of a chill roll to form a quenched film may be achieved in various ways. In illustrative embodiments, a vacuum box, blowing air (e.g., an air knife and/or an air blanket), or a vacuum box in combination with blowing air to form a quenched film may be used to cast the molten web against the chill roll. In thin film applications, the use of a vacuum box and/or blowing air may avoid the phenomenon of draw resonance that may arise in embossing processes. However, for applications requiring thicker films (e.g., basis weights greater than about 75 gsm in the case of a polypropylene film), draw resonance may not be a problem, and the quenched film may instead be formed by an embossing process. While neither desiring to be bound by any particular theory nor intending to limit in any measure the scope of the appended claims or their equivalents, it is presently believed that an embossing process may further serve to increase porosity of a quenched film in accordance with the present disclosure.
A high degree of orientation (e.g., such as found in an MDO or biaxially-oriented film) oftentimes results in a splitty film. Thus, it was surprising and unexpected to observe that a high degree of orientation was not required in order to achieve high porosity in a microporous film in accordance with the present disclosure. Rather, a gas-permeable barrier film with good properties was obtained by subjecting a quenched film to a stretching process in accordance with the present disclosure. In illustrative embodiments, the stretching process includes CD IMG stretching followed by post-stretching (e.g., in a machine direction). While neither desiring to be bound by any particular theory nor intending to limit in any measure the scope of the appended claims or their equivalents, it is presently believed that the process of CD IMG stretching and subsequent post-stretching results in lanes of unstretched material, which correspond to portions of the film that travelled atop teeth in the CD IMG rollers. These lanes of unstretched material provide toughness to the film that may prevent tear propagation.
Representative techniques for casting a molten web against a surface of a chill roll to form a quenched film in accordance with the present disclosure are described below.
In one example, the molten web is cast against the surface of the chill roll under negative pressure using a vacuum box as shown in simplified schematic form in
When a vacuum box 42 is used, the molten polymer may exit the die 40 and hit the chill roll 38 within a smaller distance than in an embossed process. For example, in some embodiments, the melt curtain is configured to hit the chill roll 38 within a distance of less than about 12 inches, 11 inches, 10 inches, 9 inches, 8 inches, 7 inches, 6 inches, 5 inches, 4 inches, 3, inches, 2 inches, or 1 inch. In illustrative embodiments, the melt curtain is configured to exit the die and hit the roll within a distance of less than about 3 inches and, in some examples, within a distance of about or less than 1 inch. One advantage of reducing the distance between the die 40 and the roll surface 38 as compared to in a nipped quench process is that smaller distances are less susceptible to the phenomenon of neck-in. Neck-in refers to a reduction in width of the molten web that occurs as the web leaves the die. By drawing the film 46 onto a surface of the chill roll 38 over a short distance as shown in
In another example, the molten web is cast against the surface of the chill roll under positive pressure using an air knife or air blanket, as shown in simplified schematic form in
In a further example, the molten web is cast against the surface of the chill roll under a combination of negative pressure from a vacuum box, as shown in
In a further example, the molten web is cast against the surface of the chill roll via an embossing process, as shown in simplified schematic form in
In illustrative embodiments, a process for making a gas-permeable barrier film 2 in accordance with the present disclosure may be executed as shown in simplified schematic form in
The thermoplastic polymer 4 (or combination of thermoplastic polymers 4) used to make a gas-permeable barrier film 2 in accordance with the present disclosure is not restricted, and may include all manner of thermoplastic polymers capable of being stretched and of forming micropores. In illustrative embodiments, the thermoplastic polymer is a polyolefin, including but not limited to homopolymers, copolymers, terpolymers, and/or blends thereof.
Representative polyolefins that may be used in accordance with the present disclosure include but are not limited to polyethylene, polypropylene, and a combination thereof. By way of example, representative polyolefins include but are not limited to low density polyethylene (LDPE), high density polyethylene (HDPE), linear low density polyethylene (LLDPE), ultra-low density polyethylene (ULDPE), polypropylene, ethylene-propylene copolymers, polymers made using a single-site catalyst, ethylene maleic anhydride copolymers (EMAs), ethylene vinyl acetate copolymers (EVAs), polymers made using Ziegler-Natta catalysts, styrene-containing block copolymers, and/or the like, and combinations thereof. Methods for manufacturing LDPE are described in The Wiley Encyclopedia of Packaging Technology, pp. 753-754 (Aaron L. Brody et al. eds., 2nd Ed. 1997) and in U.S. Pat. No. 5,399,426, both of which are incorporated by reference herein, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
ULDPE may be produced by a variety of processes, including but not limited to gas phase, solution and slurry polymerization as described in The Wiley Encyclopedia of Packaging Technology, pp. 748-50 (Aaron L. Brody et al. eds., 2nd Ed. 1997), incorporated by reference above, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
ULDPE may be manufactured using a Ziegler-Natta catalyst, although a number of other catalysts may also be used. For example, ULDPE may be manufactured with a metallocene catalyst. Alternatively, ULDPE may be manufactured with a catalyst that is a hybrid of a metallocene catalyst and a Ziegler-Natta catalyst. Methods for manufacturing ULDPE are also described in U.S. Pat. Nos. 5,399,426, 4,668,752, 3,058,963, 2,905,645, 2,862,917, and 2,699,457, each of which is incorporated by reference herein in its entirety, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail. The density of ULDPE is achieved by copolymerizing ethylene with a sufficient amount of one or more monomers. In illustrative embodiments, the monomers are selected from 1-butene, 1-hexene, 4-methyl-1-pentene, 1-octene, and combinations thereof. Methods for manufacturing polypropylene are described in Kirk-Othmer Concise Encyclopedia of Chemical Technology, pp. 1420-1421 (Jacqueline I. Kroschwitz et al. eds., 4th Ed. 1999), which is incorporated herein by reference, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
In illustrative embodiments, a polyolefin for use in accordance with the present disclosure includes polyethylene, polypropylene, or a combination thereof. In one example, the polyethylene includes linear low density polyethylene which, in some examples, includes a metallocene polyethylene. In another example, the polyethylene includes a combination of linear low density polyethylene and low density polyethylene. In a further example, the polyolefin consists essentially of only linear low density polyethylene. In another example, the polypropylene includes polypropylene impact copolymer. In a further example, the polyolefin consists essentially of polypropylene impact copolymer.
