TREA

Microporous breathable film and method of making the microporous breathable film

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Information

  • Patent Grant
  • 11872740
  • Patent Number
    11,872,740
  • Date Filed
    Friday, July 8, 2016
    7 years ago
  • Date Issued
    Tuesday, January 16, 2024
    4 months ago
Information
Abstract
Microporous breathable films include a polyolefin and an inorganic filler dispersed in the polyolefin. Methods for forming polymeric films and articles of manufacture prepared therefrom are described.
Description
BACKGROUND

The present disclosure relates to polymeric materials, and particularly to polymeric films. More particularly, the present disclosure relates to microporous breathable films formed from polymeric material and filler.


SUMMARY

According to the present disclosure, a microporous breathable 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 microporous breathable 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 using a vacuum box and/or blowing air (e.g., an air knife and/or an air blanket).


In illustrative embodiments, a microporous breathable film comprising a polyolefin and an inorganic filler dispersed in the polyolefin has a basis weight of less than about 14 gsm. The microporous breathable film also has a Dart Impact Strength of at least about 75 grams.


In illustrative embodiments, a multi-layer breathable barrier film comprises at least one microporous breathable film layer according to the present disclosure and at least one moisture-permeable barrier layer. The at least one moisture-permeable barrier layer comprises a hygroscopic polymer.


In illustrative embodiments, a personal hygiene product comprises at least one inner microporous breathable film and at least one outer non-woven layer. The at least one inner microporous breathable film is configured to contact skin and/or clothing of a user of the personal hygiene product.


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.





BRIEF DESCRIPTIONS OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures in which:



FIG. 1 is a diagrammatic view of a representative embodiment of a microporous breathable film that includes one layer;



FIG. 2 is a diagrammatic view of an exemplary process for machine direction (MD) stretching of a polymeric film;



FIG. 3 is a diagrammatic view of an exemplary process for cross-directional (CD) stretching of a polymeric film;



FIG. 4 is a diagrammatic view of an exemplary process for intermeshing gears (IMG) stretching of a polymeric film;



FIG. 5 is a diagrammatic view of an exemplary process for casting a molten web against a chill roll using a vacuum box;



FIG. 6 is a diagrammatic view of an exemplary process for casting a molten web against a chill roll using an air knife; and



FIG. 7 is a diagrammatic view of a representative embodiment of a multi-layer breathable barrier film that includes three layers.





DETAILED DESCRIPTION

A first embodiment of a microporous breathable film 2 in accordance with the present disclosure is shown, for example, in FIG. 1. Microporous breathable film 2 includes a thermoplastic polymer 4 and a solid filler 6 dispersed in the thermoplastic polymer 4. In some embodiments, the microporous breathable film 2 includes a combination of two or more thermoplastic polymers 4 and/or a combination of two or more solid fillers 6. As shown in FIG. 1, the microporous breathable film 2 includes an interconnected network of micropores 8 formed in the thermoplastic polymer resin 4. On average, the micropores 8 are smaller in size than the size of a typical water droplet but larger in size than a water vapor molecule. As a result, the micropores 8 permit the passage of water vapor but minimize or block the passage of liquid water. Two representative pathways for the transmission of water vapor through the microporous breathable film 2 are shown by the dashed lines 10 and 12 in FIG. 1.


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) orientation by a process analogous to that shown in simplified schematic form in FIG. 2. For example, the film 14 shown in FIG. 2 may be passed between at least two pairs of rollers in the direction of an arrow 15. In this example, first roller 16 and a first nip 20 run at a slower speed (V1) than the speed (V2) of a second roller 18 and a second nip 22. The ratio of V2/V1 determines the degree to which the film 14 is stretched. Since there may be enough drag on the roll surface to prevent slippage, the process may alternatively be run with the nips open. Thus, in the process shown in FIG. 2, the first nip 20 and the second nip 22 are optional.


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 FIG. 3. For example, the film 24 shown in FIG. 3 may be moved in the direction of the arrow 28 while being stretched sideways on a tenter frame in the directions of doubled-headed arrow 30. The tenter frame includes a plurality of attachment mechanisms 26 configured for gripping the film 24 along its side edges.


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 FIG. 4. For example, a film 32 may be moved between a pair of grooved or toothed rollers as shown in FIG. 4 in the direction of arrow 33. In one example, the first toothed roller 34 may be rotated in a clockwise direction while the second toothed roller 36 may be rotated in a counterclockwise direction. At each point at which one or more teeth of the rollers 34 and 36 contact the film 32, localized stresses may be applied that stretch the film 32 and introduce interconnecting micropores therein analogous to the micropores 8 shown in FIG. 1. By the use of IMG stretching, the film 32 may be stretched in the machine direction (MD), the cross direction (CD), at oblique angles to the MD, or in any combination thereof.


A precursor film containing a thermoplastic polymer 4 and a solid filler 6 dispersed in the polymer 4 that is stretched to form a microporous breathable 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 microporous breathable 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 FIGS. 2-4.


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 (e.g., diaper making). 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 100 grams per square meter (gsm). In one example, the precursor film has an initial basis weight of less than about 75 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 suggested in FIG. 7.


In one example, a microporous breathable film 2 in accordance with the present disclosure is formed via a blown film process. In another example, a microporous breathable 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.


In illustrative embodiments, a process for making a microporous breathable 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 using an air knife, an air blanket, a vacuum box, or a combination thereof to form a quenched film, and (c) stretching the quenched film to form the microporous breathable film 2.


It has been discovered that by using 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 cast the molten web against a chill roll in accordance with the present disclosure, microporous breathable films 2 exhibiting surprisingly and unexpectedly improved properties as compared to other microporous breathable films may be prepared. As further described below, these properties may include reduced basis weight, increased Dart Impact Strength, increased strain at peak machine direction, reduced alcohol penetration as measured by Pressure Penetration Through a Fabric (PPT) testing, reduced bonding force needed to achieve a destruct bond in ultrasonic sealing, and/or the like, and combinations thereof.


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 FIG. 5. A vacuum box works by evacuating air between the film and the surface of the chill roll. For example, as shown in FIG. 5, a film 46 is extruded from an extrusion die 40 in the direction of arrow 47 and quenched from the molten state with a vacuum box 42. The vacuum box 42 draws a vacuum behind the molten web 46 in the direction of arrow 44 to draw the film 46 down onto the chill roll 38. The vacuum drawn in the direction of arrow 44 removes the entrained air between the surface of the chill roll 38 and the film 46. The vacuum box process is not subject to draw resonance for high molecular weight polymers that would tend to extrude unstable thickness in a nipped quench process due to the draw resonance phenomenon.


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 FIG. 5, the vacuum box 42 may enhance web cooling, facilitate higher line speeds, reduce film neck-in, and/or reduce drag at the lip exit.


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 FIG. 6. An air knife works to promote web quenching by gently blowing a high-velocity, low-volume air curtain over the molten film, thereby pinning the molten film to the chill roll for solidification. For example, as shown in FIG. 6, a film 54 is extruded from an extrusion die 50 in the direction of arrow 55 and quenched from the molten state with an air knife 52 blowing an air curtain over the molten film 54, thereby pinning the molten web 54 against a surface of the chill roll 48. An air blanket (a.k.a. soft box) works similarly to an air knife and promotes web quenching by gently blowing an air curtain over the molten film. However, in the case of an air blanket, the air curtain is low velocity and high volume.


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 FIG. 5, and positive pressure from an air knife, as shown in FIG. 6. In illustrative embodiments, in the casting of the molten web against a surface of the chill roll, an exit temperature of cooling fluid passing through the chill roll is between about 50 degrees Fahrenheit and about 130 degrees Fahrenheit and, in some examples, between about 75 degrees Fahrenheit and about 130 degrees Fahrenheit.


The thermoplastic polymer 4 (or combination of thermoplastic polymers 4) used to make a microporous breathable 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 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 Zeigler-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 embodiments, 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 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 microporous 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 FIG. 1. The dimensions of the solid filler 6 particles may be varied based on a desired end use (e.g., the desired properties of the microporous breathable film 2). In one example, the average particle size of a solid filler particle ranges from about 0.1 microns to about 15 microns. In illustrative embodiments, the average particle size ranges from about 1 micron to about 5 microns and, in some examples, from about 1 micron to about 3 microns. The average particle size 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 average particle size of the solid filler to be one of the following values: about 0.1 microns, 0.2 microns, 0.3 microns, 0.4 microns, 0.5 microns, 0.6 microns, 0.7 microns, 0.8 microns, 0.9 microns, 1.0 microns, 1.1 microns, 1.2 microns, 1.3 microns, 1.4 microns, 1.5 microns, 1.6 microns, 1.7 microns, 1.8 microns, 1.9 microns, 2.0 microns, 2.1 microns, 2.2 microns, 2.3 microns, 2.4 microns, 2.5 microns, 2.6 microns, 2.7 microns, 2.8 microns, 2.9 microns, 3.0 microns, 3.5 microns, 4.0 microns, 4.5 microns, 5.0 microns, 5.5 microns, 6.0 microns, 6.5 microns, 7.0 microns, 7.5 microns, 8.0 microns, 8.5 microns, 9.0 microns, 9.5 microns. 10.0 microns, 10.5 microns, 11.0 microns, 11.5 microns, 12.0 microns, 12.5 microns, 13.0 microns, 13.5 microns, 14.0 microns, 14.5 microns, or 15.0 microns.


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 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 microporous breathable 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 microporous breathable 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 microporous breathable film.


The amount of solid filler 6 may be varied based on a desired end use (e.g., the desired properties of the microporous breathable 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 microporous breathable 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 microporous breathable 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 microporous breathable 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 microporous breathable 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 microporous breathable 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 microporous breathable 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 microporous breathable 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 microporous breathable 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 200 degrees Fahrenheit.


In illustrative embodiments, a process for making a microporous breathable film 2 in accordance with the present disclosure further includes (d) annealing the microporous breathable film 2. In one example, the annealing is performed at a temperature of between about 75 degrees Fahrenheit and about 225 degrees Fahrenheit.


In illustrative embodiments, as noted above, a microporous breathable film 2 prepared in accordance with the present disclosure (e.g., by using a vacuum box and/or air knife to cast a molten web containing a polyolefin and an inorganic filler against a chill roll) may have reduced basis weight, increased Dart Impact Strength, increased strain at peak machine direction, reduced alcohol penetration as measured by PPT testing, and/or reduced bonding force needed to achieve a destruct bond in ultrasonic sealing, as compared to conventional microporous breathable films.


The basis weight of a microporous breathable 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 microporous breathable film). In one example, the basis weight ranges from about 5 gsm to about 30 gsm. In another example, the basis weight ranges from about 6 gsm to about 25 gsm. In illustrative embodiments, the basis weight is less than about 14 GSM and, in some examples, less than about 12 gsm. Although basis weights outside this range may also be employed (e.g., basis weights above about 30 gsm), lower basis weights minimize material cost as well as maximize consumer satisfaction (e.g., a thinner film may provide increased comfort to the user of a personal hygiene product that includes the film). The basis weight of a microporous breathable 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 30 gsm, 29 gsm, 28 gsm, 27 gsm, 26 gsm, 25 gsm, 24 gsm, 23 gsm, 22 gsm, 21 gsm, 20 gsm, 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, 8 gsm, 7 gsm, 6 gsm, or 5 gsm.


It is also within the scope of the present disclosure for the basis weight of the microporous breathable film 2 to fall within one of many different ranges. In a first set of ranges, the basis weight of the microporous breathable film 2 is in one of the following ranges: about 5 gsm to 30 gsm, 6 gsm to 30 gsm, 7 gsm to 30 gsm, 8 gsm to 30 gsm, 9 gsm to 30 gsm, 10 gsm to 30 gsm, 11 gsm to 30 gsm, 12 gsm to 30 gsm, 13 gsm to 30 gsm, and 14 gsm to 30 gsm. In a second set of ranges, the basis weight of the microporous breathable film is in one of the following ranges: about 5 gsm to 29 gsm, 5 gsm to 28 gsm, 5 gsm to 27 gsm, 5 gsm to 26 gsm, 5 gsm to 25 gsm, 5 gsm to 24 gsm, 5 gsm to 23 gsm, 5 gsm to 22 gsm, 5 gsm to 21 gsm, 5 gsm to 20 gsm, 5 gsm to 19 gsm, 5 gsm to 18 gsm, 5 gsm to 17 gsm, 5 gsm to 16 gsm, 5 gsm to 15 gsm, 5 gsm to 14 gsm, 5 gsm to 13 gsm, 5 gsm to 12 gsm, 5 gsm to 11 gsm, 5 gsm to 10 gsm, 5 gsm to 9 gsm, 5 gsm to 8 gsm, and 5 gsm to 7 gsm. In a third set of ranges, the basis weight of the microporous breathable film 2 is in one of the following ranges: about 6 gsm to 29 gsm, 7 gsm to 29 gsm, 7 gsm to 28 gsm, 7 gsm to 27 gsm, 7 gsm to 26 gsm, 7 gsm to 25 gsm, 7 gsm to 24 gsm, 7 gsm to 23 gsm, 7 gsm to 22 gsm, 7 gsm to 21 gsm, 7 gsm to 20 gsm, 7 gsm to 19 gsm, 7 gsm to 18 gsm, 7 gsm to 17 gsm, 7 gsm to 16 gsm, 7 gsm to 15 gsm, 7 gsm to 14 gsm, and 7 gsm to 13 gsm.


In illustrative embodiments, a microporous breathable film 2 in accordance with the present disclosure exhibits a greater Dart Impact Strength than conventional microporous breathable films of similar basis weight. The basis weight of a microporous breathable film 2 in accordance with the present disclosure may be varied based on a desired Dart Impact Strength. In one example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a Dart Impact Strength of at least about 50 grams. In another example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a Dart Impact Strength of at least about 75 grams. In a further example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a Dart Impact Strength of at least about 90 grams.


The Dart Impact Strength of a microporous breathable 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, for a microporous breathable film 2 having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—it is within the scope of the present disclosure to select a Dart Impact Strength to be greater than or equal to one of the following values: about 50 grams, 51 grams, 52 grams, 53 grams, 54 grams, 55 grams, 56 grams, 57 grams, 58 grams, 59 grams, 60 grams, 61 grams, 62 grams, 63 grams, 64 grams, 65 grams, 66 grams, 67 grams, 68 grams, 69 grams, 70 grams, 71 grams, 72 grams, 73 grams, 74 grams, 75 grams, 76 grams, 77 grams, 78 grams, 79 grams, 80 grams, 81 grams, 82 grams, 83 grams, 84 grams, 85 grams, 86 grams, 87 grams, 88 grams, 89 grams, 90 grams, 91 grams, 92 grams, 93 grams, 94 grams, 95 grams, 96 grams, 97 grams, 98 grams, 99 grams, 100 grams, 101 grams, 102 grams, 103 grams, 104 grams, 105 grams, 106 grams, 107 grams, 108 grams, 109 grams, 110 grams, 111 grams, 112 grams, 113 grams, 114 grams, 115 grams, 116 grams, 117 grams, 118 grams, 119 grams, 120 grams, 121 grams, 122 grams, 123 grams, 124 grams, 125 grams, 126 grams, 127 grams, 128 grams, 129 grams, 130 grams, 131 grams, 132 grams, 133 grams, 134 grams, 135 grams, 136 grams, 137 grams, 138 grams, 139 grams, 140 grams, 141 grams, 142 grams, 143 grams, 144 grams, 145 grams, 146 grams, 147 grams, 148 grams, 149 grams, 150 grams, 151 grams, 152 grams, 153 grams, 154 grams, 155 grams, 156 grams, 157 grams, 158 grams, 159 grams, 160 grams, 161 grams, 162 grams, 163 grams, 164 grams, 165 grams, 166 grams, 167 grams, 168 grams, 169 grams, 170 grams, 171 grams, 172 grams, 173 grams, 174 grams, 175 grams, 176 grams, 177 grams, 178 grams, 179 grams, 180 grams, 181 grams, 182 grams, 183 grams, 184 grams, 185 grams, 186 grams, 187 grams, 188 grams, 189 grams, 190 grams, 191 grams, 192 grams, 193 grams, 194 grams, 195 grams, 196 grams, 197 grams, 198 grams, 199 grams, 200 grams, 201 grams, 202 grams, 203 grams, 204 grams, or 205 grams.


It is also within the scope of the present disclosure for the Dart Impact Strength of the microporous breathable film 2 to fall within one of many different ranges. In a first set of ranges, the Dart Impact Strength for a microporous breathable film having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—is in one of the following ranges: about 50 grams to 250 grams, 55 grams to 250 grams, 60 grams to 250 grams, 65 grams to 250 grams, 70 grams to 250 grams, 75 grams to 250 grams, 80 grams to 250 grams, 85 grams to 250 grams, 90 grams to 250 grams, 95 grams to 250 grams, 100 grams to 250 grams, 105 grams to 250 grams, 110 grams to 250 grams, 115 grams to 250 grams, 120 grams to 250 grams, 125 grams to 250 grams, 130 grams to 250 grams, 135 grams to 250 grams, 140 grams to 250 grams, 145 grams to 250 grams, 150 grams to 250 grams, 155 grams to 250 grams, 160 grams to 250 grams, 165 grams to 250 grams, 170 grams to 250 grams, 175 grams to 250 grams, 180 grams to 250 grams, 185 grams to 250 grams, 190 grams to 250 grams, 195 grams to 250 grams, 200 grams to 250 grams, and 205 grams to 250 grams. In a second set of ranges, the Dart Impact Strength for a microporous breathable film 2 having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—is in one of the following ranges: about 50 grams to 249 grams, 50 grams to 245 grams, 50 grams to 240 grams, 50 grams to 235 grams, 50 grams to 230 grams, 50 grams to 225 grams, 50 grams to 220 grams, 50 grams to 215 grams, and 50 grams to 210 grams. In a third set of ranges, the Dart Impact Strength for a microporous breathable film 2 having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—is in one of the following ranges: about 51 grams to about 249 grams, 55 grams to 245 grams, 60 grams to 240 grams, 65 grams to 235 grams, 70 grams to 230 grams, 75 grams to 225 grams, 80 grams to 225 grams, 85 grams to 225 grams, 90 grams to 225 grams, 95 grams to 225 grams, 100 grams to 225 grams, 105 grams to 225 grams, 110 grams to 225 grams, 115 grams to 225 grams, 120 grams to 225 grams, 125 grams to 225 grams, 130 grams to 225 grams, 135 grams to 225 grams, 140 grams to 225 grams, 145 grams to 225 grams, 150 grams to 225 grams, 155 grams to 225 grams, 160 grams to 225 grams, 165 grams to 225 grams, 170 grams to 225 grams, 175 grams to 225 grams, and 180 grams to 225 grams.


In illustrative embodiments, a microporous breathable film 2 in accordance with the present disclosure exhibits a greater strain at peak machine direction than conventional microporous breathable films of similar basis weight. The basis weight of a microporous breathable film 2 in accordance with the present disclosure may be varied based on a desired strain at peak machine direction. In one example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a strain at peak machine direction of at least about 75%. In another example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a strain at peak machine direction of at least about 100%. In a further example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 14 gsm and a strain at peak machine direction of at least about 125%.


The strain at peak machine direction of a microporous breathable 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, for a microporous breathable film having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—it is within the scope of the present disclosure to select a strain at peak machine direction to be greater than or equal to one of the following values: about 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 100%, 101%, 102%, 103%, 104%, 105%, 106%, 107%, 108%, 109%, 110%, 111%, 112%, 113%, 114%, 115%, 116%, 117%, 118%, 119%, 120%, 121%, 122%, 123%, 124%, 125%, 126%, 127%, 128%, 129%, 130%, 131%, 132%, 133%, 134%, 135%, 136%, 137%, 138%, 139%, 140%, 141%, 142%, 143%, 144%, 145%, 146%, 147%, 148%, 149%, 150%, 151%, 152%, 153%, 154%, 155%, 156%, 157%, 158%, 159%, 160%, 161%, 162%, 163%, 164%, 165%, 166%, 167%, 168%, 169%, 170%, 171%, 172%, 173%, 174%, 175%, 176%, 177%, 178%, 179%, 180%, 181%, 182%, 183%, 184%, 185%, 186%, 187%, 188%, 189%, 190%, 191%, 192%, 193%, 194%, 195%, 196%, 197%, 198%, 199%, 200%, 201%, 202%, 203%, 204%, 205%, 206%, 207%, 208%, 209%, 210%, 211%, 212%, 213%, 214%, 215%, 216%, 217%, 218%, 219%, 220%, 221%, 222%, 223%, 224%, 225%, 226%, 227%, 228%, 229%, 230%, 231%, 232%, 233%, 234%, 235%, 236%, 237%, 238%, 239%, 240%, 241%, 242%, 243%, 244%, 245%, 246%, 247%, 248%, 249%, 250%, 251%, 252%, 253%, 254%, 255%, 256%, 257%, 258%, 259%, 260%, 261%, 262%, 263%, 264%, 265%, 266%, 267%, 268%, 269%, 270%, 271%, 272%, 273%, 274%, 275%, 276%, 277%, 278%, 279%, 280%, 281%, 282%, 283%, 284%, 285%, 286%, 287%, 288%, 289%, 290%, 291%, 292%, 293%, 294%, 295%, 296%, 297%, 298%, 299%, or 300%.


It is also within the scope of the present disclosure for the strain at peak machine direction of the microporous breathable film 2 to fall within one of many different ranges. In a first set of ranges, the strain at peak machine direction for a microporous breathable film having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—is in one of the following ranges: about 75% to 350%, 75% to 345%, 75% to 340%, 75% to 335%, 75% to 330%, 75% to 325%, 75% to 320%, 75% to 315%, 75% to 310%, 75% to 305%, 75% to 300%, 75% to 295%, 75% to 290%, 75% to 285%, and 75% to 280%. In a second set of ranges, the strain at peak machine direction for a microporous breathable film 2 having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—is in one of the following ranges: about 76% to 350%, 77% to 350%, 78% to 350%, 79% to 350%, 80% to 350%, 81% to 350%, 82% to 350%, 83% to 350%, 84% to 350%, 85% to 350%, 86% to 350%, 87% to 350%, 88% to 350%, 89% to 350%, 90% to 350%, 91% to 350%, 92% to 350%, 93% to 350%, 94% to 350%, 95% to 350%, 96% to 350%, 97% to 350%, 98% to 350%, 99% to 350%, 100% to 350%, 101% to 350%, 102% to 350%, 103% to 350%, 104% to 350%, 105% to 350%, 106% to 350%, 107% to 350%, 108% to 350%, 109% to 350%, 110% to 350%, 111% to 350%, 112% to 350%, 113% to 350%, 114% to 350%, 115% to 350%, 116% to 350%, 117% to 350%, 118% to 350%, 119% to 350%, 120% to 350%, 121% to 350%, 122% to 350%, 123% to 350%, 124% to 350%, 125% to 350%, 126% to 350%, 127% to 350%, 128% to 350%, 129% to 350%, 130% to 350%, 131% to 350%, 132% to 350%, 133% to 350%, 134% to 350%, 135% to 350%, 136% to 350%, 137% to 350%, 138% to 350%, 139% to 350%, 140% to 350%, 141% to 350%, 142% to 350%, 143% to 350%, 144% to 350%, 145% to 350%, 146% to 350%, 147% to 350%, 148% to 350%, 149% to 350%, 150% to 350%, 151% to 350%, 152% to 350%, 153% to 350%, 154% to 350%, 155% to 350%, 156% to 350%, 157% to 350%, 158% to 350%, 159% to 350%, 160% to 350%, 161% to 350%, 162% to 350%, 163% to 350%, 164% to 350%, 165% to 350%, 166% to 350%, 167% to 350%, 168% to 350%, 169% to 350%, 170% to 350%, 171% to 350%, 172% to 350%, 173% to 350%, 174% to 350%, 175% to 350%, 176% to 350%, 177% to 350%, 178% to 350%, 179% to 350%, 180% to 350%, 181% to 350%, 182% to 350%, 183% to 350%, 184% to 350%, 185% to 350%, 186% to 350%, 187% to 350%, 188% to 350%, 189% to 350%, 190% to 350%, 191% to 350%, 192% to 350%, 193% to 350%, 194% to 350%, 195% to 350%, 196% to 350%, 197% to 350%, 198% to 350%, 199% to 350%, 200% to 350%, 201% to 350%, 202% to 350%, 203% to 350%, 204% to 350%, 205% to 350%, 206% to 350%, 207% to 350%, 208% to 350%, 209% to 350%, 210% to 350%, 211% to 350%, 212% to 350%, 213% to 350%, 214% to 350%, and 215% to 350%. In a third set of ranges, the strain at peak machine direction for a microporous breathable film 2 having a basis weight of less than about 14 gsm—in some embodiments, less than about 13 gsm, 12 gsm, 11 gsm, 10 gsm, 9 gsm, or 8 gsm—is in one of the following ranges: about 75% to 349%, 80% to 345%, 85% to 340%, 90% to 335%, 95% to 330%, 100% to 325%, 105% to 320%, 110% to 315%, 115% to 310%, 120% to 305%, 125% to 300%, 130% to 300%, 135% to 300%, 140% to 300%, 145% to 300%, 150% to 300%, 155% to 300%, 160% to 300%, 165% to 300%, 170% to 300%, 175% to 300%, 180% to 300%, 185% to 300%, 190% to 300%, 195% to 300%, 200% to 300%, 205% to 300%, 210% to 300%, 215% to 300%, 220% to 300%, and 225% to 300%.


In illustrative embodiments, a microporous breathable film 2 in accordance with the present disclosure exhibits reduced alcohol penetration as measured by Pressure Penetration Through a Fabric (PPT) testing. In PPT testing, the imperviousness of a film is quantified in relation to the degree to which a dye-containing alcohol penetrates the film. The amount of alcohol penetration may, in turn, be measured as the percentage of blotter paper surface area that contains red blots after a nonwoven material saturated with red dye is overlaid on a film and a weight is applied. The PPT test is further described in the Examples section below as well as in U.S. Pat. No. 9,174,420 B2, the entire contents 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.


The basis weight of a microporous breathable film 2 in accordance with the present disclosure may be varied based on a desired degree of alcohol penetration of the film as measured by PPT testing. In one example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 20 gsm and an alcohol penetration of less than about 12% as measured by PPT testing. In another example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 17 gsm and an alcohol penetration of less than about 12% as measured by PPT testing. In a further example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 12 gsm and an alcohol penetration of less than about 11% as measured by PPT testing.


The alcohol penetration of a microporous breathable film 2 in accordance with the present disclosure as measured by PPT testing may be one of several different values or fall within one of several different ranges. For example, for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—it is within the scope of the present disclosure to select an alcohol penetration of less than or equal to one of the following values: about 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or 0%.


It is also within the scope of the present disclosure for the alcohol penetration of a microporous breathable film 2 in accordance with the present disclosure as measured by PPT testing to fall within one of many different ranges. In a first set of ranges, the alcohol penetration as measured by PPT testing for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—is in one of the following ranges: about 0% to 25%, 0% to 24%, 0% to 23%, 0% to 22%, 0% to 21%, 0% to 20%, 0% to 19%, 0% to 18%, 0% to 17%, 0% to 16%, 0% to 15%, 0% to 14%, 0% to 13%, 0% to 12%, 0% to 11%, 0% to 10%, 0% to 9%, 0% to 8%, 0% to 7%, 0% to 6%, 0% to 5%, 0% to 4%, 0% to 3%, 0% to 2%, and 0% to 1%. In a second set of ranges, the alcohol penetration as measured by PPT testing for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—is in one of the following ranges: about 0.1% to 12%, 0.2% to 12%, 0.3% to 12%, 0.4% to 12%, 0.5% to 12%, 0.6% to 12%, 0.7% to 12%, 0.8% to 12%, 0.9% to 12%, 1.0% to 12%, 1.1% to 12%, 1.2% to 12%, 1.3% to 12%, 1.4% to 12%, 1.5% to 12%, 1.6% to 12%, 1.7% to 12%, 1.8% to 12%, 1.9% to 12%, 2.0% to 12%, 2.1% to 12%, 2.2% to 12%, 2.3% to 12%, 2.4% to 12%, 2.5% to 12%, 2.6% to 12%, 2.7% to 12%, 2.8% to 12%, 2.9% to 12%, and 3.0 to 12%. In a third set of ranges, the alcohol penetration as measured by PPT testing for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—is in one of the following ranges: about 0.1% to 11%, 0.2% to 10%, 0.3% to 9%, 0.4% to 8%, 0.5% to 7%, 0.5% to 6%, 0.5% to 5%, 0.5% to 4%, 0.5% to 3%, 0.5% to 2%, and 0.5% to 1%.


In some embodiments, a microporous breathable film 2 in accordance with the present disclosure is essentially impervious to one or more of water, methyl alcohol, ethyl alcohol, body fluids (e.g., blood, body fats and oils, saliva, menses, feces, urine, and/or the like), and surfactant-containing disinfectants. In some embodiments, the microporous breathable film 2 in accordance with the present disclosure has an isopropyl alcohol penetration of less than about 10%, in some embodiments less than about 5%, and in some embodiments less than about 2%. In some embodiments, a microporous breathable film 2 in accordance with the present disclosure is essentially impervious to alcohol (e.g., isopropyl alcohol).


In illustrative embodiments, a microporous breathable film 2 in accordance with the present disclosure exhibits reduced bonding force to achieve a destruct bond. The destruct bond refers to a strong bond between two materials (e.g., a microporous breathable film 2 or multi-layer breathable barrier film 56 in accordance with the present disclosure bonded to a nonwoven layer), such that an attempt to separate the two materials (e.g., by pulling) damages one of the materials (e.g., the bonding agent is stronger than the materials that are bonded together).


The basis weight of a microporous breathable film 2 in accordance with the present disclosure may be varied based on a desired bonding force. In one example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 20 gsm and a bonding force less than about 1600 Newtons for a 150-mm wide horn. In another example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 17 gsm and a bonding force less than about 1500 Newtons for a 150-mm wide horn. In a further example, a microporous breathable film 2 in accordance with the present disclosure has a basis weight of less than about 12 gsm and a bonding force less than about 1100 Newtons for a 150-mm wide horn.


The bonding force of a microporous breathable 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, for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—it is within the scope of the present disclosure to select a bonding force to be less than or equal to one of the following values for a 150-mm wide horn: about 2000 Newtons, 1900 Newtons, 1800 Newtons, 1700 Newtons, 1600 Newtons, 1500 Newtons, 1400 Newtons, 1300 Newtons, 1200 Newtons, 1100 Newtons, 1000 Newtons, 900 Newtons, 800 Newtons, 700 Newtons, 600 Newtons, 500 Newtons, or 400 Newtons.


It is also within the scope of the present disclosure for the bonding force of a microporous breathable film 2 in accordance with the present disclosure to fall within one of many different ranges. In a first set of ranges, the bonding force for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—is in one of the following ranges for a 150-mm wide horn: about 300 Newtons to 2200 Newtons, 300 Newtons to 2100 Newtons, 300 Newtons to 2000 Newtons, 300 Newtons to 1900 Newtons, 300 Newtons to 1800 Newtons, 300 Newtons to 1700 Newtons, 300 Newtons to 1600 Newtons, 300 Newtons to 1500 Newtons, 300 Newtons to 1400 Newtons, 300 Newtons to 1300 Newtons, 300 Newtons to 1200 Newtons, 300 Newtons to 1100 Newtons, 300 Newtons to 1000 Newtons, 300 Newtons to 900 Newtons, 300 Newtons to 800 Newtons, 300 Newtons to 700 Newtons, 300 Newtons to 600 Newtons, and 300 Newtons to 500 Newtons. In a second set of ranges, the bonding force for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—is in one of the following ranges for a 150-mm wide horn: about 100 Newtons to 1600 Newtons, 200 Newtons to 1600 Newtons, 300 Newtons to 1600 Newtons, 400 Newtons to 1600 Newtons, 500 Newtons to 1600 Newtons, 600 Newtons to 1600 Newtons, 700 Newtons to 1600 Newtons, 800 Newtons to 1600 Newtons, 900 Newtons to 1600 Newtons, 1000 Newtons to 1600 Newtons, 1100 Newtons to 1600 Newtons, 1200 Newtons to 1600 Newtons, 1300 Newtons to 1600 Newtons, and 1400 Newtons to 1600 Newtons. In a third set of ranges, the bonding force for a microporous breathable film having a basis weight of less than or equal to about 20 gsm—in some embodiments, less than or equal to about 19 gsm, 18 gsm, 17 gsm, 16 gsm, 15 gsm, 14 gsm, 13 gsm, 12 gsm, 11 gsm, 10 gsm, or 9 gsm—is in one of the following ranges for a 150-mm wide horn: about 150 Newtons to 1500 Newtons, 200 Newtons to 1450 Newtons, 250 Newtons to 1400 Newtons, 300 Newtons to 1350 Newtons, 350 Newtons to 1300 Newtons, 400 Newtons to 1250 Newtons, 450 Newtons to 1200 Newtons, 500 Newtons to 1150 Newtons, 550 Newtons to 1100 Newtons, 600 Newtons to 1050 Newtons, 650 Newtons to 1000 Newtons, 700 Newtons to 950 Newtons, 750 Newtons to 900 Newtons, and 800 Newtons to 850 Newtons.


In some embodiments, as described above, the present disclosure provides a monolayer microporous breathable film 2. In other embodiments, the present disclosure also provides a multi-layer microporous breathable film (not shown). In one example, a multilayer microporous breathable film includes a core layer and one or more outer skin layers adjacent to the core layer. The core layer may resemble the film 2 shown in FIG. 1 and include a thermoplastic polymer (or combination of thermoplastic polymers) and a solid filler (or combination of solid fillers) dispersed therein, whereas the one or more outer skin layers may have either the same composition as the core or a different composition than the core. In one example, the skin layers may be independently selected from compositions designed to minimize the levels of volatiles building up on the extrusion die. Upon subsequent stretching, the core layer becomes microporous and breathable, while the skin layers may or may not be breathable depending upon whether or not they contain a solid filler. The thickness and composition of one or more skin layers in a multilayer version of a microporous breathable film are selected so that, when the precursor film is subsequently stretched, the resulting film is still breathable. In one example, a pair of skin layers sandwiching a core layer are relatively thin and together account for no more than about 30% of the total film thickness. In some embodiments, regardless of whether or not a skin layer contains a solid filler, the skin layer may still be breathable. For example, the skin layer may include one or more discontinuities that are introduced during the stretching process. The likelihood of discontinuities forming in a skin layer may increase as the thickness of the skin layer subjected to stretching decreases.


In one example, a multi-layer microporous breathable films in accordance with the present disclosure may be manufactured by feed block coextrusion. In another example, a multi-layer microporous breathable 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 microporous breathable films (e.g., mono-layer or multi-layer). In other embodiments, the present disclosure further provides multi-layer breathable barrier films.


A multi-layer breathable barrier film 56 is shown, for example, in FIG. 7. The multi-layer breathable barrier film 56 shown in FIG. 7 includes at least one microporous breathable film layer 58 and at least one monolithic moisture-permeable barrier layer 60. The monolithic moisture-permeable barrier layer 60 includes a hygroscopic polymer. In illustrative embodiments, the monolithic moisture-permeable barrier layer 60 is a monolithic hydrophilic polymer. Monolithic hydrophilic polymers are able to transmit moisture without the additional need of fillers and stretching. The mechanism of breathability in a monolithic hydrophilic polymer is accomplished by absorption and desorption of moisture.


The at least one microporous breathable film layer 58 in FIG. 7 is analogous to the microporous breathable film 2 shown in FIG. 1, and may be prepared by a process analogous to that described above. In one example, the at least one microporous breathable film layer 58 includes a polyolefin and an inorganic filler dispersed in the polyolefin. In illustrative embodiments, the at least one microporous breathable film layer 58 has a basis weight of less than about 14 gsm and a Dart Impact Strength of greater than about 50 grams.


In illustrative embodiments, as shown in FIG. 7, the multi-layer breathable barrier film 56 further includes at least at least one additional microporous breathable film layer 62. The second microporous breathable film layer 62 may be the same as or different than the first microporous breathable film layer 58. For example, the first microporous breathable film layer 58 and the second microporous breathable film layer 62 may differ from each other in thickness, breathability, pore size, and/or thermoplastic composition.


The at least one additional microporous breathable film layer 62—similar to the at least one microporous breathable film layer 58—is analogous to the microporous breathable film 2 shown in FIG. 1, and may be prepared by a process analogous to that described above. In one example, the at least one additional microporous breathable film layer 62 includes a polyolefin and an inorganic filler dispersed in the polyolefin. In illustrative embodiments, the at least one additional microporous breathable film layer 62 has a basis weight of less than about 14 gsm and a Dart Impact Strength of greater than about 50 grams. In illustrative embodiments, as shown in FIG. 7, the at least one monolithic moisture-permeable barrier layer 60 is disposed between the at least one microporous breathable film layer 58 and the at least one additional microporous breathable film layer 62 although other configurations may likewise be implemented.


The monolithic moisture-permeable barrier layer 60 shown in FIG. 7 provides an internal viral and alcohol barrier layer and—unlike microporous breathable film layer 58 and microporous breathable film layer 62—may be unfilled or substantially unfilled (e.g., contain an amount of solid filler that does not result in the creation of micropores as a result of stretching). In illustrative embodiments, the monolithic moisture-permeable barrier layer 60 contains a hygroscopic polymer—including but not limited to the hygroscopic polymers described in International Patent Publication No. WO 2011/019504 A1. The entire contents of International Patent Publication No. WO 2011/019504 A1 are hereby incorporated 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.


The monolithic moisture-permeable barrier layer 60 provides a barrier to viruses and to alcohol penetration. In one example, a tie layer (not shown) may be used to combine dissimilar layers (e.g., monolithic moisture-permeable barrier layer 60 and one or both of microporous breathable film layer 58 and microporous breathable film layer 62). In another example, an adhesive may be blended in one or more of the adjacent dissimilar layers, thus avoiding potential loss in permeability arising from a continuous non-breathable tie layer.


In a further example, no tie resin is present in one, more than one, or any of the layers of a multi-layer film structure. 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 in some embodiments, the use of a tie resin adhesive to keep layers from separating during manufacture and handling may be avoided inasmuch as unstretched lanes of a film (e.g., such as may be produced by CD IMG activation) fulfill the function of the tie resin and facilitate adjoining of layers. For embodiments in which no tie resin is present, there may be advantages in terms of cost savings since tie resins tend to be costly. In addition, tie resins are prone to gel formation during the extrusion process, which is generally undesirable.