In addition to thermoplastic polymer (e.g., polyolefin), a composition to be extruded in accordance with the present disclosure further includes a solid filler. The solid filler is not restricted, and may include all manner of inorganic or organic materials that are (a) non-reactive with thermoplastic polymer, (b) configured for being uniformly blended and dispersed in the thermoplastic polymer, and (c) configured to promote a gas-permeable structure within the film when the film is stretched. In illustrative embodiments, the solid filler includes an inorganic filler.
Representative inorganic fillers for use in accordance with the present disclosure include but are not limited to sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, alumina, mica, talc, silica, clay (e.g., non-swellable clay), glass spheres, titanium dioxide, aluminum hydroxide, zeolites, and a combination thereof. In illustrative embodiments, the inorganic filler includes an alkali metal carbonate, an alkaline earth metal carbonate, an alkali metal sulfate, an alkaline earth metal sulfate, or a combination thereof. In one example, the inorganic filler includes calcium carbonate.
In another example, the solid filler includes a polymer (e.g., high molecular weight high density polyethylene, polystyrene, nylon, blends thereof, and/or the like). The use of polymer fillers creates domains within the thermoplastic polymer matrix. These domains are small areas, which may be spherical, where only the polymer filler is present as compared to the remainder of the thermoplastic matrix where no polymer filler is present. As such, these domains act as particles.
The solid filler 6 provided in a composition to be extruded in accordance with the present disclosure may be used to produce micropores 8 of film 2, as shown in
It is also within the scope of the present disclosure for the average particle size of the solid filler 6 provided in a composition to be extruded in accordance with the present disclosure to fall within one of many different ranges. In a first set of ranges, the average particle size of the solid filler 6 is in one of the following ranges: about 0.1 microns to 15 microns, 0.1 microns to 14 microns, 0.1 microns to 13 microns, 0.1 microns to 12 microns, 0.1 microns to 11 microns, 0.1 microns to 10 microns, 0.1 microns to 9.9 microns, 0.1 microns to 9.8 microns, 0.1 microns to 9.7 microns, 0.1 microns to 9.6 microns, 0.1 microns to 9.5 microns, 0.1 microns to 9.4 microns, 0.1 microns to 9.3 microns, 0.1 microns to 9.2 microns, 0.1 microns to 9.1 microns, 0.1 microns to 9 microns, 0.1 microns to 8 microns, 0.1 microns to 7 microns, 0.1 microns to 6 microns, 0.1 microns to 5 microns, 0.1 microns to 4 microns, and 0.1 microns to 3 microns. In a second set of ranges, the average particle size of the solid filler 6 is in one of the following ranges: about 0.1 microns to 5 microns, 0.2 microns to 5 microns, 0.3 microns to 5 microns, 0.4 microns to 5 microns, 0.5 microns to 5 microns, 0.6 microns to 5 microns, 0.7 microns to 5 microns, 0.8 microns to 5 microns, 0.9 microns to 5 microns, and 1.0 microns to 5 microns. In a third set of ranges, the average particle size of the solid filler 6 is in one of the following ranges: about 0.1 microns to 4.9 microns, 0.2 microns to 4.8 microns, 0.3 microns to 4.7 microns, 0.4 microns to 4.6 microns, 0.5 microns to 4.5 microns, 0.6 microns to 4.4 microns, 0.7 microns to 4.3 microns, 0.8 microns to 4.2 microns, 0.9 microns to 4.1 microns, and 1.0 microns to 4.0 microns.
In illustrative embodiments, the amount of solid filler used in accordance with the present disclosure includes from about 30% by weight to about 75% by weight of the composition to be extruded, quenched film formed from the extruded composition, and/or gas-permeable barrier film formed from the quenched film. In further illustrative embodiments, the amount of solid filler used in accordance with the present disclosure includes from about 50% by weight to about 75% by weight of the composition to be extruded, quenched film formed from the extruded composition, and/or gas-permeable barrier film formed from the quenched film. Although amounts of filler outside this range may also be employed, an amount of solid filler that is less than about 30% by weight may not be sufficient to impart uniform breathability to a film. Conversely, amounts of filler greater than about 75% by weight may be difficult to blend with the polymer and may cause a loss in strength in the final gas-permeable barrier film.
The amount of solid filler 6 may be varied based on a desired end use (e.g., the desired properties of the gas-permeable barrier film 2). In one example, the amount of solid filler 6 ranges from about 40% to about 60% by weight of the composition, quenched film, and/or gas-permeable barrier film. In another example, the amount of solid filler 6 ranges from about 45% to about 55% by weight of the composition, quenched film, and/or gas-permeable barrier film. The amount of solid filler 6 may be one of several different values or fall within one of several different ranges. For example, it is within the scope of the present disclosure to select an amount of the solid filler 6 to be one of the following values: about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, or 75% by weight of the composition, quenched film, and/or gas-permeable barrier film.
It is also within the scope of the present disclosure for the amount of the solid filler 6 to fall within one of many different ranges. In a first set of ranges, the amount of the solid filler 6 is in one of the following ranges: about 31% to 75%, 32% to 75%, 33% to 75%, 34% to 75%, 35% to 75%, 36% to 75%, 37% to 75%, 38% to 75%, 39% to 75%, 40% to 75%, 41% to 75%, 42% to 75%, 43% to 75%, 44% to 75%, and 45% to 75% by weight of the composition, quenched film, and/or gas-permeable barrier film. In a second set of ranges, the amount of the solid filler is in one of the following ranges: about 30% to 74%, 30% to 73%, 30% to 72%, 30% to 71%, 30% to 70%, 30% to 69%, 30% to 68%, 30% to 67%, 30% to 66%, 30% to 65%, 30% to 64%, 30% to 63%, 30% to 62%, 30% to 61%, 30% to 60%, 30% to 59%, 30% to 58%, 30% to 57%, 30% to 56%, 30% to 55%, 30% to 54%, 30% to 53%, 30% to 52%, 30% to 51%, 30% to 50%, 30% to 49%, 30% to 48%, 30% to 47%, 30% to 46%, and 30% to 45% by weight of the composition, quenched film, and/or gas-permeable barrier film. In a third set of ranges, the amount of the solid filler is in one of the following ranges: about 31% to 74%, 32% to 73%, 33% to 72%, 34% to 71%, 35% to 70%, 36% to 69%, 37% to 68%, 38% to 67%, 39% to 66%, 40% to 65%, 41% to 64%, 42% to 63%, 43% to 62%, 44% to 61%, 45% to 60%, 45% to 59%, 45% to 58%, 45% to 57%, 45% to 56%, and 45% to 55% by weight of the composition, quenched film, and/or gas-permeable barrier film.