The internal monolithic moisture-permeable barrier layer 60 may include a hygroscopic polymer. In illustrative embodiments, the hygroscopic polymer is selected from the group consisting of hygroscopic elastomers, polyesters, polyamides, polyetherester copolymers, polyetheramide copolymers, polyurethanes, polyurethane copolymers, poly(etherimide) ester copolymers, polyvinyl alcohols, ionomers, celluloses, nitrocelluloses, and/or the like, and combinations thereof. In some embodiments, the at least one monolithic moisture-permeable barrier layer 60 further includes an adhesive which, in some embodiments, includes polyethylene/acrylate copolymer, ethylene/methyl acrylate copolymer, acid-modified acrylate, anhydride-modified acrylate, ethylene vinyl acetate, acid/acrylate-modified ethylene vinyl acetate, anhydride-modified ethylene vinyl acetate, and/or the like, or a combination thereof. The monolithic moisture-permeable barrier layer 60 may be prepared from a hygroscopic polymer resin or from a combination of hygroscopic polymer resins and, optionally, from a blend of one or more hygroscopic polymer resins and one or more adhesives.


In one example, the internal monolithic moisture-permeable barrier layer 60 may constitute from about 0.5% to about 30% of the total thickness of the film 56. In another example, the barrier layer 60 may constitute from about 1% to about 20% of the total thickness of the film 56. In a further example, the barrier layer 60 may constitute from about 2% to about 10% of the total thickness of the film 56. In some embodiments (not shown), the film 56 includes a plurality of monolithic moisture-permeable barrier layers 60, and the above-described exemplary ranges of thickness percentages may be applied to the sum of the multiple barrier layers within the film. Multi-layer breathable barrier films 56 in accordance with the present disclosure may include one or more internal monolithic moisture-permeable barrier layers 60, which may be contiguous with each other or with interposed microporous breathable layers such as microporous breathable layer 58 and microporous breathable layer 62. In illustrative embodiments, one or more moisture-permeable barrier layers 60 provided in a multi-layer breathable barrier film 56 in accordance with the present disclosure, are monolithic and do not contain any fillers that provide sites for the development of micropores. However, monolithic moisture-permeable barrier layers may contain other additives to confer desired properties to the barrier layer.


Representative materials for the monolithic moisture-permeable barrier layer 60 include but are not limited to hygroscopic polymers such as ε-caprolactone (available from Solvay Caprolactones), polyether block amides (available from Arkema PEBAX), polyester elastomer (such as Dupont Hytrel or DSM Arnitel) and other polyesters, polyamides, celluloses (e.g., cellulose fibers), nitrocelluloses (e.g., nitrocellulose fibers), ionomers (e.g., ethylene ionomers), and/or the like, and combinations thereof. In one example, fatty acid salt-modified ionomers as described in the article entitled “Development of New Ionomers with Novel Gas Permeation Properties” (Journal of Plastic Film and Sheeting, 2007, 23, No. 2, 119-132) may be used as a monolithic moisture-permeable barrier layer 60. In some embodiments, sodium, magnesium, and/or potassium fatty acid salt-modified ionomers may be used to provide desirable water vapor transmission properties. In some embodiments, the monolithic moisture-permeable barrier layer 60 is selected from the group consisting of hygroscopic elastomers, polyesters, polyamides, polyetherester copolymers (e.g., a block polyetherester copolymer), polyetheramide copolymers (e.g., a block polyetheramide copolymer), polyurethanes, polyurethane copolymers, poly(etherimide) ester copolymers, polyvinyl alcohols, ionomers, celluloses, nitrocelluloses, and/or the like, and combinations thereof. In one example, copolyether ester block copolymers are segmented elastomers having soft polyether segments and hard polyester segments, as described in U.S. Pat. No. 4,739,012. Representative copolyether ester block copolymers are sold by DuPont under the trade name HYTREL®. Representative copolyether amide polymers are copolyamides sold under the trade name PEBAX® by Atochem Inc. of Glen Rock, New Jersey Representative polyurethanes are thermoplastic urethanes sold under the trade name ESTANE® by the B. F. Goodrich Company of Cleveland, Ohio. Representative copoly(etherimide) esters are described in U.S. Pat. No. 4,868,062.


In some embodiments, the monolithic moisture-permeable barrier layer 60 may include or be blended with a thermoplastic resin. Representative thermoplastic resins that may be used for this purpose include but are not limited to polyolefins, polyesters, polyetheresters, polyamides, polyether amides, urethanes, and/or the like, and combinations thereof. In some embodiments, the thermoplastic polymer may include (a) a polyolefin, such as polyethylene, polypropylene, poly(i-butene), poly(2-butene), poly(i-pentene), poly(2-pentene), poly(3-methyl-1-pentene), poly(4-methyl-1-pentene), 1,2-poly-1,3-butadiene, 1,4-poly-1,3-butadiene, polyisoprene, polychloroprene, polyacrylonitrile, polyvinyl acetate, poly(vinylidene chloride), polystyrene, and/or the like, and combinations thereof; (b) a polyester such as poly(ethylene terephthalate), poly(butylenes)terephthalate, poly(tetramethylene terephthalate), poly(cyclohexylene-1,4-dimethylene terephthalate), poly(oxymethylene-1,4-cyclohexylenemethyleneoxyterephthaloyl), and/or the like, and combinations thereof; and (c) a polyetherester, such as poly(oxyethylene)-poly(butylene terephthalate), poly(oxytetramethylene)-poly(ethylene terephthalate), and/or the like, and combinations thereof; and/or (d) a polyamide, such as poly(6-aminocaproic acid), poly(,-caprolactam), poly(hexamethylene adipamide), poly(hexamethylene sebacamide), poly(1 1-aminoundecanoic acid), and/or the like, and combinations thereof.


In illustrative embodiments the hygroscopic polymer is a hygroscopic elastomer. A variety of additives may be added to the monolithic moisture-permeable barrier layer 60 to provide additional properties such as antimicrobial effects, odor control, static decay, and/or the like. One or more monolithic moisture-permeable barrier layers 60 is placed in the film 56 to impede the flow of liquids, liquid borne pathogens, viruses, and other microorganisms that may be carried by a liquid challenge.


One or more of the monolithic moisture-permeable bather layers 60, microporous breathable film layer 58, and microporous breathable film layer 62 in the multi-layer breathable barrier film 56 may include one or more adhesives for adhering the internal monolithic moisture-permeable barrier layer 60 to contiguous layers to form the multi-layer film 56. In one example, adhesive may be components suitable for adhering two or more layers together. In one example, adhesives are compatibilizing adhesives that increase the compatibility of the layers as well as adhering the layers to one another. The adhesives may be included in the resin or other extrudable material before extruding that resin into the monolithic moisture-permeable barrier layer 60. Representative compatibilizing adhesives include but are not limited to polyethylene/acrylate copolymer, ethylene/methyl acrylate copolymer, acid-modified acrylate, anhydride-modified acrylate, ethylene vinyl acetate, acid/acrylate-modified ethylene vinyl acetate, anhydride-modified ethylene vinyl acetate, and/or the like, and combinations thereof. In one example, when one of the microporous breathable layer 58, the microporous breathable layer 62 and the monolithic moisture-permeable barrier layer 60 includes an adhesive, the adhesive may have a relatively high methacrylate content (e.g., a methacrylate content of at least about 20% to 25%). In some embodiments, the internal monolithic moisture-permeable barrier layer 60 may be prepared from blends including up to about 50% by weight adhesive and at least about 50% by weight hygroscopic polymer.


In some embodiments, the hygroscopic polymer may be dried before it is extruded. Feeding pre-dried hygroscopic elastomer in small amounts to an extruder has proven to be effective in avoiding moisture absorption, preventing hydrolysis of the hygroscopic elastomer, and reducing or eliminating the formation of dark blue gels and holes in web. In some higher stretch ratio cases, gels rendered holes and even web break.


A multi-layer breathable barrier film 56 in accordance with the present disclosure may contain one or a plurality of monolithic moisture-permeable barrier layers 60, each of which may be placed in any order in the inner layers of the film structure. In illustrative embodiments, the monolithic moisture-permeable barrier layer 60 is not placed on the outer surface of the resultant film 56 in order to avoid damage caused by foreign materials. In one example, when the film 56 contains a plurality of monolithic moisture-permeable barrier layers 60, individual monolithic moisture-permeable barrier layers 60 are not placed adjacent to each other inside the film in order to increase efficacy. When a plurality of monolithic moisture-permeable barrier layers 60 is used, the individual monolithic moisture-permeable barrier layers 60 may differ from each other in thickness and/or type of thermoplastic polymer.


In one example, a representative structure for a multi-layer breathable barrier film 56 contains five layers (not shown), with one monolithic moisture-permeable barrier layer being in the core of the structure and four microporous breathable film layers being arranged around the core. In one example, the five-layer breathable barrier film has a A-C-B-C-A structure, wherein A represents a first microporous breathable film layer, C represents a second microporous breathable film layer that is different than or the same as the first microporous breathable film layer, and B represents a monolithic moisture-permeable barrier layer.


In one example, the outermost microporous breathable film layer (A and/or C) contains Dow 5230G LLDPE or Dow PL1280 ULDPE or Dow 5630 LLDPE, and calcium carbonate. Additional antioxidants, colorants, and/or processing aids may optionally be added. The microporous breathable film layer A may differ from the microporous breathable film layer C in the amount and/or identity of solid filler present (e.g., calcium carbonate, barium sulfate, talc, glass spheres, other inorganic particles, etc.). The inner monolithic moisture-permeable barrier layer B may contain a hygroscopic elastomer such as Dupont HYTREL PET and an adhesive such as Dupont BYNEL 3101 20% EVA or Dupont AC1820 acrylate, with additional antioxidants, colorants, and processing aids optionally being added. In one example, the inner monolithic moisture-permeable barrier layer B contains about 50% adhesive and about 50% by weight or more of hygroscopic elastomer. Instead of a polyester elastomer, other hygroscopic polymers, such as ε-caprolactone, polyester block amides, polyester elastomers, polyamides, and blends thereof may be utilized as the inner monolithic moisture-permeable barrier layers.


Multi-layer breathable 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 FIG. 7 or the five-layer structure A-C-B-C-A described above. Film structure is a function of equipment design and capability. For example, the number of layers in a film depends only on the technology available and the desired end use for the film. Representative examples of film structures that may be implemented in accordance with the present disclosure include but are not limited to the following, wherein A represents a microporous breathable film layer (e.g., 58 or 62) and B represents an alcohol and viral monolithic moisture-permeable barrier layer (e.g., 60):

    • A-B-A
    • A-A-B-A
    • A-B-A-A
    • A-A-B-A-A
    • A-B-A-A-A
    • A-B-A-B-A
    • A-B-A-A-A-A-A
    • A-A-B-A-A-A-A
    • A-A-A-B-A-A-A
    • A-B-A-A-A-B-A
    • A-B-A-A-B-A-A
    • A-B-A-B-A-A-A
    • A-B-A-B-A-B-A
    • A-B-A-A-A-A-A-A
    • A-A-B-A-A-A-A-A
    • A-A-A-B-A-A-A-A
    • A-B-A-A-A-A-B-A.


In the above-described exemplary film structures, each of the microporous breathable film layers A may include two or more microporous breathable film layers in order to better control other film properties, such as the ability to bond to nonwovens. For example, when there are two microporous breathable film layers in one A microporous breathable film layer, and when C represents the second microporous breathable film layer, some exemplary film structures are as follows:

    • A-C-B-C-A
    • A-C-A-C-B-C-A
    • A-C-B-C-A-C-A
    • A-C-A-C-B-C-A-C-A
    • A-C-B-C-A-C-A-C-A
    • A-C-B-C-A-B-C-A


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:

    • A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A


Representative applications using a microporous breathable film 2 and/or a multi-layer breathable 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. The encasing of the monolithic moisture-permeable barrier layer 60 protects the monolithic moisture-permeable barrier layer 60 from mechanical damage or thermal damage and allows for thermal and ultrasonic bonding of the multilayer film at extremely low thicknesses.


Multi-layer breathable 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 Tyvek (spunbond HDPE). The multi-layer breathable barrier films 56 in accordance with the present disclosure may be used to replace either of these products in such applications.


In one example, multi-layer breathable 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 multilayer breathable 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 microporous breathable films 2 (e.g., mono-layer or multi-layer) and multi-layer breathable barrier films 56. In other embodiments, the present disclosure further provides personal hygiene products containing one or more microporous breathable films (e.g., mono-layer or multi-layer) in accordance with the present disclosure, and/or one or more multi-layer breathable barrier films in accordance with the present disclosure. In illustrative embodiments, a personal hygiene product in accordance with the present disclosure includes at least one inner microporous breathable film 2 prepared by a process as described above and at least one outer non-woven layer. The at least one inner microporous breathable film 2 is configured for contacting skin and/or clothing of a user of the personal hygiene product. In some embodiments, the personal hygiene product further includes at least one monolithic moisture-permeable barrier layer 60 disposed between the at least one inner microporous breathable film 2 and the at least one outer non-woven layer.


In one example, the at least one inner microporous breathable film 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 microporous breathable film 2 and the at least one outer non-woven layer comprises polypropylene and/or polyethylene. In illustrative embodiments, the inner microporous breathable film 2 includes calcium carbonate as the solid filler.


In illustrative embodiments, the personal hygiene product in accordance with the present disclosure is configured as an incontinence brief, a surgical gown, or a feminine hygiene product.


The following numbered clauses include embodiments that are contemplated and non-limiting:


Clause 1. A process for making a microporous breathable film comprising the steps of

    • extruding a composition comprising a polyolefin and an inorganic filler to form a molten web,
    • casting the molten web against a surface of a chill roll using an air knife, air blanket, a vacuum box, or a combination thereof to form a quenched film, and
    • stretching the quenched film to form the microporous breathable film.


Clause 2. The process of clause 1, wherein the polyolefin comprises polyethylene, polypropylene, or a combination thereof.


Clause 3. The process of clause 1, wherein the polyolefin comprises low density polyethylene, high density polyethylene, linear low density polyethylene, ultra-low density polyethylene, or a combination thereof.


Clause 4. The process of clause 1, wherein the polyolefin comprises linear low density polyethylene.


Clause 5. The process of clause 1, wherein the polyolefin comprises linear low density polyethylene and the linear low density polyethylene comprises a metallocene polyethylene.


Clause 6. The process of clause 1, wherein the polyolefin comprises polypropylene.


Clause 7. The process of clause 1, wherein the inorganic filler comprises from about 30% to about 75% by weight of the microporous breathable film.


Clause 8. The process of clause 1, wherein an average particle size of the inorganic filler is between about 0.1 microns and about 15 microns.


Clause 9. The process of clause 1, wherein the inorganic filler is selected from the group consisting of sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, alumina, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolites, and a combination thereof.


Clause 10. The process of clause 1, wherein the inorganic filler comprises an alkali metal carbonate, an alkaline earth metal carbonate, an alkali metal sulfate, an alkaline earth metal sulfate, or a combination thereof.


Clause 11. The process of clause 1, wherein the inorganic filler comprises calcium carbonate.


Clause 12. The process of clause 1, wherein the molten web is cast against the surface of the chill roll under negative pressure by the vacuum box.


Clause 13. The process of clause 1, wherein the molten web is cast against the surface of the chill roll under positive pressure by the air knife.


Clause 14. The process of clause 1, wherein an exit temperature of cooling fluid passing through the chill roll is between about 50 degrees Fahrenheit and about 130 degrees Fahrenheit.


Clause 15. The process of clause 1, wherein the stretching comprises machine direction (MD) stretching, cross-direction (CD) stretching, intermeshing gear (IMG) stretching, cold drawing, or a combination thereof.


Clause 16. The process of clause 1, wherein the stretching comprises cross-directional intermeshing gear (CD IMG) stretching.


Clause 17. The process of clause 1, wherein the stretching comprises cross-directional intermeshing gear (CD IMG) stretching and cold draw.


Clause 18. The process of clause 1, wherein at least a portion of the stretching is performed at a temperature of between about 60 degrees Fahrenheit and about 200 degrees Fahrenheit.


Clause 19. The process of clause 1, further comprising annealing the microporous breathable film.


Clause 20. The process of clause 1, further comprising annealing the microporous breathable film in which the annealing is performed at a temperature of between about 75 degrees Fahrenheit and about 225 degrees Fahrenheit.


Clause 21. The process of clause 1, wherein the microporous breathable film has a basis weight of less than about 14 gsm.


Clause 22. The process of clause 21, wherein the microporous breathable film has a basis weight of less than about 12 gsm.


Clause 23. A process for making a microporous breathable film comprising the steps of

    • extruding a composition that comprises polyethylene, polypropylene, or a combination thereof and an alkaline earth metal carbonate to form a molten web, the alkaline earth metal carbonate comprising at least about 50% by weight of the microporous breathable film,
    • casting the molten web against a surface of a chill roll under negative pressure by a vacuum box to form a quenched film,
    • stretching the quenched film by cross-directional intermeshing gear (CD IMG) stretching to form the microporous breathable film, and
    • annealing the microporous breathable film at a temperature of between about 75 and about 225 degrees Fahrenheit.


Clause 24. A microporous breathable film comprising

    • a polyolefin and an inorganic filler dispersed in the polyolefin,
    • wherein the microporous breathable film has a basis weight of less than about 14 gsm and a Dart Impact Strength of greater than about 50 grams.


Clause 25. The microporous breathable film of clause 24, wherein the microporous breathable film has a basis weight of less than about 13 gsm and a Dart Impact Strength of at least about 75 grams.


Clause 26. The microporous breathable film of clause 24, wherein the microporous breathable film has a basis weight of less than about 13 gsm and a Dart Impact Strength of at least about 100 grams.


Clause 27. The microporous breathable film of clause 24, wherein the microporous breathable film has a basis weight of less than about 9 gsm and a Dart Impact Strength of at least about 100 grams.


Clause 28. The microporous breathable film of clause 24, wherein the microporous breathable film has a basis weight of less than about 8 gsm.


Clause 29. The microporous breathable film of clause 24, wherein the polyolefin comprises polyethylene, polypropylene, or a combination thereof.


Clause 30. The microporous breathable film of clause 24, wherein the polyolefin comprises low density polyethylene, high density polyethylene, linear low density polyethylene, ultra-low density polyethylene, or a combination thereof.


Clause 31. The microporous breathable film of clause 24, wherein the polyolefin comprises linear low density polyethylene.


Clause 32. The microporous breathable film of clause 24, wherein the polyolefin consists essentially of linear low density polyethylene.


Clause 33. The microporous breathable film of clause 24, wherein the polyolefin comprises linear low density polyethylene, and the linear low density polyethylene comprises a metallocene polyethylene.


Clause 34. The microporous breathable film of clause 24, wherein the polyolefin comprises polypropylene.


Clause 35. The microporous breathable film of clause 24, wherein the inorganic filler comprises from about 30% to about 75% by weight of the microporous breathable film.


Clause 36. The microporous breathable film of clause 24, wherein the inorganic filler comprises from about 50% to about 75% by weight of the microporous breathable film.


Clause 37. The microporous breathable film of clause 24, wherein the inorganic filler comprises an alkali metal carbonate, an alkaline earth metal carbonate, an alkali metal sulfate, an alkaline earth metal sulfate, or a combination thereof.