Although filler loading may be conveniently expressed in terms of weight percentages, the phenomenon of microporosity may alternatively be described in terms of volume percent of filler relative to total volume. By way of illustration, for calcium carbonate filler having a specific gravity of 2.7 g/cc and a polymer having a specific gravity of about 0.9, 35% by weight CaCO3 corresponds to a filler loading of about 15% by volume {(0.35/2.7)/(0.65/0.9+0.35/2.7)}. Similarly, the 75 weight percent upper end of the range described above corresponds to about 56% by volume of CaCO3. Thus, the amount of filler may be adjusted to provide comparable volume percentages for alternative solid fillers that have different (e.g., unusually low or high) specific gravities as compared to calcium carbonate.
In some embodiments, to render the solid filler particles free-flowing and to facilitate their dispersion in the polymeric material, the filler particles may be coated with a fatty acid and/or other suitable processing acid. Representative fatty acids for use in this context include but are not limited to stearic acid or longer chain fatty acids.
The type of stretching used to transform a quenched film into a gas-permeable barrier film 2 in accordance with the present disclosure is not restricted. All manner of stretching processes—and combinations of stretching processes—that are capable of moving (e.g., pulling) polymeric material 4 away from the surface of solid filler 6 dispersed therein in order to form micropores 8—are contemplated for use. In some examples, the stretching includes MD stretching. In other examples, the stretching includes CD IMG stretching. In further examples, the stretching includes MD IMG stretching. In still further examples, the stretching includes cold draw. In some embodiments, the stretching includes a combination of two or more different types of stretching including but not limited to MD stretching, CD IMG stretching, MD IMG stretching, cold draw, and/or the like. In some examples, the stretching includes a combination of CD IMG stretching and cold draw (which, in some embodiments, is performed subsequently to the CD IMG stretching).
In illustrative embodiments, the type of stretching used to transform a quenched film into a gas-permeable barrier film 2 in accordance with the present disclosure includes CD IMG stretching. In addition, in illustrative embodiments, at least a portion of the stretching is performed at a temperature above ambient temperature. In one example, at least a portion of the stretching is performed at a temperature of between about 60 degrees Fahrenheit and about 225 degrees Fahrenheit.
In illustrative embodiments, a process for making a gas-permeable barrier film 2 in accordance with the present disclosure further includes (d) annealing the gas-permeable barrier film 2. In one example, the annealing is performed at a temperature of between about 75 degrees Fahrenheit and about 225 degrees Fahrenheit.
The basis weight of a gas-permeable barrier film 2 in accordance with the present disclosure may be varied based on a desired end use (e.g., the desired properties and/or applications of the gas-permeable barrier film). In one example, the basis weight ranges from about 5 gsm to about 100 gsm. In another example, the basis weight ranges from about 10 gsm to about 90 gsm. In illustrative embodiments, the basis weight is less than about 100 gsm, in some examples less than about 90 gsm, and in other examples less than about 80 gsm. Although basis weights outside this range may also be employed (e.g., basis weights above about 100 gsm), lower basis weights minimize material cost and may be preferable for at least this reason.
The basis weight of a gas-permeable barrier film 2 in accordance with the present disclosure may be one of several different values or fall within one of several different ranges. For example, it is within the scope of the present disclosure to select a basis weight to be one of the following values: about 60 gsm, 61 gsm, 62 gsm, 63 gsm, 64 gsm, 65 gsm, 66 gsm, 67 gsm, 68 gsm, 69 gsm, 70 gsm, 71 gsm, 72 gsm, 73 gsm, 74 gsm, 75 gsm, 76 gsm, 77 gsm, 78 gsm, 79 gsm, 80 gsm, 81 gsm, 82 gsm, 83 gsm, 84 gsm, 85 gsm, 86 gsm, 87 gsm, 88 gsm, 89 gsm, 90 gsm, 91 gsm, 92 gsm, 93 gsm, 94 gsm, 95 gsm, 96 gsm, 97 gsm, 98 gsm, 99 gsm, or 100 gsm.
It is also within the scope of the present disclosure for the basis weight of the gas-permeable barrier film 2 to fall within one of many different ranges. In a first set of ranges, the basis weight of the gas-permeable barrier film 2 is in one of the following ranges: about 60 gsm to 100 gsm, 60 gsm to 99 gsm, 60 gsm to 98 gsm, 60 gsm to 97 gsm, 60 gsm to 96 gsm, 60 gsm to 95 gsm, 60 gsm to 94 gsm, 60 gsm to 93 gsm, 60 gsm to 92 gsm, 60 gsm to 91 gsm, 60 gsm to 90 gsm, 60 gsm to 89 gsm, 60 gsm to 88 gsm, 60 gsm to 87 gsm, 60 gsm to 86 gsm, 60 gsm to 85 gsm, 60 gsm to 84 gsm, 60 gsm to 83 gsm, 60 gsm to 82 gsm, 60 gsm to 81 gsm, 60 gsm to 80 gsm, 60 gsm to 79 gsm, 60 gsm to 78 gsm, 60 gsm to 77 gsm, 60 gsm to 76 gsm, 60 gsm to 75 gsm, 60 gsm to 74 gsm, 60 gsm to 73 gsm, 60 gsm to 72 gsm, 60 gsm to 71 gsm, and 60 gsm to 70 gsm. In a second set of ranges, the basis weight of the gas-permeable barrier film is in one of the following ranges: about 60 gsm to 90 gsm, 61 gsm to 90 gsm, 62 gsm to 90 gsm, 63 gsm to 90 gsm, 64 gsm to 90 gsm, 65 gsm to 90 gsm, 66 gsm to 90 gsm, 67 gsm to 90 gsm, 68 gsm to 90 gsm, 69 gsm to 90 gsm, 70 gsm to 90 gsm, 71 gsm to 90 gsm, 72 gsm to 90 gsm, 73 gsm to 90 gsm, 74 gsm to 90 gsm, 75 gsm to 90 gsm, 76 gsm to 90 gsm, 77 gsm to 90 gsm, 78 gsm to 90 gsm, 79 gsm to 90 gsm, and 80 gsm to 90 gsm. In a third set of ranges, the basis weight of the gas-permeable barrier film 2 is in one of the following ranges: about 61 gsm to 99 gsm, 62 gsm to 98 gsm, 63 gsm to 97 gsm, 64 gsm to 96 gsm, 65 gsm to 95 gsm, 66 gsm to 94 gsm, 67 gsm to 93 gsm, 68 gsm to 92 gsm, 69 gsm to 91 gsm, 70 gsm to 89 gsm, 70 gsm to 88 gsm, 70 gsm to 87 gsm, 70 gsm to 86 gsm, 70 gsm to 85 gsm, 70 gsm to 84 gsm, 70 gsm to 83 gsm, 70 gsm to 82 gsm, 70 gsm to 81 gsm, 70 gsm to 80 gsm, 71 gsm to 79 gsm, 72 gsm to 78 gsm, 73 gsm to 77 gsm, and 74 gsm to 76 gsm.
In illustrative embodiments, as noted above, a gas-permeable barrier film 2 prepared in accordance with the present disclosure (e.g., by casting a molten web containing a polyolefin and an inorganic filler against a chill roll and stretching the resultant quenched film) may exhibit high gas transmission rate as evidenced, for example, by a low Gurley porosity value. The Gurley porosity value is measured in units of time (i.e., seconds) and describes the number of seconds required for 100 cubic centimeters of air to pass through 1.0 square inch of a given material at a pressure differential of 4.88 inches of water (0.176 psi).
The Gurley porosity of a gas-permeable barrier film 2 in accordance with the present disclosure may be one of several different values. For example, for a gas-permeable barrier film 2 having a basis weight of less than about 100 gsm—in some embodiments, less than about 90 gsm, less than about 80 gsm, or between about 70 gsm and 80 gsm—it is within the scope of the present disclosure to select a Gurley porosity to be less than or equal to one of the following values: about 330 seconds, 329 seconds, 328 seconds, 327 seconds, 326 seconds, 325 seconds, 324 seconds, 323 seconds, 322 seconds, 321 seconds, 320 seconds, 319 seconds, 318 seconds, 317 seconds, 316 seconds, 315 seconds, 314 seconds, 313 seconds, 312 seconds, 311 seconds, 310 seconds, 309 seconds, 308 seconds, 307 seconds, 306 seconds, 305 seconds, 304 seconds, 303 seconds, 302 seconds, 301 seconds, 300 seconds, 299 seconds, 298 seconds, 297 seconds, 296 seconds, 295 seconds, 294 seconds, 293 seconds, 292 seconds, 291 seconds, 290 seconds, 289 seconds, 288 seconds, 287 seconds, 286 seconds, 285 seconds, 284 seconds, 283 seconds, 282 seconds, 281 seconds, 280 seconds, 279 seconds, 278 seconds, 277 seconds, 276 seconds, 275 seconds, 274 seconds, 273 seconds, 272 seconds, 271 seconds, 270 seconds, 269 seconds, 268 seconds, 267 seconds, 266 seconds, 265 seconds, 264 seconds, 263 seconds, 262 seconds, 261 seconds, 260 seconds, 259 seconds, 258 seconds, 257 seconds, 256 seconds, 255 seconds, 254 seconds, 253 seconds, 252 seconds, 251 seconds, 250 seconds, 249 seconds, 248 seconds, 247 seconds, 246 seconds, 245 seconds, 244 seconds, 243 seconds, 242 seconds, 241 seconds, 240 seconds, 239 seconds, 238 seconds, 237 seconds, 236 seconds, 235 seconds, 234 seconds, 233 seconds, 232 seconds, 231 seconds, 230 seconds, 229 seconds, 228 seconds, 227 seconds, 226 seconds, 225 seconds, 224 seconds, 223 seconds, 222 seconds, 221 seconds, 220 seconds, 219 seconds, 218 seconds, 217 seconds, 216 seconds, 215 seconds, 214 seconds, 213 seconds, 212 seconds, 211 seconds, 210 seconds, 209 seconds, 208 seconds, 207 seconds, 206 seconds, 205 seconds, 204 seconds, 203 seconds, 202 seconds, 201 seconds, 200 seconds, 199 seconds, 198 seconds, 197 seconds, 196 seconds, 195 seconds, 194 seconds, 193 seconds, 192 seconds, 191 seconds, 190 seconds, 189 seconds, 188 seconds, 187 seconds, 186 seconds, 185 seconds, 184 seconds, 183 seconds, 182 seconds, 181 seconds, 180 seconds, 179 seconds, 178 seconds, 177 seconds, 176 seconds, 175 seconds, 174 seconds, 173 seconds, 172 seconds, 171 seconds, 170 seconds, 169 seconds, 168 seconds, 167 seconds, 166 seconds, 165 seconds, 164 seconds, 163 seconds, 162 seconds, 161 seconds, 160 seconds, 159 seconds, 158 seconds, 157 seconds, 156 seconds, 155 seconds, 154 seconds, 153 seconds, 152 seconds, 151 seconds, 150 seconds, 149 seconds, 148 seconds, 147 seconds, 146 seconds, 145 seconds, 144 seconds, 143 seconds, 142 seconds, 141 seconds, 140 seconds, 139 seconds, 138 seconds, 137 seconds, 136 seconds, 135 seconds, 134 seconds, 133 seconds, 132 seconds, 131 seconds, 130 seconds, 129 seconds, 128 seconds, 127 seconds, 126 seconds, 125 seconds, 124 seconds, 123 seconds, 122 seconds, 121 seconds, 120 seconds, 119 seconds, 118 seconds, 117 seconds, 116 seconds, 115 seconds, 114 seconds, 113 seconds, 112 seconds, 111 seconds, 110 seconds, 109 seconds, 108 seconds, 107 seconds, 106 seconds, 105 seconds, 104 seconds, 103 seconds, 102 seconds, 101 seconds, 100 seconds, 99 seconds, 98 seconds, 97 seconds, 96 seconds, 95 seconds, 94 seconds, 93 seconds, 92 seconds, 91 seconds, 90 seconds, 89 seconds, 88 seconds, 87 seconds, 86 seconds, 85 seconds, 84 seconds, 83 seconds, 82 seconds, 81 seconds, 80 seconds, 79 seconds, 78 seconds, 77 seconds, 76 seconds, 75 seconds, 74 seconds, 73 seconds, 72 seconds, 71 seconds, 70 seconds, 69 seconds, 68 seconds, 67 seconds, 66 seconds, 65 seconds, 64 seconds, 63 seconds, 62 seconds, 61 seconds, 60 seconds, 59 seconds, 58 seconds, 57 seconds, 56 seconds, 55 seconds, 54 seconds, 53 seconds, 52 seconds, 51 seconds, 50 seconds, 49 seconds, 48 seconds, 47 seconds, 46 seconds, 45 seconds, 44 seconds, 43 seconds, 42 seconds, 41 seconds, 40 seconds, 39 seconds, 38 seconds, 37 seconds, 36 seconds, 35 seconds, 34 seconds, 33 seconds, 32 seconds, 31 seconds, or 30 seconds.