Clause 38. The microporous breathable film of clause 24, wherein the inorganic filler comprises calcium carbonate.


Clause 39. The microporous breathable film of clause 24, wherein the microporous breathable film has a strain at peak machine direction of at least about 150%.


Clause 40. The microporous breathable film of clause 24, wherein the microporous breathable film has a strain at peak machine direction of at least about 175%.


Clause 41. The microporous breathable film of clause 24, wherein the microporous breathable film has a strain at peak machine direction of at least about 200%.


Clause 42. The microporous breathable film of clause 24, wherein the microporous breathable film has a strain at peak machine direction of at least about 215%.


Clause 43. A microporous breathable film comprising

    • linear low density polyethylene and an alkaline earth metal dispersed in the linear low density polyethylene,
    • wherein the alkaline earth metal comprises from about 50% to about 75% by weight of the microporous breathable film,
    • wherein the microporous breathable film has a basis weight of less than about 13 gsm and a Dart Impact Strength of at least about 90 grams, and
    • wherein the microporous breathable film has a strain at peak machine direction of at least about 90%.


Clause 44. The microporous breathable film of clause 43, wherein the microporous breathable film has a strain at peak machine direction of at least about 125%.


Clause 45. The microporous breathable film of clause 43, wherein the microporous breathable film has a strain at peak machine direction of at least about 150%.


Clause 46. The microporous breathable film of clause 43, wherein the microporous breathable film has a strain at peak machine direction of at least about 200%.


Clause 47. A multi-layer breathable barrier film comprising

    • at least one microporous breathable film layer comprising a polyolefin and an inorganic filler dispersed in the polyolefin, wherein the at least one microporous breathable film layer has a basis weight of less than about 14 gsm and a Dart Impact Strength of greater than about 50 grams, and
    • at least one moisture-permeable barrier layer comprising a hygroscopic polymer.


Clause 48. The multi-layer breathable barrier film of clause 47 further comprising at least one additional microporous breathable film layer, wherein the at least one additional microporous breathable film layer comprises a polyolefin and an inorganic filler dispersed in the polyolefin, wherein the at least one additional microporous breathable film layer has a basis weight of less than about 14 gsm and a Dart Impact Strength of greater than about 50 grams, wherein the at least one microporous breathable film layer and the at least one additional microporous breathable film layer are the same or different, and wherein the at least one moisture-permeable barrier layer is disposed between the at least one microporous breathable film layer and the at least one additional microporous breathable film layer.


Clause 49. The multi-layer breathable barrier film of clause 47, wherein the hygroscopic polymer is selected from the group consisting of hygroscopic elastomers, polyesters, polyamides, polyetherester copolymers, polyetheramide copolymers, polyurethanes, polyurethane copolymers, poly(etherimide) ester copolymers, polyvinyl alcohols, ionomers, celluloses, nitrocelluloses, and a combination thereof.


Clause 50. A multi-layer breathable barrier film comprising

    • at least one microporous breathable film layer prepared by the process of clause 1,
    • at least one moisture-permeable barrier layer comprising a hygroscopic polymer, and
    • at least one additional microporous breathable film prepared by the process of clause 1,
    • wherein the at least one microporous breathable film layer and the at least one additional microporous breathable film layer are the same or different, and
    • wherein the at least one moisture-permeable barrier layer is disposed between the at least one microporous breathable film layer and the at least one additional microporous breathable film.


Clause 51. The multi-layer breathable barrier film of clause 50, wherein the hygroscopic polymer is selected from the group consisting of hygroscopic elastomers, polyesters, polyamides, polyetherester copolymers, polyetheramide copolymers, polyurethanes, polyurethane copolymers, poly(etherimide) ester copolymers, polyvinyl alcohols, ionomers, celluloses, nitrocelluloses, and a combination thereof.


Clause 52. The multi-layer breathable barrier film of clause 50, wherein the at least one moisture-permeable barrier layer further comprises an adhesive.


Clause 53. The multi-layer breathable barrier film of clause 50, wherein the at least one moisture-permeable barrier layer further comprises an adhesive, and the adhesive comprises polyethylene/acrylate copolymer, ethylene/methyl acrylate copolymer, acid-modified acrylate, anhydride-modified acrylate, ethylene vinyl acetate, acid/acrylate-modified ethylene vinyl acetate, anhydride-modified ethylene vinyl acetate, or a combination thereof.


Clause 54. A personal hygiene product comprising

    • at least one inner microporous breathable film prepared by the process of clause 1, the at least one inner microporous breathable film being configured for contacting skin and/or clothing of a user of the personal hygiene product, and
    • at least one outer non-woven layer.


Clause 55. The personal hygiene product of clause 54 further comprising at least one moisture-permeable barrier layer disposed between the at least one inner microporous breathable film and the at least one outer non-woven layer.


Clause 56. The personal hygiene product of clause 54, wherein the at least one inner microporous breathable film is bonded to the at least one outer non-woven layer without an adhesive.


Clause 57. The personal hygiene product of clause 54, wherein each of the at least one inner microporous breathable film and the at least one outer non-woven layer comprises polypropylene.


Clause 58. The personal hygiene product of clause 54, wherein the product is configured as an incontinence brief.


Clause 59. The personal hygiene product of clause 54, wherein the product is configured as a surgical gown.


Clause 60. The personal hygiene product of clause 54, wherein the product is configured as a feminine hygiene product.


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.


EXAMPLES
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, TX, 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, NJ 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.


Example 1
Comparison of Conventional Embossed Film to Chill Cast Vacuum Box Film

In this experiment, microporous breathable films were made from the formulation XC3-121-2205.0 shown in Table 1.









TABLE 1







Composition of XC3-121-2205.0













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)













A
97
T994L3
75




(CaCO3)




3527
15




(metallocene




polyethylene)




640
10




(LDPE)


C
1.5/1.5
LD516.LN
100


(split)

(polyethylene)









The molten web formed by extrusion of the composition XC3-121-2205.0 shown in Table 1 was quenched by either a conventional embossed roll process or a chill cast vacuum box process in accordance with the present disclosure on a 250T roll (1749.9 rpm setting). The physical properties of a film made by the conventional embossed roll process and a film made by the chill cast process in accordance with the present disclosure are shown in Table 2. Table 2 further includes physical properties for a third film made by the chill cast vacuum box process, which was down-gauged to 12.21 gsm. In Table 2 and in subsequent tables, Elmendorf tear results that are below the assay range of the equipment are indicated by an asterisk and should be regarded as being for reference only.









TABLE 2







Comparison of Physical Properties of Microporous Breathable


Film Prepared by Conventional Embossing Process vs. Chill


Cast Vacuum Box Process.















Down-






Gauged




Embossed
Chill
Chill


Physical Property
Units
FST250
Cast
Cast














Basis Weight
g/m2
16.60
16.60
12.21


Emboss Depth
mil
0.90
0.70
0.60


Light Transmission
%
43.3
40.5
47.7


COF, Static - In\In
Index
0.56
0.54
0.56


COF, Static - Out\Out
Index
0.58
0.57
0.57


COF, Kinetic - In\In
Index
0.53
0.51
0.53


COF, Kinetic - Out\Out
Index
0.56
0.56
0.52


WVTR 100K
g/m2/day
4109
2276
2569


Force @ Peak MD
g/in
563
695
584


Strain @ Peak MD
%
292
164
83


Force @ Break MD
g/in
563
695
581


Strain @ Break MD
%
292
164
93


Force @ Yield MD
g/in
402
624
429


Strain @ Yield MD
%
13
13
8


Force @ 5% Strain MD
g/in
285
360
316


Force @ 10% Strain MD
g/in
385
575
515


Force @ 25% Strain MD
g/in
429
670
577


Force @ 50% Strain MD
g/in
438
669
576


Force @ 100% Strain
g/in
447
673
—


MD


Elmendorf Tear MD
gf
32.3*
19.2*
9.3*


Force @ Peak TD
g/in
337
334
245


Strain @ Peak TD
%
523
492
516


Force @ Break TD
g/in
337
334
245


Strain @ Break TD
%
523
492
515


Force @ Yield TD
g/in
206
228
161


Strain @ Yield TD
%
24
24
25


Force @ 5% Strain TD
g/in
126
145
100


Force @ 10% Strain TD
g/in
162
184
126


Force @ 25% Strain TD
g/in
208
231
161


Force @ 50% Strain TD
g/in
225
248
176


Force @ 100% Strain
g/in
227
248
175


TD


Elmendorf Tear TD
gf
275
451
324


§ Slow Puncture - ¼″
gf
234
282
214


(D3)









As shown by the data in Table 2, a microporous breathable film in accordance with the present disclosure shows substantially improved TD tear, and puncture properties as compared to a conventional embossed roll film. For example, microporous breathable films prepared by the chill cast process show greater MD tensile strength and less MD elongation as compared to the embossed film. Moreover, surprisingly, the non-embossed microporous breathable film exhibits a reduced water vapor transmission rate (WVTR) as compared to the comparable embossed film. This observation stands in contrast to the findings reported in U.S. Pat. No. 6,656,581, which states that the MVTR (moisture vapor transmission rate) of a non-embossed film is greater than the MVTR of a comparable embossed film that is incrementally stretched under essentially the same conditions.


The embossed process is prone to draw resonance. As a result, microporous breathable films prepared by a conventional embossing process typically include LDPE to assist in the processing. However, for microporous breathable films prepared by a chill cast vacuum box quenching process in accordance with the present teachings, the LDPE may be omitted, thereby affording stronger films having properties that were heretofore unachievable with conventional films.


Example 2
Microporous Breathable Films Prepared by Vacuum Box Process

Seven formulations containing a CaCO3-containing compound (CF7414 or T998K5) were used to prepare microporous breathable films in accordance with the present disclosure. In each of these seven formulations, the CaCO3-containing compound (CF7414 or T998K5) is present in 70% by weight and PPA is present in 2%. The remainder of the formulations is a polymer or polymer blend. The composition of the seven formulations, including the compositions of the polymer/polymer blend constituting the balance, is shown in Table 3 below.









TABLE 3







Formulations for Microporous Breathable Films.










CaCO3




Compound


Formulation
70%
Polymer/Polymer Blend


No.
(w/w)
28% (w/w)





1
CF7414
18% EXCEED LL3527 (ExxonMobil, metallocene




polyethylene resin, narrow MWD, density = 0.927 g/cm3)/




10% Dow 640 (DOW Chemical Company, low density




polyethylene resin, autoclave, branched broad MWD,




density = 0.922 g/cm3)


2
CF7414
28% LL3527


3
CF7414
28% EXCEED LL3518 (ExxonMobil, metallocene




polyethylene resin, narrow MWD, density = 0.918 g/cm3)


4
CF7414
28% EXCEED LL1018 (ExxonMobil, metallocene




polyethylene resin, narrow MWD, density = 0.918 g/cm3)


5
CF7414
28% D350 (Chevron Phillips, MARFLEX linear low




density polyethylene, density = 0.933 g/cm3)


6
T998K5
18% LL3527, 10% Dow 640


7
T998K5
28% LL3527









The films made from formulations 1 and 6 were 14 gsm, whereas films made from formulations 2-5 and 7 were 12 gsm.


The composition of the CaCO3-containing compounds CF7414 and T998K5 shown in Table 3 are specified in Table 4 below.









TABLE 4







Composition of CaCO3 Compounds used in the


Formulations of Table 3.










CF7414
T998K5


Component
Amount of Component
Amount of Component





EXCEED LL3518
28



EXCEED LL3527

26


FilmLink 500
60
60


(CaCO3)


TiO2
12
14









The seven formulations shown in Table 3 were used to make a series of microporous breathable films. The films were subjected to varying amounts of pre-stretch and, in some cases to MD IMG stretching. The physical properties of the films thus prepared are summarized in Tables 5, 6, and 7 below.









TABLE 5







Physical Properties of Microporous Breathable Films A-G.















A
B
C
D
E
F
G




















Formulation
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-




2251.0
2251.0
2251.0
2251.1
2251.1
2251.1
2251.2



Pre-stretch
50
70
 50
50
70
50
50



MD IMG?
No
No
Yes
No
No
Yes
No



Polymer/Polymer
Blend 3527/
Blend 3527/
Blend 3527/
Sole 3527
Sole 3527
Sole 3527
Sole 3518



Blend
640
640
640



Compound
CF7414
CF7414
CF7414
CF7414
CF7414
CF7414
CF7414





Physical Property
Units





Basis Weight
g/m2
13.60
13.61
   13.07
11.32
12.19
11.63
11.31


Density
g/cc
1.4052
1.4655
    1.4089
1.4752
1.4010
1.4636
1.3619


Light Transmission
%
41.8
39.3
  42.1
46.3
44.4
45.3
49.1


Gloss - In
% @ 45°
9.5
9.2
   8.8
6.7
6.9
7.2
7.0


Gloss - Out
% @ 45°
9.1
8.7
   9.1
7.0
6.9
7.3
7.1


COF, Static - In\In
—
0.500
0.535
    0.552
0.580
0.618
0.625
0.610


COF, Static -
—
0.548
0.517
    0.530
0.600
0.612
0.607
0.620


Out\Out


COF, Kinetic - In\In
—
0.451
0.458
    0.456
0.486
0.503
0.490
0.519


COF, Kinetic -
—
0.450
0.460
    0.459
0.494
0.499
0.486
0.518


Out\Out


WVTR 100K
g/m2/day
4186
3652
3957 
4439
3755
3719
2703


Tensile Gauge MD
mil
0.38
0.37
   0.37
0.30
0.34
0.31
0.33


Force @ Peak MD
g/in
737
1,015
806
690
887
660
861


Strain @ Peak MD
%
148
177
154
217
220
193
224


Force @ Break MD
g/in
694
969
746
675
844
650
844


Strain @ Break MD
%
154
180
158
219
222
193
225


Force @ Yield MD
g/in
665
813
712
274
250
278
210


Strain @ Yield MD
%
15
15
 15
11
8
11
9


Force @ 5% Strain
g/in
274
314
272
191
205
186
139


MD


Force @ 10% Strain
g/in
522
607
528
270
295
272
215


MD


Force @ 25% Strain
g/in
681
839
731
323
361
334
272


MD


Force @ 50% Strain
g/in
662
817
708
343
387
358
303


MD


Force @ 100%
g/in
675
838
721
369
420
390
353


Strain MD


TEA MD
FtLb/in2
976
1,485
1,103  
1,099
1,179
942
1,061


Elmendorf Tear MD
g
200
200
200
200
200
200
200


Arm


Elmendorf Tear MD
gf
6.7*
6.2*
  7*
13.8*
9.4*
14.2*
16.1*


Tensile Gauge TD
mil
0.38
0.37
   0.37
0.30
0.34
0.31
0.33


Force @ Peak TD
g/in
270
229
256
204
212
194
184


Strain @ Peak TD
%
403
422
468
403
407
400
445


Force @ Break TD
g/in
259
217
245
194
204
185
177


Strain @ Break TD
%
410
429
472
408
411
404
450


Force @ Yield TD
g/in
173
159
167
160
163
143
125


Strain @ Yield TD
%
21
25
 26
31
31
28
27


Force @ 5% Strain
g/in
99
89
 88
77
79
76
72


TD


Force @ 10% Strain
g/in
135
119
124
106
108
100
95


TD


Force @ 25% Strain
g/in
180
158
166
151
153
140
123


TD


Force @ 50% Strain
g/in
182
171
179
171
176
149
137


TD


Force @ 100%
g/in
197
178
181
171
175
160
139


Strain TD


TEA TD
FtLb/in2
859
809
934
875
803
788
738


Elmendorf Tear TD
g
1,600
800
1,600  
1,600
1,600
1,600
1,600


Arm


Elmendorf Tear TD
gf
330
247
301
312
378
335
355


Dart Drop (26″)
g
63
67
 62
124
128
125
141


§ Slow Puncture -
gf
311
332
277
214
229
213
195


¼″ (D3)
















TABLE 6







Physical Properties of Microporous Breathable Films H-N.















H
I
J
K
L
M
N




















Formulation
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-




2251.2
2251.2
2251.3
2251.3
2251.3
2251.4
2251.4



Pre-stretch
70
50
50
70
50
50
 70



MD IMG?
No
Yes
No
No
Yes
No
No



Polymer/Polymer
Sole 3518
Sole 3518
Sole 1018
Sole 1018
Sole 1018
Sole D350
Sole D350



Blend



Compound
CF7414
CF7414
CF7414
CF7414
CF7414
CF7414
CF7414





Physical Property
Units





Basis Weight
g/m2
11.45
11.37
11.25
11.48
11.56
11.79
   11.05


Density
g/cc
1.4603
1.3375
1.4667
1.3047
1.4626
1.4212
    1.4600


Light Transmission
%
46.1
47.4
45.9
45.0
45.1
43.6
  43.7


Gloss - In
% @ 45°
6.9
7.1
6.9
7.1
7.0
6.4
   7.1


Gloss - Out
% @ 45°
7.2
7.4
7.2
7.3
7.1
7.4
   7.2


COF, Static - In\In
—
0.652
0.630
0.625
0.622
0.617
0.600
    0.600


COF, Static -
—
0.650
0.640
0.640
0.628
0.627
0.593
    0.567


Out\Out


COF, Kinetic - In\In
—
0.524
0.523
0.508
0.515
0.515
0.481
    0.483


COF, Kinetic -
—
0.526
0.535
0.521
0.524
0.522
0.484
    0.479


Out\Out


WVTR 100K
g/m2/day
2614
2574
1054
1140
1395
2807
2735 


Tensile Gauge MD
mil
0.31
0.33
0.30
0.35
0.31
0.33
   0.30


Force @ Peak MD
g/in
944
754
1,298
1,487
1,436
1,297
1,335  


Strain @ Peak MD
%
202
198
153
137
148
178
150


Force @ Break MD
g/in
912
742
1,245
1,403
1,400
1,241
1,297  


Strain @ Break MD
%
202
199
154
138
148
179
150


Force @ Yield MD
g/in
274
218
230
177
215
341
381


Strain @ Yield MD
%
10
10
8
6
8
10
 10


Force @ 5% Strain
g/in
185
143
158
161
142
201
216


MD


Force @ 10% Strain
g/in
278
222
273
294
267
339
370


MD


Force @ 25% Strain
g/in
353
285
393
450
406
468
542


MD


Force @ 50% Strain
g/in
394
318
472
560
499
508
598


MD


Force @ 100% Strain
g/in
462
373
664
882
755
628
802


MD


TEA MD
FtLb/in2
1,219
902
1,173
1,041
1,176
1,350
1,351  


Elmendorf Tear MD
g
200
200
200
200
200
200
200


Arm


Elmendorf Tear MD
gf
14.7*
18.2*
6.4*
4.6*
5.6*
4.4*
  5*


Tensile Gauge TD
mil
0.31
0.33
0.30
0.35
0.31
0.33
   0.30


Force @ Peak TD
g/in
201
201
221
199
194
254
218


Strain @ Peak TD
%
521
482
500
503
464
505
487


Force @ Break TD
g/in
189
193
207
189
189
246
210


Strain @ Break TD
%
525
485
503
505
468
508
492


Force @ Yield TD
g/in
113
122
128
115
122
174
153


Strain @ Yield TD
%
24
25
20
18
19
27
 28


Force @ 5% Strain
g/in
70
74
88
85
85
89
 84


TD


Force @ 10% Strain
g/in
90
96
110
103
106
123
111


TD


Force @ 25% Strain
g/in
114
123
133
121
127
170
149


TD


Force @ 50% Strain
g/in
128
136
144
131
138
179
160


TD


Force @ 100% Strain
g/in
129
137
144
132
139
176
162


TD


TEA TD
FtLb/in2
908
818
994
779
832
1,101
1,052  


Elmendorf Tear TD
g
1,600
800
1,600
1,600
800
1,600
1,600  


Arm


Elmendorf Tear TD
gf
312
320
396
364
347
417
297


Dart Drop (26″)
g
129
146
179
200
197
160
154


§ Slow Puncture -
gf
209
208
285
283
282
296
275


¼″ (D3)
















TABLE 7







Physical Properties of Microporous Breathable Films O-U.