In some embodiments, as described above, the present disclosure provides a monolayer gas-permeable barrier film 2. In other embodiments, the present disclosure also provides a multi-layer gas-permeable barrier film 56, as shown in
In one example, a multi-layer gas-permeable barrier films in accordance with the present disclosure may be manufactured by feed block coextrusion. In another example, a multi-layer gas-permeable barrier films in accordance with the present disclosure may be made by blown film (tubular) coextrusion. Methods for feed block and blown film extrusion are described in The Wiley Encyclopedia of Packaging Technology, pp. 233-238 (Aaron L. Brody et al. eds., 2nd Ed. 1997), which is incorporated herein by reference, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail. Methods for film extrusion are also described in U.S. Pat. No. 6,265,055, the entire contents of which are likewise incorporated by reference herein, except that in the event of any inconsistent disclosure or definition from the present specification, the disclosure or definition herein shall be deemed to prevail.
In some embodiments, as described above, the present disclosure provides mono-layer gas-permeable barrier films. In other embodiments, the present disclosure further provides multi-layer gas-permeable barrier films.
A multi-layer gas-permeable barrier film 56 is shown, for example, in
Each of the first gas-permeable barrier film layer 58, the second gas-permeable barrier film layer 60, and the third gas-permeable barrier film layer 62 shown in
A multi-layer gas-permeable barrier film 56 in accordance with the present disclosure may contain one or a plurality of different types of gas-permeable barrier layers each of which may be placed in any order in the inner layers of the film structure. When a plurality of gas-permeable barrier layers is used, the individual gas-permeable barrier layers may differ from each other in thickness and/or type of thermoplastic polymer.
Multi-layer gas-permeable barrier films 56 of a type described above are not limited to any specific kind of film structure. Other film structures may achieve the same or similar result as the three-layer film 56 shown in
In the above-described exemplary film structures, each of the gas-permeable barrier film layers A may include two or more gas-permeable barrier film layers in order to better control other film properties, such as the ability to bond to nonwovens. For example, when there are two gas-permeable barrier film layers in one A gas-permeable barrier film layer, and when C represents the second gas-permeable barrier film layer, some exemplary film structures are as follows:
Additionally, die technology that allows production of multiple layers in a multiplier fashion may be used. For example, an ABA structure may be multiplied from about 10 to about 1000 times. The resulting 10-time multiplied ABA structure may be expressed as follows:
The basis weight of a gas-permeable barrier film 2 or a multi-layer gas permeable film 56 in accordance with the present disclosure may be varied based on a desired Gurley porosity. In one example, a gas-permeable barrier film 2 in accordance with the present disclosure (or a multi-layer gas permeable film 56 containing two or more gas-permeable film layers in accordance with the present disclosure) has a basis weight of less than about 100 gsm and a Gurley porosity of less than about 330 seconds. In another example, a gas-permeable barrier film 2 in accordance with the present disclosure (or a multi-layer gas permeable film 56 containing two or more gas-permeable film layers in accordance with the present disclosure) has a basis weight of less than about 90 gsm and a Gurley porosity of less than about 300 seconds. In a further example, a gas-permeable barrier film 2 in accordance with the present disclosure (or a multi-layer gas permeable film 56 containing two or more gas-permeable film layers in accordance with the present disclosure) has a basis weight of less than about 80 gsm and a Gurley porosity of less than about 280 seconds. In a further example, a gas-permeable barrier film 2 in accordance with the present disclosure (or a multi-layer gas permeable film 56 containing two or more gas-permeable film layers in accordance with the present disclosure) has a basis weight of between about 60 gsm and about 90 gsm and a Gurley porosity of less than about 250 seconds. In a further example, a gas-permeable barrier film 2 in accordance with the present disclosure (or a multi-layer gas permeable film 56 containing two or more gas-permeable film layers in accordance with the present disclosure) has a basis weight of between about 70 gsm and about 80 gsm and a Gurley porosity of less than about 300 seconds. In a further example, a gas-permeable barrier film 2 in accordance with the present disclosure (or a multi-layer gas permeable film 56 containing two or more gas-permeable film layers in accordance with the present disclosure) has a basis weight of between about 70 gsm and about 80 gsm and a Gurley porosity of less than about 220 seconds. In a further example, a gas-permeable barrier film 2 in accordance with the present disclosure (or a multi-layer gas permeable film 56 containing two or more gas-permeable film layers in accordance with the present disclosure) has a basis weight of about 75 gsm and a Gurley porosity of less than about 300 seconds.
Representative applications of a gas-permeable barrier film 2 and/or a multi-layer gas-permeable barrier film 56 in accordance with the present disclosure include applications involving a high gas transmission rate coupled with moisture and/or microbial barrier properties. These representative applications include but are not limited to the manufacture of articles that were heretofore formed almost exclusively from porous webs (e.g., sterilizable packages for medical devices and/or pharmaceutical agents; garments such as coveralls, medical gowns, and the like; building construction materials such as house wraps; etc.).
Representative applications using a microporous gas-permeable film 2 and/or a multi-layer gas-permeable barrier film 56 include but are not limited to medical gowns, diaper back sheets, drapes, packaging, garments, articles, carpet backing, upholstery backing, bandages, protective apparel, feminine hygiene, building construction, bedding, and/or the like. Films in accordance with the present disclosure may be laminated to a fabric, scrim, or other film support by thermal, ultrasonic, and/or adhesive bonding. The support may be attached to at least one face of the film and or to both faces of the film. The laminate may be made using wovens, knits, nonwovens, paper, netting, or other films. Adhesive bonding may be used to prepare such laminates. Adhesive bonding may be performed with adhesive agents such as powders, adhesive webs, liquid, hot-melt and solvent-based adhesives. Additionally, these types of support may be used with ultrasonic or thermal bonding if the polymers in the support are compatible with the film surface. Laminates of the present multilayer films and nonwoven fabrics may provide surgical barriers. In one example, the fabrics are spunbonded or spunbond-meltblown-spunbond (SMS) fabrics. In another example, the fabrics may be spunlaced, airlaid, powder-bonded, thermal-bonded, or resin-bonded.
Gas-permeable barrier layers 2 and/or multi-layer gas-permeable barrier films 56 in accordance with the present disclosure may be used in applications in the medical field. Porous webs are used currently in the medical field for ethylene oxide (EtO) sterilization as the gas must be able to permeate packaging in order to sterilize the contents. These porous webs are often used as the top sheets for rigid trays and as breather films in pouches. Medical paper is commonly used for these purposes as is the flashspun high density polyethylene sold under the trade name TYVEK. The gas-permeable barrier films 2 and/or multi-layer gas-permeable barrier films 56 in accordance with the present disclosure may be used to replace either of these products in such applications. For example, as shown in
In one example, gas-permeable barrier films 2 and/or multi-layer gas-permeable barrier films 56 in accordance with the present disclosure may be used in any application that involves a blood barrier. For example, disposable blankets, operating table covers, or surgical drapes may incorporate a gas-permeable barrier film 2 and/or a multilayer gas-permeable barrier film 56 in accordance with the present disclosure, as they represent blood barrier applications that might function more comfortably with a breathable substrate.
In some embodiments, as described above, the present disclosure provides gas-permeable barrier films 2 and multi-layer gas-permeable barrier films 56. In other embodiments, the present disclosure further provides garments containing one or more gas-permeable barrier films and/or one or more multi-layer gas-permeable barrier films in accordance with the present disclosure. In illustrative embodiments, a garment in accordance with the present disclosure includes at least one gas-permeable barrier film 2 and/or multi-layer gas-permeable barrier film 56 prepared by a process as described above and, optionally, at least one additional layer (which, in some examples, may be a non-woven layer).
In one example, the at least one inner gas-permeable barrier film 2 and/or multi-layer gas-permeable barrier film 56 is bonded to the at least one outer non-woven layer without an adhesive (e.g., via heat sealing, ultrasonic welding, and/or the like). In some embodiments, each of the at least one inner gas-permeable barrier film 2 and/or multi-layer gas-permeable barrier film 56 and the at least one outer non-woven layer comprises polypropylene and/or polyethylene.
In illustrative embodiments, the garment in accordance with the present disclosure is configured as a coverall or surgical gown.
The following examples and representative procedures illustrate features in accordance with the present disclosure, and are provided solely by way of illustration. They are not intended to limit the scope of the appended claims or their equivalents.
General
For production of the example films, an extrusion cast line with up to 3 extruders was used. The “A” and “B” extruders are 2½″ in diameter, and the “C” extruder is 1¾″ in diameter. The extruders feed into a combining feedblock manufactured by Cloeren Corporation of Orange, Tex., which can layer the A, B and C extruder outputs in a variety of configurations. From the feedblock, the molten polymer proceeds into a monolayer cast die (manufactured by Cloeren) that is about 36″ wide. The die has an adjustable gap. For the samples described herein, the adjustable gap was maintained between 10 and 40 mils. The molten polymer drops down to a chill roll. For the samples described herein, the chill roll had an embossed pattern FST-250 which was engraved by Pamarco of Roselle, N.J. as their pattern P-2739. The embossed pattern P-2739 is a square pattern (e.g., with lines nearly aligned with the Machine Direction) with 250 squares per inch and a depth of about 31 microns. The roll itself has an 18″ diameter with internal water cooling. The engrave roll pattern may be replaced with other patterns that are shallow enough not to interfere with a vacuum box quench. One alternative is a 40 Ra pattern (40 micro-inch average roughness) generated by a sand-blasting process on a chrome plated roll.
Gurley Porosity Testing
Gurley Porosity is measured according to the procedure described in the “Air Resistance of Paper (Gurley Method)” test method published as TAPPI test method “T 460 om-11” by TAPPI (Technical Association of the Pulp and Paper Industry).
In this experiment, mono-layer gas-permeable barrier films were made from the formulation XC1-8-2271.0 shown in Table 1.
The composition of the CaCO3-containing compound T1000J2 shown in Table 1 is specified in Table 2 below.
Additional gas-permeable barrier films were made from the formulation XC1-8-2271.1 shown in Table 3 below. The composition of the CaCO3-containing compound T1000J2 shown in Table 3 is the same as that specified in Table 2 above.