O
P
Q
R
S
T
U




















Formulation
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-
XC1-2-




2251.4
2251.5
2251.5
2251.5
2251.6
2251.6
2251.6



Pre-stretch
50
 50
70
50
50
70
50



MD IMG?
Yes
No
No
Yes
No
No
Yes



Polymer/Polymer
Sole D350
Blend 3527
Blend 3527
Blend 3527
Sole 3527
Sole 3527
Sole 3527



Blend

640
640
640



Compound
CF7414
T998K5
T998K5
T998K5
T998K5
T998K5
T998K5





Physical Property
Units





Basis Weight
g/m2
11.37
   13.24
13.67
13.59
12.23
12.19
12.20


Density
g/cc
1.4289
    1.4489
1.3988
1.4491
1.4211
1.4426
1.4135


Light Transmission
%
44.4
  43.0
41.2
42.4
45.5
46.1
45.2


Gloss - In
% @ 45°
7.3
   8.6
8.8
8.7
6.8
6.9
6.6


Gloss - Out
% @ 45°
7.3
   9.0
8.9
8.7
7.0
6.8
6.9


COF, Static - In\In
—
0.593
    0.553
0.513
0.518
0.598
0.587
0.585


COF, Static -
—
0.597
    0.510
0.523
0.493
0.537
0.565
0.565


Out\Out


COF, Kinetic - In\In
—
0.498
    0.456
0.440
0.451
0.465
0.472
0.465


COF, Kinetic -
—
0.483
    0.441
0.436
0.440
0.460
0.461
0.464


Out\Out


WVTR 100K
g/m2/day
2610
3949 
5316
5031
6446
6024
5829


Tensile Gauge MD
mil
0.31
   0.36
0.38
0.37
0.35
0.33
—


Force @ Peak MD
g/in
1,354
854
863
891
693
715
764


Strain @ Peak MD
%
175
157
175
192
241
206
247


Force @ Break MD
g/in
1,278
797
844
865
684
685
764


Strain @ Break MD
%
176
174
177
195
241
207
247


Force @ Yield MD
g/in
357
670
614
783
304
314
310


Strain @ Yield MD
%
10
 13
11
15
11
11
11


Force @ 5% Strain
g/in
208
329
293
333
218
212
213


MD


Force @ 10% Strain
g/in
352
589
557
600
298
304
304


MD


Force @ 25% Strain
g/in
493
787
774
798
344
368
354


MD


Force @ 50% Strain
g/in
536
758
743
766
354
384
364


MD


Force @ 100%
g/in
666
762
751
768
367
405
377


Strain MD


TEA MD
FtLb/in2
1,477
1,342  
1,271
1,487
1,056
1,018
—


Elmendorf Tear MD
g
200
200
200
200
200
200
200


Arm


Elmendorf Tear MD
gf
4.9*
  5*
4.6*
5.4*
16.2*
13.4*
14.9*


Tensile Gauge TD
mil
0.31
   0.36
0.38
0.37
0.35
0.33
0.34


Force @ Peak TD
g/in
224
265
291
258
261
217
274


Strain @ Peak TD
%
476
449
504
445
463
402
464


Force @ Break TD
g/in
216
256
280
247
251
200
267


Strain @ Break TD
%
481
454
508
452
466
409
467


Force @ Yield TD
g/in
161
204
197
198
190
172
193


Strain @ Yield TD
%
28
 27
29
27
30
30
29


Force @ 5% Strain
g/in
90
102
100
102
84
81
88


TD


Force @ 10% Strain
g/in
117
143
138
141
121
113
127


TD


Force @ 25% Strain
g/in
157
199
190
194
182
164
186


TD


Force @ 50% Strain
g/in
170
217
212
213
202
186
206


TD


Force @ 100%
g/in
168
211
209
208
197
183
201


Strain TD


TEA TD
FtLb/in2
1,021
1,013  
1,100
964
1,008
850
1,087


Elmendorf Tear TD
g
1,600
1,600  
1,600
1,600
800
1,600
1,600


Arm


Elmendorf Tear TD
gf
323
414
350
453
274
380
340


Dart Drop (26″)
g
169
 64
62
59
125
124
112


§ Slow Puncture -
gf
275
284
307
279
243
232
237


¼″ (D3)









Example 3
Comparative Examples Showing Physical Properties of Conventional Microporous Breathable Films

Data for a series of microporous breathable films prepared by conventional methods (e.g., Windmoeller & Hoelscher blown MDO film, cast MDO films, and cast IMG films) are shown in Table 8 below. Data for a series of microporous breathable films prepared by a vacuum box process in accordance with the present teachings are shown in Table 9 below.


As shown by the data in Table 8, the blown MDO film exhibits poor strain and tear properties. Moreover, the strain at peak MD corresponding to the films in Table 9 are substantially higher than those in Table 8. In addition, the films in Table 9 exhibit excellent Dart Drop and slow puncture characteristics.









TABLE 8







Comparative Data for Microporous Breathable Films Prepared by Conventional Processes.




















XC5-121-
XC5-121-

XC3-121-







2265.0
2265.1
XC3-121-
2224.0




W&H
XP8790C1
XP8790C
(3518/
(3527/
2218.1M
16 gsm




Blown
(Cast
(Cast
FilmLink
FilmLink
16 gsm
(Cast IMG)


Physical Property
Units
MDO
MDO)
MDO)
500)
500)
(Cast IMG)
(MCA data)


















Basis Weight
gsm

16.7
19.2
15.5
15.4
17.42
15.8


Gauge
mil
0.55
0.52



0.45


WVTR 100K
g/m2/
3741
6640

6963
16577
3754
3972



day


Force @ Peak MD
g/in
2,167
2752
2784
2510
2318
950
1111


Strain @ Peak MD
%
58
85
139
84
83
193
179


Force @ 5% Strain MD
g/in
487

361


388


Force @ 10% Strain MD
g/in
842

616


652


Force @ 25% Strain MD
g/in
1,765
1158
1023
1070
1305
734
814


Force @ 50% Strain MD
g/in
2,080

1441


734


Elmendorf Tear MD
gf
2

7


7.4


Force @ Peak TD
g/in
211
268
285
288
296
256
341


Strain @ Peak TD
%
25
394
377
215
336
458
473


Force @ 5% Strain TD
g/in
149

174


117


Force @ 10% Strain TD
g/in
194

229


158


Force @ 25% Strain TD
g/in
210
240
270
215
233
198
236


Force @ 50% Strain TD
g/in
202

267


202


Elmendorf Tear TD
gf
73

126


146
















TABLE 9







Physical Properties of Microporous Breathable Films V-AA.









Stretching
















50% Pre-


50% Pre-



50% Pre-
70% Pre-
stretch
50% Pre-
70% Pre-
stretch



stretch
stretch
w/MD IMG
stretch
stretch
w/MD IMG









Polymer/Polymer Blend



















Blend 3518/
Blend 3518/
Blend 3518/




Sole 3518
Sole 3518

D350
D350
D350


Physical Property
Units
V
W
X
Y
Z
AA

















Basis Weight
gsm
11.32
12.19
11.63
11.79
11.05
11.37


Gauge
mil
0.3
0.34
0.31
0.33
0.3
0.31


WVTR 100K
g/m2/
4439
3755
3719
2807
2735
2610



day


Force @ Peak MD
g/in
690
887
660
1297
1335
1354


Strain @ Peak MD
%
217
220
193
178
150
175


Force @ 5% Strain MD
g/in
191
205
186
201
216
208


Force @ 10% Strain MD
g/in
270
295
272
339
370
352


Force @ 25% Strain MD
g/in
323
361
334
468
542
493


Force @ 50% Strain MD
g/in
343
387
358
508
598
536


Elmendorf Tear MD
gf
13.8
9.4
14.2
4.4
5
4.4


Force @ Peak TD
g/in
204
212
194
254
218
224


Strain @ Peak TD
%
403
407
400
505
487
476


Force @ 5% Strain TD
g/in
77
79
76
89
84
90


Force @ 10% Strain TD
g/in
106
108
100
123
111
117


Force @ 25% Strain TD
g/in
151
153
140
170
149
157


Force @ 50% Strain TD
g/in
171
175
160
179
160
170


Elmendorf Tear TD
gf
312
229
213
417
297
323


Dart Drop
g
124
128
125
160
154
169


Slow Puncture
gf
214
229
213
296
275
275









Example 4
Skinless Microporous Breathable Films

A series of 16 skinless microporous breathable films having a structure BBBBB were prepared from the formulation XC1-2-2269.0 shown in Table 10. The composition of compound CF7414 is given above in Table 4.


The 16 films were subjected to the following different processing conditions: basis weights (9 gsm vs. 12 gsm), pre-stretch (35%/35% vs. 50%/50%), depth of engagement (0.070 vs. 0.085), and post-stretch (0% vs. 30%). The physical properties of the resultant films are summarized in Table 11-12.









TABLE 10







Composition of Formulation XC1-2-2269.0 Used to Make


BBBBB Skinless Microporous Breathable Films.











Component







B extruder
70% Heritage CF7414



(100%)
28% LL3518




1% Ampacet 102823 PA (process aid)










In Tables 11-12, the legend W/X/Y/Z is a shorthand nomenclature signifying basis weight (gsm)/pre-stretch/depth of engagement of IMG rolls/post-stretch. For example, the designation 9/35/070/0 represents a basis weight of 9 gsm, 35%/35% pre-stretch, a depth of engagement of 70 mm, and 0% post-stretch.









TABLE 11







Physical Properties of Skinless Microporous Breathable Films A1-H1.
















A1
B1
C1
D1
E1
F1
G1
H1









W/X/Y/Z


















9/35/
9/35/
9/35/
9/35/
9/50/
9/50/
9/50/
9/50/


Physical Properties
Units
070/0
070/30
085/0
085/30
070/0
070/30
085/0
085/30



















Gauge
mil
0.20
0.24
   0.24
0.24
   0.25
0.24
0.23
0.25


Basis Weight
g/m2
7.74
8.58
   8.95
8.76
   9.12
8.79
8.70
9.08


Density
g/cc
1.4714
1.4226
    1.4643
1.4338
    1.4616
1.4713
1.4658
1.4061


Emboss Depth
mil
0.37
0.30
   0.30
0.37
   0.27
0.30
0.30
0.33


Light Transmission
%
56.2
51.7
  54.1
48.4
  53.1
50.1
50.5
47.7


WVTR 100K
g/m2/
2414
4885
3892 
5837
2329 
5073
4541
8367



day


Tensile Gauge MD
mil
0.21
0.24
   0.24
0.24
   0.25
0.24
0.23
0.25


Force @ Peak MD
g/in
687
878
566
570
682
747
657
988


Strain @ Peak MD
%
207
162
193
136
177
124
188
158


Force @ Break MD
g/in
675
878
566
570
682
747
657
988


Strain @ Break MD
%
207
162
193
136
177
124
188
158


Force @ Yield MD
g/in
186
191
171
186
196
181
145
205


Strain @ Yield MD
%
9
8
 9
7
 8
6
7
8


Force @ 5% Strain
g/in
133
137
121
155
143
159
126
139


MD


Force @ 10% Strain
g/in
194
217
177
225
211
244
187
236


MD


Force @ 25% Strain
g/in
233
286
218
291
261
328
238
328


MD


Force @ 50% Strain
g/in
259
340
245
343
294
399
273
395


MD


Force @ 100% Strain
g/in
300
455
287
447
360
573
328
533


MD


TEA MD
FtLb/
1,259
1,106
923
772
965
838
1,052
1,171



in2


Elmendorf Tear MD
g
200
200
200
200
200
200
200
200


Arm


Elmendorf Tear MD
gf
11.2*
5.1*
 13*
9.8*
  8*
5.6*
9.6*
5.7*


Tensile Gauge TD
mil
0.21
0.24
   0.24
0.24
   0.25
0.24
0.23
0.25


Force @ Peak TD
g/in
161
142
172
215
155
134
183
154


Strain @ Peak TD
%
518
485
417
449
493
495
476
460


Force @ Break TD
g/in
152
142
172
215
155
134
183
154


Strain @ Break TD
%
522
485
417
448
494
494
476
459


Force @ Yield TD
g/in
116
104
116
138
112
99
117
97


Strain @ Yield TD
%
26
22
 26
30
 24
22
29
26


Force @ 5% Strain
g/in
74
62
 59
64
 70
61
65
44


TD


Force @ 10% Strain
g/in
92
87
 85
95
 92
86
86
72


TD


Force @ 25% Strain
g/in
115
105
113
132
112
102
111
96


TD


Force @ 50% Strain
g/in
119
110
126
150
118
104
127
111


TD


Force @ 100% Strain
g/in
115
106
125
150
114
102
126
113


TD


TEA TD
FtLb/
1,112
823
836
1,091
868
795
1,013
786



in2


Elmendorf Tear TD
g
800
800
800
800
800
800
800
800


Arm


Elmendorf Tear TD
gf
293
246
223
215
246
239
240
240


Dart Drop (26″)
g
114
105
120
124
123
100
121
104


§ Slow Puncture -
gf
134
164
149
209
164
193
173
196


¼″ (D3)
















TABLE 12







Physical Properties of Skinless Microporous Breathable Films I1-P1.
















I1
J1
K1
L1
M1
N1
O1
P1









W/X/Y/Z


















12/35/
12/35/
12/35/
12/35/
12/50/
12/50/
12/50/
12/50/


Physical Properties
Units
070/0
070/30
085/0
085/30
070/0
070/30
085/0
085/30



















Gauge
mil
0.31
0.32
0.31
0.31
0.33
0.31
0.32
   0.32


Basis Weight
g/m2
11.57
11.79
11.61
11.43
12.16
11.43
12.12
   11.85


Density
g/cc
1.4601
1.4345
1.4606
1.4331
1.4597
1.4692
1.4277
    1.4695


Emboss Depth
mil
0.43
0.43
0.50
0.40
1.07
0.57
1.00
   0.63


Light Transmission
%
48.5
45.6
46.3
43.6
46.0
44.1
42.2
  41.6


WVTR 100K
g/m2/
3621
6457
5037
10038
3478
6026
5546
9365 



day


Tensile Gauge MD
mil
0.31
0.32
0.31
0.31
0.31
0.32
0.32
   0.32


Force @ Peak MD
g/in
892
1,121
761
1,205
1,174
972
714
984


Strain @ Peak MD
%
257
207
259
207
252
159
207
168


Force @ Break MD
g/in
892
1,121
761
1,205
1,160
972
714
984


Strain @ Break MD
%
257
207
259
207
252
159
207
168


Force @ Yield MD
g/in
229
281
232
249
272
296
251
285


Strain @ Yield MD
%
9
9
10
9
9
9
10
 9


Force @ 5% Strain
g/in
168
201
169
164
189
210
181
201


MD


Force @ 10% Strain
g/in
238
295
235
266
282
316
254
302


MD


Force @ 25% Strain
g/in
280
367
279
353
345
411
311
392


MD


Force @ 50% Strain
g/in
303
413
300
407
377
477
344
454


MD


Force @ 100% Strain
g/in
337
489
330
494
427
595
392
558


MD


TEA MD
FtLb/
1,315
1,354
1,230
1,422
1,652
1,027
1,003
1,069  



in2


Elmendorf Tear MD
g
200
200
200
200
200
200
200
200


Arm


Elmendorf Tear MD
gf
21.4*
8.5*
24.8*
12.5*
15.2*
7.3*
18.4*
  6*


Tensile Gauge TD
mil
0.31
0.32
0.31
0.31
0.31
0.31
0.32
   0.32


Force @ Peak TD
g/in
220
185
257
208
186
188
231
185


Strain @ Peak TD
%
486
486
452
430
459
487
405
402


Force @ Break TD
g/in
220
185
256
206
186
187
231
184


Strain @ Break TD
%
486
486
452
430
461
487
406
401


Force @ Yield TD
g/in
156
134
150
142
146
138
168
127


Strain @ Yield TD
%
23
21
24
24
21
21
27
 23


Force @ 5% Strain
g/in
96
83
76
77
97
83
90
 68


TD


Force @ 10% Strain
g/in
127
112
112
108
123
116
123
 98


TD


Force @ 25% Strain
g/in
159
136
152
143
149
140
165
130


TD


Force @ 50% Strain
g/in
161
141
164
155
152
143
186
148


TD


Force @ 100% Strain
g/in
157
137
164
158
147
140
184
151


TD


TEA TD
FtLb/
964
805
964
836
833
845
872
695



in2


Elmendorf Tear TD
g
800
800
800
800
800
800
800
800


Arm


Elmendorf Tear TD
gf
328
264
281
293
289
250
324
268


Dart Drop (26″)
g
141
116
144
125
160
109
153
141


§ Slow Puncture -
gf
199
202
209
251
206
221
208
238


¼″ (D3)









Example 5
Skinned Microporous Breathable Films

A series of 16 skinned microporous breathable films having a structure CBBBC were prepared from the formulation XC1-22-2270.0 shown in Table 13. The composition of compound CF7414 is given above in Table 4.


The 16 films were subjected to the following different processing conditions: basis weights (9 gsm vs. 12 gsm), pre-stretch (35%/35% vs. 50%/50%), depth of engagement (0.07 vs. 0.085), and post-stretch (0% vs. 30%). The physical properties of the resultant films are summarized in Table 14-15.









TABLE 13







Composition of Formulation XC3-22-2270.0 Used to Make


CBBBC Skinned Microporous Breathable Films.









Component














B extruder
70% Heritage CF7414



(98%)
28% LL3518



C extruder
100% MobilExxon LD516



(2%)










In Tables 14-15, the legend W/X/Y/Z is a shorthand nomenclature signifying basis weight (gsm)/pre-stretch/depth of engagement of IMG rolls/post-stretch. For example, the designation 9/35/070/0 represents a basis weight of 9 gsm, 35%/35% pre-stretch, a depth of engagement of 70 mm, and 0 post-stretch.









TABLE 14







Physical Properties of Skinned Microporous Breathable Films A2-H2.
















A2
B2
C2
D2
E2
F2
G2
H2









W/X/Y/Z


















9/35/
9/35/
9/35/
9/35/
9/50/
9/50/
9/50/
9/50/


Physical Properties
Units
070/0
070/30
085/0
085/30
070/0
070/30
085/0
085/30



















Gauge
mil
   0.25
0.25
0.25
0.25
   0.24
0.30
0.25
0.26


Basis Weight
g/m2
   9.27
9.01
9.13
9.10
   8.90
10.88
9.07
9.45


Density
g/cc
    1.4470
1.3980
1.4576
1.4211
    1.4471
1.4183
1.4383
1.4182


Emboss Depth
mil
   0.70
0.57
0.37
0.20
   0.30
0.57
0.30
0.27


Light Transmission
%
  53.9
51.6
51.0
49.2
  52.3
46.0
50.6
46.4


WVTR 100K
g/m2/
2632 
3545
3950
5835
3104 
4424
3941
6188



day


Tensile Gauge MD
mil
   0.25
0.25
0.25
0.25
   0.24
0.30
0.25
0.26


Force @ Peak MD
g/in
722
882
665
661
675
1,031
611
754


Strain @ Peak MD
%
232
180
236
152
176
159
172
125


Force @ Break MD
g/in
722
882
665
661
675
1,031
611
754


Strain @ Break MD
%
232
180
236
152
176
159
172
125


Force @ Yield MD
g/in
139
201
215
258
237
252
225
171


Strain @ Yield MD
%
 4
8
10
10
 9
8
10
6


Force @ 5% Strain
g/in
147
160
143
161
160
197
151
178


MD


Force @ 10% Strain
g/in
221
253
214
253
242
318
228
284


MD


Force @ 25% Strain
g/in
261
319
253
320
294
410
280
379


MD


Force @ 50% Strain
g/in
285
363
275
368
329
474
315
450


MD


Force @ 100% Strain
g/in
321
444
308
451
393
601
376
601


MD


TEA MD
FtLb/
1,294  
1,240
1,249
926
1,065  
1,115
941
851



in2


Elmendorf Tear MD
g
200
200
200
200
200
200
200
200


Arm


Elmendorf Tear MD
gf
 11*
5.4*
12.5*
6.3*
  7*
4.6*
9.8*
4.6*


Tensile Gauge TD
mil
   0.25
0.25
0.25
0.25
   0.24
0.30
0.25
0.26


Force @ Peak TD
g/in
196
165
217
190
181
195
180
174


Strain @ Peak TD
%
540
510
464
465
514
524
461
440


Force @ Break TD
g/in
192
165
216
190
181
195
180
174


Strain @ Break TD
%
540
511
465
465
514
524
461
440


Force @ Yield TD
g/in
118
104
123
111
112
135
105
104


Strain @ Yield TD
%
 24
23
28
29
 24
20
28
26


Force @ 5% Strain
g/in
 68
58
56
53
 66
89
56
54


TD


Force @ 10% Strain
g/in
 92
83
81
75
 88
114
75
76


TD


Force @ 25% Strain
g/in
119
106
118
106
112
138
102
103


TD


Force @ 50% Strain
g/in
125
111
136
125
120
142
118
121


TD


Force @ 100% Strain
g/in
122
112
136
128
119
140
121
125


TD


TEA TD
FtLb/
1,080  
917
1,025
940
1,029  
969
887
824



in2


Elmendorf Tear TD
g
1,600  
1,600
1,600
1,600
1,600  
1,600
1,600
1,600


Arm


Elmendorf Tear TD
gf
277
246
220
262
271
225
248
233


Dart Drop (26″)
g
146
124
157
122
129
131
122
120


§ Slow Puncture -
gf
152
177
158
197
167
224
182
220


¼″ (D3)
















TABLE 15





Physical Properties of Skinned Microporous Breathable Films I2-P2.




















I2
J2
K2
L2









W/X/Y/Z














12/35/
12/35/
12/35/
12/35/


Physical Properties
Units
070/0
070/30
085/0
085/30





Gauge
mil
0.34
0.34
0.34
   0.32


Basis Weight
g/m2
12.30
12.00
12.24
   11.46


Density
g/cc
1.4425
1.4087
1.4379
    1.4065


Emboss Depth
mil
0.50
0.33
0.43
   0.60


Light Transmission
%
49.3
46.2
45.7
  44.2


WVTR 100K
g/m2/
3160
4754
4917
8594 



day


Tensile Gauge MD
mil
0.34
0.34
0.34
   0.32


Force @ Peak MD
g/in
945
1,067
818
1,123  


Strain @ Peak MD
%
263
187
272
224


Force @ Break MD
g/in
945
1,066
817
1,122  


Strain @ Break MD
%
263
187
272
224


Force @ Yield MD
g/in
280
309
270
302


Strain @ Yield MD
%
10
9
10
 10


Force @ 5% Strain
g/in
195
207
197
188


MD


Force @ 10% Strain
g/in
281
317
271
295


MD


Force @ 25% Strain
g/in
326
397
313
373


MD


Force @ 50% Strain
g/in
350
446
335
415


MD


Force @ 100% Strain
g/in
386
541
366
479


MD


TEA MD
FtLb/
1,369
1,166
1,302
1,465  



in2


Elmendorf Tear MD
g
200
200
200
200


Arm


Elmendorf Tear MD
gf
18.6*
8.4*
23.6*
 11*


Tensile Gauge TD
mil
0.34
0.32
0.34
   0.32


Force @ Peak TD
g/in
273
235
262
254


Strain @ Peak TD
%
521
503
401
471


Force @ Break TD
g/in
273
234
262
253


Strain @ Break TD
%
521
502
402
472


Force @ Yield TD
g/in
162
160
176
144


Strain @ Yield TD
%
23
21
27
 26


Force @ 5% Strain
g/in
94
98
89
 71


TD


Force @ 10% Strain
g/in
128
130
124
103


TD


Force @ 25% Strain
g/in
165
163
173
142


TD


Force @ 50% Strain
g/in
171
167
194
164


TD


Force @ 100% Strain
g/in
168
166
191
167


TD


TEA TD
FtLb/
1,060
1,028
879
982



in2


Elmendorf Tear TD
g
1,600
1,600
1,600
1,600  


Arm


Elmendorf Tear TD
gf
328
340
266
333


Dart Drop (26″)
g
197
159
208
164


§ Slow Puncture -
gf
207
242
237
274


¼″ (D3)















M2
N2
O2
P2









W/X/Y/Z














12/50/
12/50/
12/50/
12/50/



Physical Properties
070/0
070/30
085/0
085/30







Gauge
0.34
   0.35
   0.32
0.34



Basis Weight
12.53
   12.39
   11.81
12.21



Density
1.4328
    1.4101
    1.4478
1.4234



Emboss Depth
0.57
   0.30
   0.43
0.57



Light Transmission
46.3
  43.5
  44.9
40.8



WVTR 100K
3567
4989 
5350 
8575



Tensile Gauge MD
0.34
   0.35
   0.32
0.34



Force @ Peak MD
1,117
1,216  
1,014  
1,143



Strain @ Peak MD
248
175
254
171



Force @ Break MD
1,117
1,216  
1,014  
1,141



Strain @ Break MD
248
175
254
171



Force @ Yield MD
292
364
271
264



Strain @ Yield MD
10
 10
 10
7



Force @ 5% Strain
200
235
180
207



MD



Force @ 10% Strain
295
367
271
331



MD



Force @ 25% Strain
355
467
326
438



MD



Force @ 50% Strain
387
530
356
505



MD



Force @ 100% Strain
438
652
400
626



MD



TEA MD
1,472
1,229  
1,465  
1,152



Elmendorf Tear MD
200
200
200
200



Arm



Elmendorf Tear MD
12.2*
  6*
 13*
5.8*



Tensile Gauge TD
0.34
   0.35
   0.32
0.34



Force @ Peak TD
251
203
262
206



Strain @ Peak TD
505
481
463
392



Force @ Break TD
251
203
262
206



Strain @ Break TD
505
481
463
391



Force @ Yield TD
165
146
150
141



Strain @ Yield TD
23
 22
 26
25



Force @ 5% Strain
102
 89
 77
71



TD



Force @ 10% Strain
133
119
108
102



TD



Force @ 25% Strain
168
148
149
141



TD



Force @ 50% Strain
175
154
171
162



TD



Force @ 100% Strain
172
154
173
166



TD



TEA TD
1,015
821
993
715



Elmendorf Tear TD
1,600
1,600  
1,600  
1,600



Arm



Elmendorf Tear TD
333
263
282
292



Dart Drop (26″)
169
150
173
143



§ Slow Puncture -
244
262
225
275



¼″ (D3)










Example 6
Microporous Breathable Films with Exceptionally Low Basis Weights

Two microporous breathable films A3 and B3 having a structure CBBBC were prepared from the formulation XC3-22-2270.0 shown in Table 13. The physical properties of the resultant films are shown in Table 16.


In Table 16, the legend X/Y/Z is a shorthand nomenclature signifying pre-stretch/depth of engagement of IMG rolls/post-stretch. For example, the designation 50/085/0 corresponding to film A2 represents a 50%/50% pre-stretch, a depth of engagement of 85 mm, and 0% post-stretch. Surprisingly and unexpectedly, the films A2 and B2 exhibit high Dart Impact Strength (e.g., greater than 90 grams) in spite of exceptionally low basis weights (e.g., less than 9 gsm).









TABLE 16







Physical Properties of Skinned Microporous Breathable


Films A3 and B3.










A3
B3









X/Y/Z










Physical Properties
Units
50/085/0
50/085/30













Gauge
mil
0.23
0.19


Basis Weight
g/m2
8.42
7.03


Density
g/cc
1.4600
1.4288


Emboss Depth
mil
0.20
0.33


Light Transmission
%
51.1
51.9


WVTR 100K
g/m2/day
4185
5426


Tensile Gauge MD
mil
0.23
0.19


Force @ Peak MD
g/in
723
584


Strain @ Peak MD
%
182
95


Force @ Break MD
g/in
723
584


Strain @ Break MD
%
182
95


Force @ Yield MD
g/in
214
19


Strain @ Yield MD
%
9
0


Force @ 5% Strain MD
g/in
137
133


Force @ 10% Strain MD
g/in
219
235


Force @ 25% Strain MD
g/in
273
326


Force @ 50% Strain MD
g/in
308
398


Force @ 100% Strain MD
g/in
375
480


TEA MD
FtLb/in2
1,144
703


Elmendorf Tear MD Arm
g
200
200


Elmendorf Tear MD
gf
7.1*
3.3*


Tensile Gauge TD
mil
0.23
0.19


Force @ Peak TD
g/in
198
107


Strain @ Peak TD
%
501
425


Force @ Break TD
g/in
198
107


Strain @ Break TD
%
501
425


Force @ Yield TD
g/in
108
68


Strain @ Yield TD
%
28
23


Force @ 5% Strain TD
g/in
50
38


Force @ 10% Strain TD
g/in
74
55


Force @ 25% Strain TD
g/in
104
70


Force @ 50% Strain TD
g/in
122
81


Force @ 100% Strain TD
g/in
121
84


TEA TD
FtLb/in2
1,067
701


Elmendorf Tear TD Arm
g
1,600
1,600


Elmendorf Tear TD
gf
203
152


Dart Drop (26″)
g
102
93


§ Slow Puncture - ¼″ (D3)
gf
155
154









The overall thickness of the microporous breathable film may be varied depending on the particular end use for which the film is manufactured. In illustrative embodiments, films in accordance with the present disclosure have a thickness that is less than typical thicknesses for microporous breathable films. As described above, the beneficial properties of microporous breathable films prepared in accordance with the present disclosure by using a vacuum box, air knife, and/or air blanket to cast a molten web against a chill roll may include one or more of reduced basis weight, increased Dart Impact Strength, increased strain at peak machine direction, and/or the like, and may allow the films to be used at a decreased gauge or thickness as compared to conventional microporous breathable films. However, basis weights and thicknesses may be easily adjusted to fit a desired end use.


Example 7
Polypropylene Microporous Breathable Films

Polypropylene microporous breathable films A4 through D4 having a structure A/B/A (20/60/20 layering), and polypropylene microporous breathable films E4 through H4 having a structure A/B/A (10/80/10 layering), were prepared from the formulation XC3-828-2287 shown in Table 17. The composition of compounds T1000J2 and CF7414* shown in Table 17 is specified in Table 18 below.









TABLE 17







Composition of XC3-828-2287 Used to Make ABA


Skinned Polypropylene Microporous Breathable Films













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)













A
40
T1000J2
60


(split)

(Heritage Plastics)




C702-20
39




(Braskem, polypropylene




impact copolymer)




102823
1




(fluoroelastomer




processing aid)


B
60
CF7414*
70




EXCEED LL3518
30




(ExxonMobil,




metallocene




polyethylene)
















TABLE 18







Composition of CaCO3 Compounds used in the


Formulation of Table 17.










T1000J2
CF7414*


Component
Amount of Component
Amount of Component












C702-20
30



ExxonMobil 3518P

26


FilmLink 500
70
60


(CaCO3)


TiO2

14


antioxidant
0.15
0.15









The physical properties of the resultant polypropylene films are shown in Table 19 below. The films A4, B4, E4, and F4 were not subjected to any post-stretching, whereas the films C4, D4, G4, and H4 received 30% post-stretch. The films A4, B4, C4, and D4 have a 20/60/20 A/B/A layering, whereas the films E4, F4, G4, and H4 have a 10/80/10 A/B/A layering.


As shown in Table 19, the 16-gsm film D4 exhibits an impressive force at peak MD of 1049 g/in and an impressive force at 25% strain MD of 475 g/in. The force at 25% strain MD measurement reflects the degree to which a film may be stretched when pulled (e.g., by a consumer). In addition, as shown in Table 19, the 16-gsm film D4 also exhibits a high TEA MD of 1572 Ft·Lb/in2, which is a measure of the toughness of the film (wherein higher numbers corresponding to increased robustness).


The 16-gsm film D4 shown in Table 19 was ultrasonically bonded to a 17-gsm spunbond polypropylene homopolymer material by Herrmann Ultrasonics. The film D4 was bonded to the polypropylene homopolymer using microgap control, a 20-kHz ultrasonic horn, and a bond roll having a discrete bond pattern. The ultrasonically bonded material thus formed exhibited good bonding characteristics and represents an example of how a film in accordance with the present disclosure may be bonded to a nonwoven material without the use of an adhesive. As such, a film in accordance with the present disclosure (e.g., a polypropylene film including but not limited to the film D4 shown in Table 19) may be desirable for use in forming personal hygiene products (e.g., including but not limited to incontinence briefs, adult underpads for incontinence, surgical gowns, drapes, feminine hygiene products), and Protective Apparel such as garments, aprons, gloves or the like).









TABLE 19







Physical Properties of Skinned Microporous Breathable


Films A4-H4 Prepared from Formulation XC3-828-2287.










20/60/20 Layering
10/80/10 Layering











30% Post-stretch

30% post-stretch
















Physical Properties
Units
A4
B4
C4
D4
E4
F4
G4
H4



















Basis Weight
g/m2
10.47
12.94
11.79
15.71
11.79
15.56
11.85
15.81


Light Transmission
%
58.4
55.3
51
45.4
54.5
50.7
50.2
44.9


WVTR
g/m2/
1177
2060
4067
5441
1305
1672
5631
7364



day


Tensile Gauge MD
mil
0.29
0.37
0.33
0.45
0.33
0.44
0.32
0.35


Force @ Peak MD
g/in
495
563
789
1049
619
718
739
1011


Strain @ Peak MD
%
309
328
281
318
354
390
275
308


Force @ Break MD
g/in
476
540
764
1025
616
704
731
992


Strain @ Break MD
%
310
331
282
319
354
390
275
308


Force @ Yield MD
g/in
229
293
322
444
254
313
282
388


Strain @ Yield MD
%
9
8
10
10
8
8
9
10


Force @ 5% Strain MD
g/in
209
276
260
369
233
291
227
317


Force @ 10% Strain MD
g/in
233
298
323
446
259
317
286
391


Force @ 25% Strain MD
g/in
246
308
357
475
269
319
314
423


Force @ 50% Strain MD
g/in
245
301
356
472
265
315
323
429


Force @ 100% Strain MD
g/in
254
308
373
490
271
318
340
448


TEA MD
FtLb/
1179
1189
1418
1572
1344
1307
1308
1424



in2


Elmendorf Tear MD
g
200
200
200
200
200
200
200
200


Arm


††††Elmendorf Tear
gf
25.1
68.12
25.7
48.56
62.28
98.12
29.6
46.88


MD


Tensile Gauge TD
mil
5.07
0.37
0.33
0.45
0.33
0.44
0.32
0.44


Force @ Peak TD
g/in
254
395
288
414
326
472
265
433


Strain @ Peak TD
%
316
482
417
435
471
493
407
468


Force @ Break TD
g/in
246
383
281
405
324
467
261
423


Strain @ Break TD
%
339
483
420
436
472
493
409
469


Force @ Yield TD
g/in
181
233
194
276
197
268
182
258


Strain @ Yield TD
%
13
14
16
16
14
14
15
15


Force @ 5% Strain TD
g/in
114
148
120
171
129
179
117
162


Force @ 10% Strain TD
g/in
171
214
173
248
183
247
166
235


Force @ 25% Strain TD
g/in
199
235
202
286
201
271
190
266


Force @ 50% Strain TD
g/in
198
237
205
288
197
265
196
274


Force @ 100% Strain TD
g/in
205
241
208
289
199
271
192
269


TEA TD
FtLb/
705
1303
1050
1124
1195
1292
977
1186



in2


Elmendorf Tear TD
g
400
400
400
400
400
400
400
400


Arm


Elmendorf Tear TD
gf
150.2
165.9
210.2
254.3
184.1
210.1
263.4
271.0


Dart Drop (26″)
g
65
123
148
154
132
176
87
173


§ Slow Puncture -
gf
140
177
186
241
170
206
180
244


¼″ (D3)









Example 8
Polyethylene-Blended Polypropylene Microporous Breathable Films

Polypropylene microporous breathable films I4 through L4 having a structure A/B/A (20/60/20 layering) were prepared from the formulation XC3-222-2286 shown in Table 20. The composition of compound CF7414* shown in Table 20 is specified above in Table 18.









TABLE 20







Composition of XC3-222-2286 Used to Make


ABA Skinned Polyethylene-Blended Polypropylene


Microporous Breathable Films













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)













A
40
CF7414*
70


(split)

(Heritage Plastics)




C702-20
29




(Braskem, polypropylene




impact copolymer)




102823
1




(processing aid)


B
60
CF7414*
70




EXCEED LL3518
30




(ExxonMobil,




metallocene




polyethylene)









The physical properties of the resultant polyethylene with blended polypropylene films are shown in Table 21 below. The films I4 and K4 were not subjected to any post-stretching, whereas the films J4 and L4 received 30% post-stretch. The films I4, J4, K4, and L4 have a 20/60/20 A/B/A layering.









TABLE 21







Physical Properties of Skinned Microporous Breathable


Films I4-J4 Prepared from Formulation XC3-222-2286.