The molten web formed by extrusion of the formulation XC1-8-2271.0 shown in Table 1 and formulation XC1-8-2271.1 shown in Table 3 was quenched by a chill cast vacuum box process in accordance with the present disclosure on a FST-250 roll. The resultant films were subjected to varying degrees of CD IMG stretching and post-stretching according to the conditions summarized in Table 4 below. Films A through D were made from the formulation XC1-8-2271.0 and films E through H were made from the formulation XC1-8-2271.1.
The Gurley porosity of each of films A through H was measured in duplicate as shown in Table 5 below.
The data in Tables 4 and 5 show that each of (a) using higher levels of CaCO3 filler, (b) increasing the depth of CD IMG engagement, and (c) incorporating a post-stretch following CD IMG stretching substantially improved the Gurley porosity of the corresponding films. As shown in Table 5, film H exhibited an average Gurley porosity of only 283.15 seconds. A sample of TYVEK obtained from a Cardinal header bag was measured under analogous conditions and exhibited an average Gurley porosity of 26.2 seconds (three runs: 31.3, 23.0, and 24.3 seconds).
Ten three-layer gas-permeable barrier films Nos. 1-10 were made by co-extrusion of the formulation XC3-888-2308 shown in Table 6. Each of the films 1-10 had a basis weight of 75 gsm.
An additional ten three-layer gas-permeable barrier films Nos. 11-20 were made by co-extrusion of the formulation XC3-888-2309 shown in Table 7. Each of the films 11-20 had a basis weight of 75 gsm.
Two additional three-layer gas-permeable barrier films Nos. 21-22 were made by co-extrusion of the formulation XC3-888-2310 shown in Table 8. Each of the films 21 and 22 had a basis weight of 75 gsm.
The composition of the CaCO3-containing compound T1000J2 shown in each of Tables 6, 7, and 8 is the same as that specified in Table 2 above.
The molten web formed by extrusion of the formulation XC3-888-2308 shown in Table 6 was quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 1-10 were subjected to varying degrees of pre-stretching, CD IMG stretching, and/or post-stretching according to the conditions summarized in Table 9 below.
†Pre-stretching is done until tiger striping is gone.
The molten web formed by extrusion of the formulation XC3-888-2309 shown in Table 7 was quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 11-20 were subjected to varying degrees of pre-stretching, CD IMG stretching, and/or post-stretching according to the conditions summarized in Table 10 below.
†Pre-stretching is done until tiger striping is gone.
The molten web formed by extrusion of the formulation XC3-888-2310 shown in Table 8 was quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 21 and 22 were subjected to varying degrees of pre-stretching, CD IMG stretching, and/or post-stretching according to the conditions summarized in Table 11 below.
†Pre-stretching is done until tiger striping is gone.
A gas-permeable barrier film was made by co-extrusion of the formulation XC3-888-2318-2/B shown in Table 12.
The film prepared from formulation XC3-888-2318-2/B was CD IMG stretched at a depth of engagement of a 0.14 inch, followed by 100% post-stretching. The stretching temperature and the annealing temperature were 200° F., and the basis weight of the resultant film was 75 gsm. The Gurley porosity of the resultant film (100 cc, 20 oz.) was 182 seconds, and the moisture vapor transmission rate (MVTR) was 23,114 g/(m2*day). Additional physical properties of the resultant film are summarized in Table 14 below.
Another gas-permeable barrier film was made by co-extrusion of the formulation XC3-888-2318-11/L shown in Table 13.
The film prepared from formulation XC3-888-2318-11/L was CD IMG stretched at a depth of engagement of a 0.14 inch, followed by 100% post-stretching. The stretching temperature and the annealing temperature were 200° F., and the basis weight of the resultant film was 75 gsm. The Gurley porosity of the resultant film (100 cc, 20 oz.) was 163 seconds, and the MVTR was 19,727 g/(m2*day). Additional physical properties of the resultant film are summarized in Table 14 below.
Sixteen three-layer gas-permeable barrier films were made by co-extrusion of the formulations shown in Table 15. The film B/2 formed from formulation XC3-888-2318-2 is the same as the film formed from formulation XC3-888-2318-2/B shown in Table 12 of Example 3. Similarly, the film L/11 formed from formulation XC3-888-2318-11 is the same as the film formed from formulation XC3-888-2318-11/L shown in Table 13 of Example 3. The Gurley porosity testing was done in triplicate using a 20-oz. cylinder and a 110 cc timer. For reference, the average Gurley porosity of a TYVEK peelable pouch sample from TECHNIPAQ was determined to be 26 seconds.
The composition of the CaCO3-containing compound T1000J2 shown in Table 15 is the same as that specified in Table 2 above. The compositions of the other CaCO3 compounds in Table 15 are shown below in Table 16.
The physical properties of the films A/1 through H/8 are summarized in Table 17, and the physical properties of the films I/8b through P/15 are summarized in Table 18.
Four three-layer gas-permeable barrier films Nos. 23-26 were made by co-extrusion of the formulation XC3-222-2315.1-4 shown in Table 20. Each of the films 23-26 had a basis weight of 75 gsm.
The composition of the CaCO3-containing formulation (CF7414) listed in Table 20 is specified below in Table 21.
An additional four three-layer gas-permeable barrier films Nos. 27-30 were made by co-extrusion of the formulation XC3-222-2315.5-8 shown in Table 22. Each of the films 27-30 had a basis weight of 75 gsm.
An additional three-layer gas-permeable barrier film No. 31 was made by co-extrusion of the formulation XC3-222-2315.9 shown in Table 23. The film 31 had a basis weight of 75 gsm.
Three additional three-layer gas-permeable barrier film Nos. 32-34 were made by co-extrusion of the formulation XC3-222-2315.10-12 shown in Table 24. Each of the films 32-34 had a basis weight of 75 gsm.
The composition of the CaCO3-containing compound CF7414 shown in each of Tables 22, 23, and 24 is the same as that specified in Table 21 above.
The molten web formed by extrusion of the formulation XC3-222-2315.1-4 shown in Table 20 was quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 23-26 were subjected to varying degrees of CD IMG stretching and post-stretching according to the conditions summarized in Table 25 below.