Properties
Units
I4
J4
K4
L4





Amount of Post-

0%
30%
0%
30%


Stretching


Gauge
mil
0.33
0.32
0.43
0.43


Basis Weight
g/m2
12.16
11.69
15.86
15.70


Density
g/cc
1.45
1.42
1.44
1.43


Light Transmission
%
52.1
49.2
47.3
42.6


WVTR
g/m2/day
2525
4160
2935
4845


Tensile Gauge MD
mil
0.33
0.32
0.43
0.43


Force @ Peak MD
g/in
867
1,003
1,061
1,600


Strain @ Peak MD
%
343
276
397
337


Force @ Break MD
g/in
867
1,002
1,060
1,598


Strain @ Break MD
%
343
276
397
338


Force @ Yield MD
g/in
259
287
338
443


Strain @ Yield MD
%
7
9
8
9


Force @ 5% Strain MD
g/in
238
225
317
357


Force @ 10% Strain MD
g/in
269
294
343
452


Force @ 25% Strain MD
g/in
283
338
347
495


Force @ 50% Strain MD
g/in
292
357
351
508


Force @ 100% Strain MD
g/in
313
396
366
543


TEA MD
FtLb/in2
1,643
1,627
1,762
2,238


Elmendorf Tear MD Arm
g
200
200
200
200


††††Elmendorf Tear MD
gf
41
16
70
40


Tensile Gauge TD
mil
0.33
0.32
0.43
0.43


Force @ Peak TD
g/in
310
265
590
456


Strain @ Peak TD
%
433
492
545
524


Force @ Break TD
g/in
310
265
588
456


Strain @ Break TD
%
433
492
546
524


Force @ Yield TD
g/in
227
166
308
256


Strain @ Yield TD
%
17
18
16
18


Force @ 5% Strain TD
g/in
154
107
209
162


Force @ 10% Strain TD
g/in
202
144
277
222


Force @ 25% Strain TD
g/in
232
171
314
264


Force @ 50% Strain TD
g/in
224
172
303
264


Force @ 100% Strain TD
g/in
221
172
299
264


TEA TD
FtLb/in2
1,149
1,084
1,687
1,365


Elmendorf Tear TD Arm
g
800
800
800
800


Elmendorf Tear TD
gf
256
286
280
409


Dart Drop (26″)
g
160
163
235
216


§ Slow Puncture - ¼″
gf
162
176
197
224


(D3)









As shown in Table 21, the 16-gsm film L4 exhibits an impressive force at peak MD of 1,600 g/in and an impressive force at 25% strain MD of 495 g/M. In addition, as shown in Table 21, the 16-gsm film D4 also exhibits a high TEA MD of 2,238 Ft·Lb/in2, which is a measure of the toughness of the film (with higher numbers corresponding to increased robustness).


Surprisingly and unexpectedly, the polyethylene-blended polypropylene film L4 manufactured from the formulation XC3-222-2286 is softer to the touch than the pure polypropylene film D4 manufactured from the formulation XC3-828-2287. Moreover, surprisingly and unexpectedly, a polyethylene-blended polypropylene film (e.g., the film L4 shown in Table 21) may exhibit better properties that a pure polypropylene film (e.g., the film D4 shown in Table 19).


The 16-gsm film L4 shown in Table 21 was ultrasonically bonded to a 17-gsm spunbond polypropylene homopolymer material by Herrmann Ultrasonics. The film L4 was bonded to the polypropylene homopolymer using microgap control, a 20-kHz ultrasonic horn with a width of 150 mm, and a bond roll having a discrete bond pattern. The ultrasonically bonded material thus formed exhibited good bonding characteristics and represents a further example of how a film in accordance with the present disclosure may be bonded to a nonwoven material without the use of an adhesive. As such, a film in accordance with the present disclosure (e.g., a polyethylene-blended polypropylene film including but not limited to the film L4 shown in Table 21) may be desirable for use in forming personal hygiene products (e.g., including but not limited to incontinence briefs, surgical gowns, feminine hygiene products, and/or the like).


Example 9
Pressure Penetration Through a Fabric (PPT) Testing of Polyethylene-Blended Polypropylene Microporous Breathable Films and Comparative Polypropylene Non-Breathable Films

Pressure penetration of simulated blood was tested using the “Pressure Penetration Through a Fabric (PPT)” test. The PPT test is used to determine whether or not, and to what degree, simulated blood penetrates through a fabric or film under pressure for a specified time.


A sample is placed on a blotter paper on a flat surface and challenged by a 70% IPA/water solution containing Astrazon Red Violet dye for 3 minutes while under a 1 psi load. The number of red spots showing on the blotter paper are determined and recorded. The test solution contains 70% IPA/30% DI water with 0.1% (1 gram per liter or 0.1 gm per 100 ml) of Astrazon Red Violet 3RN liquid dye added for visibility. This method is performed in a lab at standard atmosphere for testing textiles: 70° F. (20° C.), 65% RH.


In the PPT test, the pre-marked blotter paper is laid on a hard, flat surface near a sink A 3″×3″′ test specimen is placed, face side up, on the blotter on each of the 4 or 6 pre-marked lane squares. A 2″×2″ piece of absorbent spun-bond non-woven fabric is placed in the center of each specimen. A pipette is filled with the test solution and the 2″×2″ nonwoven is saturated with it. A cylindrical, 2.0″ diameter; 3.14 lb (1.0 psi) weight is placed on top of the saturated specimen and a timer is started. After 3.0 minutes, the weights are removed and all except the blotter paper are discarded. The blotter paper is examined, and all red spots are counted. The number of red spots is recorded. A size limit may be specified for red spots to be counted. If one large red blotch is present, the result may be recorded as “99.”


Polypropylene microporous breathable film samples A5-C5 having a structure A/B/A (20/60/20 layering) were prepared from the formulation XC3-222-2286 shown in Table 20 above. Polypropylene microporous breathable film samples D5-F5 having a structure A/B/A (20/60/20 layering) were prepared from the formulation XC3-828-2287 shown in Table 17 above. Polypropylene microporous cored film samples G5 and H5 having a structure A/B/A (20/60/20 layering) were prepared from the formulation XC3-828-2300 shown in Table 22 below. The microporous cored films have a microporous core layer, but are not breathable as they have solid skin layers surrounding the breathable core layer. The composition of compound CF7414* shown in Table 22 is specified above in Table 18.









TABLE 22







Composition of XC3-828-2300 Used to Make


ABA Skinned Polyethylene-Blended Polypropylene


Microporous Breathable Films













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)





B
60
CF7414*
70




(Heritage Plastics)




EXCEED LL3518
30




(ExxonMobil,




metallocene




polyethylene)


C
40
C702-20
90


(split)

(Braskem, polypropylene




impact copolymer)




LGA-105
10




ExxonMobil, low density




polyethylene)









The PPT Test Data for the polyethylene-blended polypropylene microporous breathable films A5-H5 are summarized in Table 23 below.









TABLE 23







PPT Test Data for Polyethylene-Blended Polypropylene


Microporous Breathable Films A5-H5.















Basis
Bonding




% Red

Weight
Force


Sample
Area
Formulation
(gsm)
(Newtons)
Bond Quality















A5
0
XC3-222-
16
600
Destruct Bond




2286


B5
1.5
XC3-222-
16
1000
Destruct Bond




2286


C5
3
XC3-222-
16
1400
Destruct Bond




2286


D5
3
XC3-828-
16
600
Destruct Bond




2287


E5
3
XC3-828-
16
1000
Destruct Bond




2287


F5
3
XC3-828-
16
1400
Destruct Bond




2287


G5
10
XC3-828-
9
600
Destruct Bond




2300


H5
33
XC3-828-
9
1000
Destruct Bond




2300









Additional PPT testing on films A5-H5 was performed using a 6-inch square film. The nonwoven side of the film was placed on the blotter paper, and 3 cm3 of dye was added for a duration of 30 seconds. The results of this additional testing are shown in Table 24 below.









TABLE 24







Additional PPT Test Data for Polyethylene-Blended


Polypropylene Microporous Breathable Films A5-H5.















Basis
Bonding




No. Red

Weight
Force


Sample
Dots
Formulation
(gsm)
(Newtons)
Bond Quality















A5
4
XC3-222-
16
400
Destruct Bond




2286


B5
8
XC3-222-
16
1000
Destruct Bond




2286


C5
36
XC3-222-
16
1400
Destruct Bond




2286


D5
8
XC3-828-
16
400
Destruct Bond




2287


E5
29
XC3-828-
16
1000
Destruct Bond




2287


F5
82
XC3-828-
16
1400
Destruct Bond




2287


G5
45
XC3-828-
9
400
Destruct Bond




2300


H5
138
XC3-828-
9
1000
Destruct Bond




2300









For comparative purposes, polypropylene-containing non-breathable film samples A6-F6 having a structure A/B/A (20/60/20 layering) were prepared from the formulation XP-1943SX shown in Table 25 below.









TABLE 25







Composition of XP-1943SX Used to Make ABA Skinned Polyethylene-


Blended Polypropylene Non-Breathable Films













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)





A
40
Total 5724
25


(split)

(polypropylene impact




copolymer with melt




mass-flow rate = 20 g/10




min)




Exxon Mobil PD3155
63




(polypropylene




homopolymer with MFR =




36 g/10 min)




LGA-105
12




ExxonMobil, low density




polyethylene)


B
60
Total 5724
14




ExxonMobil PD3155
52




LGA105
12




Ampacet 111017P
22




(White PE Masterbatch)









The PPT Test Data for the comparative polyethylene-blended polypropylene non-breathable films A6-F6 are summarized in Table 26 below.









TABLE 26







PPT Test Data for Polyethylene-Blended Polypropylene


Non-Breathable Films A6-D6.















Basis
Bonding




%

Weight
Force


Sample
Failure
Formulation
(gsm)
(Newtons)
Bond Quality















A6
0
XP-1943SX
13
600
Slight Bond







Easily Peeled


B6
5
XP-1943SX
13
1000
Destruct Bond


C6
5 to 10
XP-1943SX
13
1400
Destruct Bond


D6
0
XP-1943SX
9
600
Slight Bond







Easily Peeled


E6
5
XP-1943SX
9
1000
Destruct Bond


F6
20 
XP-1943SX
9
1400
Destruct Bond









As shown by the data in Tables 23 and 24, polyethylene cored films with polypropylene containing skins in accordance with the present disclosure were able to provide a destruct bond at a low bonding force (e.g., 600 Newtons). By comparison, as shown by the data in Table 26, polyethylene-blended with polypropylene non-cavitated films were unable to provide a destruct bond at such a comparably low bonding force despite the high level of polypropylene in the formula. Moreover, while the PPT test results for the microporous breathable films A5-G5 are comparable to the PPT test results for the non-breathable films A6-E6, it is surprising and unexpected that a microporous breathable film in accordance with the present disclosure is able to provide barrier performance comparable to that of a non-breathable film while further providing breathability.


Example 10
Multi-Layer Breathable Barrier Films

Four hybrid microporous-monolithic multi-layer breathable barrier films A7-D7 having polyethylene-containing microporous breathable skins, a thermoplastic copolyester elastomer core, and an A/B/C/B/A structure were prepared from the formulation XC5-22922-2301.0 shown in Table 27 below.









TABLE 27







Composition of XC5-22922-2301.0 Used to Make ABCBA


Multi-Layer Breathable Barrier Films A7-D7.













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)













A
62.5
Heritage CF7414*
80




EXCEED LL3527
19




(ExxonMobil,




metallocene polyethylene




resin)




Ampacet 102823 PA
1




(process aid)


B
30
Heritage CF7414*
80




ELVALOY 1609 AC
20




(DuPont, ethylene and




9% methyl acrylate




copolymer)


C
7.5
ARNITEL VT3104
90




(DSM, thermoplastic




copolyester elastomer)




BYNEL 22E757
10




(DuPont, modified




ethylene acrylate)









Four hybrid microporous-monolithic multi-layer breathable barrier films E7-H7 having polypropylene-containing microporous breathable skins, a thermoplastic copolyester elastomer core, and an A/B/C/B/A structure were prepared from the formulation XC5-828-2302.0 shown in Table 28 below.









TABLE 28







Composition of XC5-828-2302.0 Used to Make ABCBA


Multi-Layer Breathable Barrier Films E7-H7.













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)













A
62.5
Heritage T1000J2
70




C702-20
29




(Braskem, polypropylene




impact copolymer)




Ampacet 102823 PA
1




(process aid)


B
30
Heritage CF7414*
70




EXCEED LL3527
11




(ExxonMobil,




metallocene polyethylene




resin)




ELVALOY 1609 AC
19




(DuPont, ethylene and




9% methyl acrylate




copolymer)


C
7.5
ARNITEL VT3104
90




(DSM, thermoplastic




copolyester elastomer)




BYNEL 22E757
10




(DuPont, modified




ethylene acrylate)









Four hybrid microporous-monolithic multi-layer breathable barrier films I7-L7 having polyethylene-containing microporous breathable skins, a thermoplastic polyester elastomer core, and an A/B/C/B/A structure were prepared from the formulation XC5-22922-2306.0 shown in Table 29 below.









TABLE 29







Composition of XC5-22922-2306.0 Used to Make ABCBA


Multi-Layer Breathable Barrier Films I7-L7.













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)













A
62.5
Heritage CF7414*
80




EXCEED LL3527
19




(ExxonMobil,




metallocene polyethylene




resin)




Ampacet 102823 PA
1




(process aid)


B
30
Heritage CF7414*
80




ELVALOY 1609 AC
20




(DuPont, ethylene and




9% methyl acrylate




copolymer)


C
7.5
HYTREL HTR8206
90




(DuPont, thermoplastic




polyester elastomer)




BYNEL 22E757
10




(DuPont, modified




ethylene acrylate)









Four hybrid microporous-monolithic multi-layer breathable barrier films M7-P7 having polypropylene-containing microporous breathable skins, a thermoplastic polyester elastomer core, and an A/B/C/B/A structure were prepared from the formulation XC5-82928-2307.0 shown in Table 30 below.









TABLE 30







Composition of XC5-82928-2307.0 Used to Make ABCBA


Multi-Layer Breathable Barrier Films M7-P7.













Amount of



Layer %

Component


EXTRUDER
(Total)
COMPONENT
(Weight %)













A
62.5
Heritage T1000J2
70




C702-20
29




(Braskem, polypropylene




impact copolymer)




Ampacet 102823 PA
1




(process aid)


B
30
Heritage CF7414*
70




EXCEED LL3527
11




(ExxonMobil,




metallocene polyethylene




resin)




ELVALOY 1609 AC
19




(DuPont, ethylene and




9% methyl acrylate




copolymer)


C
7.5
HYTREL HTR8206
90




(DuPont, thermoplastic




polyester elastomer)




BYNEL 22E757
10




(DuPont, modified




ethylene acrylate)









The composition of the CaCO3-containing compound CF7414* shown in Tables 27-30, and the composition of the CaCO3-containing compound T1000J2 shown in Tables 28 and 30, are specified in Table 18 above.


The physical properties of the resultant films A7-H7 are shown in Table 31 below, and the physical properties of the resultant films I7-P7 are shown in Table 32 below. Each of films A7-P7 received 30% post-stretch. The alcohol penetration test data shown in Tables 31 and 32 represents the degree to which the monolithic layer remains intact, with values between 0 and 10 being indicative of particularly good performance As shown in Tables 31 and 32, many of the films exhibit high Dart Impact Strength (e.g., greater than 90 grams) in spite of low basis weights (e.g., 12 gsm).









TABLE 31





Physical Properties of Skinned Multi-Layer Breathable Barrier Films A7-D7 Prepared from


Formulation XC5-22922-2301.0 and Films E7-H7 Prepared from Formulation XC5-828-2302.0.

















XC5-22922-2301.0












A7
B7
C7
D7










ASTM
CD IMG Depth













Properties
Units
Test Method
.08″
.08′
.100″
.100″





Basis Weight
gsm

12
25
12
25


Alcohol
%

5
5
20
10


Penetration Test


Gauge
mil
D6988
0.27
0.58
0.30
0.62


Basis Weight
g/m2
Tappi T410
11.20
23.21
12.21
24.32


Density
g/cc
D2103
1.6177
1.5791
1.6151
1.5470


Emboss Depth
mil
—
0.63
0.77
0.63
0.97


Light
%
D1003
46.8
31.4
43.0
29.2


Transmission


Gloss - In
% @ 45°
D2457
5.8
6.4
6.4
7.0


Gloss - Out
% @ 45°
D2457
5.7
6.5
6.1
7.2


COF, Static -
—
D1894
0.550
0.505
0.533
0.497


In\In


COF, Static -
—
D1894
0.510
0.492
0.567
0.495


Out\Out


COF, Kinetic -
—
D1894
0.501
0.456
0.502
0.467


In\In


COF, Kinetic -
—
D1894
0.495
0.473
0.494
0.452


Out\Out


WVTR 100K
g/m2/day
D6701
2989
3026
3763
4211


Tensile Gauge
mil
D6988
0.27
0.58
0.30
0.62


MD


Force @ Peak
g/in
D882
576
1,056
706
1,083


MD


Strain @ Peak
%
D882
140
251
175
283


MD


Force @ Break
g/in
D882
576
1,055
706
1,083


MD


Strain @ Break
%
D882
140
251
175
283


MD


Force @ Yield
g/in
D882
349
573
384
597


MD


Strain @ Yield
%
D882
13
14
15
15


MD


Force @ 5%
g/in
D882
205
358
197
384


Strain MD


Force @ 10%
g/in
D882
316
513
318
526


Strain MD


Force @ 25%
g/in
D882
421
649
452
663


Strain MD


Force @ 50%
g/in
D882
463
712
528
742


Strain MD


Force @ 100%
g/in
D882
513
782
597
794


Strain MD


Secant Modulus
PSI
D882
34,630
34,095
27,794
32,937


MD (1%)


TEA MD
FtLb/in2
D882
887
1,272
1,182
1,382


Elmendorf Tear
g

200
200
200
200


MD Arm


††††Elmendorf
gf
D1922
4.2*
16.8*
5.8*
32.2*


Tear MD


Tensile Gauge
mil
D6988
0.27
0.58
0.30
0.62


TD


Force @ Peak
g/in
D882
223
368
316
553


TD


Strain @ Peak
%
D882
67
121
108
345


TD


Force @ Break
g/in
D882
181
354
286
548


TD


Strain @ Break
%
D882
307
306
262
392


TD


Force @ Yield
g/in
D882
122
271
136
442


TD


Strain @ Yield
%
D882
8
15
12
33


TD


Force @ 5%
g/in
D882
89
143
74
162


Strain TD


Force @ 10%
g/in
D882
135
217
121
253


Strain TD


Force @ 25%
g/in
D882
193
317
218
407


Strain TD


Force @ 50%
g/in
D882
216
348
292
494


Strain TD


Force @ 100%
g/in
D882
215
363
313
514


Strain TD


Secant Modulus
PSI
D882
14,557
16,922
13,146
11,895


TD (1%)


TEA TD
FtLb/in2
D882
804
647
892
1,139


Elmendorf Tear
g

800
400
800
800


TD Arm


††††Elmendorf
gf
D1922
224
313
185
295


Tear TD


Dart Drop (26″)
g
D1709
58
100
63
126




Method A


§ Slow Puncture -
gf
D7192
167
293
186
356


¼″ (D3)












XC5-828-2302.0












E7
F7
G7
H7









CD IMG Depth













Properties
.08″
.08″
.100″
.100″







Basis Weight
12
25
12
25



Alcohol
0
0
10
0



Penetration Test



Gauge
0.35
0.73
0.32
0.76



Basis Weight
12.83
25.33
12.05
27.20



Density
1.4256
1.3730
1.4603
1.4048



Emboss Depth
0.67
1.13
0.60
1.33



Light
54.9
40.9
52.2
35.0



Transmission



Gloss - In
4.6
5.4
5.1
6.1



Gloss - Out
4.6
5.5
5.0
5.7



COF, Static -
0.750
0.610
0.702
0.625



In\In



COF, Static -
0.712
0.573
0.728
0.605



Out\Out



COF, Kinetic -
0.648
0.599
0.627
0.583



In\In



COF, Kinetic -
0.633
0.557
0.675
0.579



Out\Out



WVTR 100K
1727
1693
2978
3304



Tensile Gauge
0.35
0.73
0.32
0.76



MD



Force @ Peak
836
1,357
732
1,220



MD



Strain @ Peak
175
296
189
276



MD



Force @ Break
836
1,357
732
1,219



MD



Strain @ Break
175
296
189
276



MD



Force @ Yield
547
845
484
799



MD



Strain @ Yield
14
13
14
12



MD



Force @ 5%
323
601
298
605



Strain MD



Force @ 10%
478
791
429
767



Strain MD



Force @ 25%
635
922
559
878



Strain MD



Force @ 50%
706
980
629
939



Strain MD



Force @ 100%
760
1,043
677
999



Strain MD



Secant Modulus
57,518
59,234
50,836
53,702



MD (1%)



TEA MD
1,311
1,613
1,376
1,345



Elmendorf Tear
200
200
200
200



MD Arm



††††Elmendorf
4.8*
18.9*
4.2*
17.7*



Tear MD



Tensile Gauge
0.35
0.73
0.32
0.76



TD



Force @ Peak
380
604
360
769



TD



Strain @ Peak
109
156
82
311



TD



Force @ Break
337
584
336
769



TD



Strain @ Break
231
362
164
311



TD



Force @ Yield
197
387
141
653



TD



Strain @ Yield
10
14
9
29



TD



Force @ 5%
134
238
98
226



Strain TD



Force @ 10%
204
357
161
367



Strain TD



Force @ 25%
312
523
280
621



Strain TD



Force @ 50%
361
586
344
701



Strain TD



Force @ 100%
376
597
316
716



Strain TD



Secant Modulus
20,398
19,466
16,248
14,795



TD (1%)



TEA TD
838
1,027
598
1,045



Elmendorf Tear
200
200
200
200



TD Arm



††††Elmendorf
56
124
48
122



Tear TD



Dart Drop (26″)
66
107
68
126



§ Slow Puncture -
225
432
216
519



¼″ (D3)

















TABLE 32





Physical Properties of Skinned Multi-Layer Breathable Barrier Films I7-L7 Prepared from


Formulation XC5-22922-2306.0 and Films M7-P7 Prepared from Formulation XC5-82928-2307.0.

