The molten web formed by extrusion of the formulation XC3-222-2315.5-8 shown in Table 22 was quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 27-30 were subjected to varying degrees of CD IMG stretching and post-stretching according to the conditions summarized in Table 26 below.
The molten web formed by extrusion of the formulation XC3-222-2315.9 shown in Table 23 was quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant film 31 was subjected to varying degrees of CD IMG stretching and post-stretching according to the conditions summarized in Table 27 below.
The molten web formed by extrusion of the formulation XC3-222-2315.10-12 shown in Table 24 was quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 32-34 were subjected to varying degrees of CD IMG stretching and post-stretching according to the conditions summarized in Table 28 below.
A gas-permeable barrier film was made by co-extrusion of the formulation XC3-222-2315.5-8 shown in Table 22 above. The film prepared from formulation XC3-222-2315.5-8 was CD IMG stretched at a depth of engagement of a 0.14 inch, followed by 20% post-stretching. The stretching temperature and the annealing temperature were 200° F., and the basis weight of the resultant film was 75 gsm. The Gurley porosity of the resultant film (100 cc, 20 oz.) was 313 seconds, and the MVTR was 17,953 g/(m2*day). Additional physical properties of the resultant film are summarized in Table 29 below. Another gas-permeable barrier film was made by co-extrusion of the formulation XC3-222-2315.10-12 shown in Table 24 above. The film prepared from formulation XC3-222-2315.10-12 was CD IMG stretched at a depth of engagement of a 0.14 inch, followed by 60% post-stretching. The stretching temperature and the annealing temperature were 200° F., and the basis weight of the resultant film was 75 gsm. The Gurley porosity of the resultant film (100 cc, 20 oz.) was 199 seconds, and the MVTR was 25,522 g/(m2*day). Additional physical properties of the resultant film are summarized in Table 29 below.
Three three-layer gas-permeable barrier films Nos. 35-37 were made by co-extrusion of the formulation XC3-828-2290 shown in Table 30. Each of the films 35-37 had a basis weight of 75 gsm.
Three additional three-layer gas-permeable barrier films Nos. 38-40 were made by co-extrusion of the formulation XC3-282-2291 shown in Table 31. Each of the films 38-40 had a basis weight of 75 gsm.
Three additional two-layer gas-permeable barrier film Nos. 41-43 were made by co-extrusion of the formulation XC2-28-2292 shown in Table 32. Each of the films 41-43 had a basis weight of 75 gsm.
The composition of the CaCO3-containing formulation T1000J2 and the composition of the CaCO3-containing formulation CF7414 listed in each of Tables 30, 31, and 32 are specified above in Tables 2 and 21, respectively.
The molten web formed by extrusion of the formulation XC3-828-2290 shown in Table 30, the molten web formed by extrusion of the formulation XC3-282-2291 shown in Table 31, and the molten web formed by extrusion of the formulation XC2-28-2292 shown in Table 32 were each quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films were subjected to varying degrees of CD IMG stretching and post-stretching according to the conditions summarized in Table 33 below. Films 35 through 39 were made from the formulation XC3-828-2290, films 40 and 41 were made from the formulation XC3-282-2291, and films 42 through 44 were made from the formulation XC2-28-2292.
The Gurley porosity of each of films 35 through 44 was measured in duplicate as shown in Table 34 below.
Additional physical properties of the resultant films are summarized in Tables 35-37 below.
A three-layer gas-permeable barrier film No. 45 was made by co-extrusion of the formulation shown in Table 38. Film no. 45 had a basis weight of 75 gsm.
An additional three-layer gas-permeable barrier films No. 46 was made by co-extrusion of the formulation shown in Table 39. The film no. 46 had a basis weight of 75 gsm.
An additional three-layer gas-permeable barrier film No. 47 was made by co-extrusion of the formulation shown in Table 40. The film no. 47 had a basis weight of 75 gsm.
An additional three-layer gas-permeable barrier film No. 48 was made by co-extrusion of the formulation shown in Table 41. The film no. 48 had a basis weight of 75 gsm.
The composition of the CaCO3-containing compound CF7414 shown in each of Tables 38, 39, 40, and 41 is the same as that specified in Table 21 above.
The molten webs formed by extrusion of the formulations shown in Tables 38, 39, 40, and 41 were quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 45, 46, 47, and 48 were each subjected to CD IMG stretching and post-stretching according to the conditions summarized in Table 42 below, and each had a basis weight of 75 gsm. The Gurley porosity testing was done in triplicate and the average Gurley porosities for films 45-48 is listed in Table 42.
A three-layer gas-permeable barrier film No. 49 was made by co-extrusion of the formulation shown in Table 42. Film no. 49 had a basis weight of 75 gsm.
An additional three-layer gas-permeable barrier film No. 50 was made by co-extrusion of the formulation shown in Table 43. The film no. 50 had a basis weight of 75 gsm.
The composition of the CaCO3-containing compound T1000J2 shown in each of Tables 42 and 43 is the same as that specified in Table 2 above.
The molten webs formed by extrusion of the formulations shown in Tables 42 and 43 were quenched by a chill cast vacuum box process in accordance with the present disclosure. The resultant films 49 and 50 were each subjected to CD IMG stretching and post-stretching according to the conditions summarized in Table 44 below, and each had a basis weight of 75 gsm. The Gurley porosity testing was done in triplicate and the average Gurley porosities for films 49 and 50 is listed in Table 44.
The overall thickness of the gas-permeable barrier films and/or multi-layer gas-permeable barrier films in accordance with the present disclosure may be varied depending on the particular end use for which the film is manufactured. As described above, the beneficial properties of gas-permeable barrier films and/or multi-layer gas-permeable barrier films prepared in accordance with the present disclosure may include one or more of high gas transmission rate (e.g., high porosity), moisture barrier protection, microbial barrier protection, and/or the like. However, basis weights and thicknesses may be easily adjusted to fit a desired end use.
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 62/296,181, filed Feb. 17, 2016, which is expressly incorporated by reference herein.
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| Number | Date | Country | |
|---|---|---|---|
| 20170232652 A1 | Aug 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62296181 | Feb 2016 | US |