XC5-22922-2306.0












I7
J7
K7
L7










ASTM
CD IMG Depth













Properties
Units
Test Method
.08″
.08′
.100″
.100″





Basis Weight
gsm

12
25
 12
 25


Alcohol
%

30
40
 70
 20


Penetration Test


Gauge
mil
D6988
0.31
0.62
   0.30
   0.62


Basis Weight
g/m2
Tappi T410
12.66
24.25
   11.89
   23.87


Density
g/cc
D2103
1.6023
1.5391
    1.5638
    1.5351


Emboss Depth
mil
—
0.47
1.07
   0.43
   0.80


Light
%
D1003
44.8
29.1
   43.1
   31.5


Transmission


Gloss - In
% @ 45°
D2457
6.9
7.7
   6.8
   7.4


Gloss - Out
% @ 45°
D2457
7.1
7.7
   7.0
   7.4


COF, Static -
—
D1894
0.510
0.467
    0.537
    0.495


In\In


COF, Static -
—
D1894
0.505
0.493
    0.497
    0.473


Out\Out


COF, Kinetic -
—
D1894
0.461
0.451
    0.474
    0.453


In\In


COF, Kinetic -
—
D1894
0.467
0.466
    0.476
    0.445


Out\Out


WVTR 100K
g/m2/day
D6701
3399
5164
3990 
867


Tensile Gauge
mil
D6988
0.31
0.62
   0.30
   0.62


MD


Force @ Peak
g/in
D882
738
1,027
650
1,034  


MD


Strain @ Peak
%
D882
164
269
214
165


MD


Force @ Break
g/in
D882
738
1,027
650
1,034  


MD


Strain @ Break
%
D882
165
269
214
165


MD


Force @ Yield
g/in
D882
516
671
395
812


MD


Strain @ Yield
%
D882
14
16
 16
 13


MD


Force @ 5%
g/in
D882
270
403
202
470


Strain MD


Force @ 10%
g/in
D882
454
582
319
731


Strain MD


Force @ 25%
g/in
D882
589
736
451
912


Strain MD


Force @ 50%
g/in
D882
647
795
513
965


Strain MD


Force @ 100%
g/in
D882
689
836
550
1,001  


Strain MD


Secant Modulus
PSI
D882
36,432
33,636
29,191  
38,151  


MD (1%)


TEA MD
FtLb/in2
D882
1,259
1,335
1,385  
925


Elmendorf Tear
g

200
200
200
200


MD Arm


††††Elmendorf
gf
D1922
4.8*
30.7*
  7*
 12*


Tear MD


Tensile Gauge
mil
D6988
0.31
0.62
   0.30
   0.62


TD


Force @ Peak
g/in
D882
291
517
311
448


TD


Strain @ Peak
%
D882
68
361
 75
154


TD


Force @ Break
g/in
D882
219
514
257
403


TD


Strain @ Break
%
D882
350
426
260
393


TD


Force @ Yield
g/in
D882
109
400
 85
261


TD


Strain @ Yield
%
D882
7
33
 6
 13


TD


Force @ 5%
g/in
D882
89
148
 78
171


Strain TD


Force @ 10%
g/in
D882
139
230
124
255


Strain TD


Force @ 25%
g/in
D882
230
372
220
386


Strain TD


Force @ 50%
g/in
D882
280
464
297
439


Strain TD


Force @ 100%
g/in
D882
286
479
306
436


Strain TD


Secant Modulus
PSI
D882
17,210
13,696
13,826  
16,351  


TD (1%)


TEA TD
FtLb/in2
D882
937
1,130
809
910


Elmendorf Tear
g

800
800
800
800


TD Arm


††††Elmendorf
gf
D1922
302
326
188
457


Tear TD


Dart Drop (26″)
g
D1709
48
112
 62
 69




Method A


§ Slow Puncture -
gf
D7192
190
363
180
353


¼″ (D3)












XC5-82928-2307.0












M7
N7
O7
P7









CD IMG Depth













Properties
.08″
.08″
.100″
.100″







Basis Weight
 12
25
 12
25



Alcohol
 30
5
 25
10



Penetration Test



Gauge
   0.34
0.64
   0.33
0.67



Basis Weight
   12.54
22.58
   12.58
24.35



Density
    1.4497
1.3810
    1.4879
1.4335



Emboss Depth
   0.73
1.13
   0.80
1.37



Light
   53.6
42.0
  50.1
36.1



Transmission



Gloss - In
   4.3
5.4
   4.5
5.4



Gloss - Out
   4.3
5.3
   4.3
5.4



COF, Static -
    0.663
0.573
    0.657
0.622



In\In



COF, Static -
    0.623
0.602
    0.690
0.573



Out\Out



COF, Kinetic -
    0.619
0.571
    0.607
0.568



In\In



COF, Kinetic -
    0.594
0.569
    0.581
0.549



Out\Out



WVTR 100K
3834 
3953
4433 
5057



Tensile Gauge
   0.34
0.64
   0.33
0.67



MD



Force @ Peak
562
861
522
910



MD



Strain @ Peak
112
133
178
242



MD



Force @ Break
553
859
522
910



MD



Strain @ Break
166
150
178
242



MD



Force @ Yield
431
726
393
705



MD



Strain @ Yield
 11
10
 13
12



MD



Force @ 5%
293
553
250
481



Strain MD



Force @ 10%
424
730
366
668



Strain MD



Force @ 25%
501
801
425
734



Strain MD



Force @ 50%
538
835
444
753



Strain MD



Force @ 100%
559
856
475
788



Strain MD



Secant Modulus
49,001  
52,989
44,211  
44,802



MD (1%)



TEA MD
938
701
905
1,052



Elmendorf Tear
200
200
200
200



MD Arm



††††Elmendorf
  4*
3.8*
   3.7*
3.6*



Tear MD



Tensile Gauge
   0.34
0.64
   0.33
0.67



TD



Force @ Peak
336
526
290
474



TD



Strain @ Peak
 69
76
109
102



TD



Force @ Break
331
523
290
474



TD



Strain @ Break
 85
87
109
102



TD



Force @ Yield
 77
139
 62
120



TD



Strain @ Yield
 4
4
 4
6



TD



Force @ 5%
96
167
 76
120



Strain TD



Force @ 10%
150
241
115
180



Strain TD



Force @ 25%
255
393
190
302



Strain TD



Force @ 50%
320
499
257
418



Strain TD



Force @ 100%
—
—
296
481



Strain TD



Secant Modulus
17,634  
19,055
13,466  
13,455



TD (1%)



TEA TD
252
205
281
205



Elmendorf Tear
200
200
200
200



TD Arm



††††Elmendorf
   17.5*
18.5*
 22*
28.7*



Tear TD



Dart Drop (26″)
—
48
 47
77



§ Slow Puncture -
191
337
199
397



¼″ (D3)










As shown by the data in Tables 31 and 32, multi-layer breathable barrier films in accordance with the present disclosure are able to achieve low alcohol penetration (e.g., 0% to 10%) at low basis weights (e.g., 12 gsm).


Example 11
Tie Resin-Free and Tie Resin-Containing Multi-Layer Breathable Barrier Films

A tie resin-containing multi-layer breathable barrier film A8 having polypropylene microporous breathable skins, a thermoplastic copolyester elastomer core, and an A/B/C/B/A structure was prepared from the formulation XC5-82328-2351.6A shown in Table 33 below. The tie resin (BYNEL 22E757) is a modified ethylene acrylate.









TABLE 33







Composition of Tie Resin-Containing ABCBA Multi-Layer Breathable


Barrier Film Made from Formulation XC5-82328-2351.6A.















Amount of




Layer %

Component



Layer
(Total)
COMPONENT
(Weight %)
















A
62.5
T1001R1
75





C702-20
24





(Braskem, polypropylene





impact copolymer)





Ampacet 102823 PA
1





(process aid)



B
30
T1001R1
75





EXCEED LL3527
15





(ExxonMobil,





metallocene polyethylene





resin)





BYNEL 22E757
10





(DuPont, modified





ethylene acrylate)



C
7.5
ARNITEL VT3104
90





(DSM, thermoplastic





copolyester elastomer)





BYNEL 22E757
10





(DuPont, modified





ethylene acrylate)










A tie resin-free multi-layer breathable barrier film B8 having polypropylene microporous breathable skins, a thermoplastic copolyester elastomer core, and an A/B/C/B/A structure was prepared from the formulation XC5-82328-2351.1 shown in Table 34 below.









TABLE 34







Composition of Tie Resin-Free ABCBA Multi-Layer Breathable


Barrier Film Made from Formulation XC5-82328-2351.1.















Amount of




Layer %

Component



Layer
(Total)
COMPONENT
(Weight %)
















A
62.5
T1001R1
75





C702-20
24





(Braskem, polypropylene





impact copolymer)





Ampacet 102823 PA
1





(process aid)



B
30
T1001R1
75





EXCEED LL3527
25





(ExxonMobil,





metallocene polyethylene





resin)



C
7.5
ARNITEL VT3104
100





(DSM, thermoplastic





copolyester elastomer)










The composition of the CaCO3-containing compound T1001R1 shown in Tables 33 and 34 is specified in Table 35 below.









TABLE 35







Composition of CaCO3 Compound T1001R1 used


in the Formulation of Tables 33 and 34.











Amount of Component



Component
(Weight %)







EXCEED 3518PA (ExxonMobil,
30



3.5 MI, .918 g/cm3 mLLDPE resin)



FilmLink 500 (CaCO3)
70



Thermal stabilizers
(minor)










The physical properties of the resultant films A8 and B8 are shown in Table 36 below. Each of films A8 and B8 received 25% post-stretch and was subjected to CD IMG stretching at a depth of 0.1 inches.









TABLE 36







Physical Properties of Tie Resin-Containing Film A8 Prepared


from Formulation XC5-82328-2351.6A and Tie Resin-Free Film


B8 Prepared from Formulation XC5-82328-2351.1.










Properties
Units
A8
B8













Gauge
mil
0.38
   0.36


Basis Weight
g/m2
13.17
   12.53


Density
g/cc
1.3509
    1.3510


Light Transmission
%
55.9
  60.6


Treat - In
Dyne/cm
34
 34


Treat - Out
Dyne/cm
36
 36


WVTR 100K
g/m2/day
5638
4843 


Tensile Gauge MD
mil
0.38
   0.36


Stress @ Peak MD
grams/inch
878
932


Strain @ Peak MD
%
227
246


Stress @ Break MD
grams/inch
878
931


Strain @ Break MD
%
227
246


Stress @ Yield MD
grams/inch
339
353


Strain @ Yield MD
%
10
 10


Stress @ 5% Strain MD
grams/inch
245
247


Stress @ 10% Strain MD
grams/inch
338
352


Stress @ 25% Strain MD
grams/inch
406
424


Stress @ 50% Strain MD
grams/inch
450
470


Stress @ 100% Strain MD
grams/inch
516
532


Secant Modulus MD (1%)
grams/inch
28,597
38,403  


TEA MD
FtLb/in2
1,227
1,486  


Elmendorf Tear MD Arm
g
200
200


††††Elmendorf Tear MD
gf
8.7*
  8*


Tensile Gauge TD
mil
0.38
   0.36


Stress @ Peak TD
grams/inch
402
414


Strain @ Peak TD
%
356
374


Stress @ Break TD
grams/inch
401
414


Strain @ Break TD
%
357
374


Stress @ Yield TD
grams/inch
203
199


Strain @ Yield TD
%
29
 28


Stress @ 5% Strain TD
grams/inch
80
 82


Stress @ 10% Strain TD
grams/inch
120
122


Stress @ 25% Strain TD
grams/inch
191
189


Stress @ 50% Strain TD
grams/inch
246
244


Stress @ 100% Strain TD
grams/inch
257
261


Secant Modulus TD (1%)
PSI
11,904
13,430  


TEA TD
FtLb/in2
971
1,094  


Elmendorf Tear TD Arm
g
200
200


Elmendorf Tear TD
gf
100
 91


Dart Drop (26″)
g
101
115


§ Slow Puncture -
gf
266
254


¼″ (D3)









Surprisingly and unexpectedly, it was possible to successfully produce rolls of film that were subsequently hot melt-adhesively-laminated to a nonwoven layer with both the tie resin-containing formulation XC5-82328-2351.6A and the tie resin-free formulation XC5-82328-2351.1. Heretofore, it had been believed that a tie resin adhesive would be required to keep the layers from separating during manufacture or handling. However, a manufacturing process in accordance with the present disclosure utilizing CD IMG activation allows the layers to remain together, thereby dispensing with the requirement of a tie resin.


As shown by the data in Table 36, excellent WVTR values and Dart Impact Strength were obtained in spite of the low basis weights of the films and the use of polypropylene (normally a brittle polymer with orientation) in the structure.

Claims
  • 1. A process for making a multi-layer breathable barrier film comprising the steps of co-extruding at least a first composition comprising a polyolefin and an inorganic filler and a second composition comprising a hygroscopic polymer to form a multi-layer molten web, the multi-layer molten web comprising a microporous breathable film layer and a moisture-permeable barrier layer,casting the molten web against a surface of a chill roll using a vacuum box, or a combination of a vacuum box and one or both of an air knife and an air blanket, and without use of a nip, to form a quenched film, wherein the molten web is configured to hit the surface of the chill roll within a distance of less than about 3 inches, andstretching the quenched film to form the multi-layer breathable barrier film, wherein the stretching comprises cross-directional intermeshing gear (CD-IMG) stretching and machine direction (MD) stretching, and wherein at least a portion of the stretching is performed at a temperature of between about 60 degrees Fahrenheit and about 200 degrees Fahrenheit;wherein the process for making the multi-layer breathable barrier film does not include MD-IMG stretching, and wherein the MD stretching occurs after the CD-IMG stretching; andwherein the microporous breathable film layer made by the process has a basis weight of less than about 10 gsm, a Dart Impact Strength of greater than about 90 grams, and a strain at peak machine direction of at least about 125%.
  • 2. The process of claim 1, wherein the polyolefin comprises polyethylene, polypropylene, or a combination thereof.
  • 3. The process of claim 1, wherein the polyolefin comprises low density polyethylene, high density polyethylene, linear low density polyethylene, ultra-low density polyethylene, or a combination thereof.
  • 4. The process of claim 1, wherein the polyolefin comprises linear low density polyethylene.
  • 5. The process of claim 1, wherein the polyolefin comprises linear low density polyethylene and the linear low density polyethylene comprises a metallocene polyethylene.
  • 6. The process of claim 1, wherein the polyolefin comprises polypropylene.
  • 7. The process of claim 1, wherein the inorganic filler comprises from about 30% to about 75% by weight of the microporous breathable film.
  • 8. The process of claim 1, wherein an average particle size of the inorganic filler is between about 0.1 microns and about 15 microns.
  • 9. The process of claim 1, wherein the inorganic filler is selected from the group consisting of sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, alumina, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolites, and a combination thereof.
  • 10. The process of claim 1, wherein the inorganic filler comprises an alkali metal carbonate, an alkaline earth metal carbonate, an alkali metal sulfate, an alkaline earth metal sulfate, or a combination thereof.
  • 11. The process of claim 1, wherein the inorganic filler comprises calcium carbonate.
  • 12. The process of claim 1, wherein the molten web is cast against the surface of the chill roll under negative pressure by the vacuum box.
  • 13. The process of claim 1, wherein the molten web is cast against the surface of the chill roll under positive pressure by the air knife.
  • 14. The process of claim 1, wherein an exit temperature of cooling fluid passing through the chill roll is between about 50 degrees Fahrenheit and about 130 degrees Fahrenheit.
  • 15. The process of claim 1, further comprising annealing the multi-layer breathable barrier film.
  • 16. The process of claim 1, further comprising annealing the multi-layer breathable barrier film in which the annealing is performed at a temperature of between about 75 degrees Fahrenheit and about 225 degrees Fahrenheit.
  • 17. A process for making a multi-layer breathable barrier film comprising the steps of co-extruding a first composition that comprises polyethylene, polypropylene, or a combination thereof and an alkaline earth metal carbonate and a second composition that comprises a hygroscopic polymer to form a multi-layer molten web, the alkaline earth metal carbonate comprising at least about 50% by weight of the microporous breathable film, the multi-layer molten web comprising a microporous breathable film layer and a moisture-permeable barrier layer,casting the molten web against a surface of a chill roll under negative pressure by a vacuum box, and without use of a nip, to form a quenched film, wherein the molten web is configured to hit the surface of the chill roll within a distance of less than about 3 inches,stretching the quenched film by cross-directional intermeshing gear (CD IMG) stretching and machine direction (MD) stretching to form the multi-layer breathable barrier film, wherein at least a portion of the stretching is performed at a temperature of between about 60 degrees Fahrenheit and about 200 degrees Fahrenheit, andannealing the multi-layer breathable barrier film at a temperature of between about 75 and about 225 degrees Fahrenheit;wherein the process for making the multi-layer breathable barrier film does not include MD-IMG stretching, and wherein the MD stretching occurs after the CD-IMG stretching; andwherein the microporous breathable film layer made by the process has a basis weight of less than about 10 gsm, a Dart Impact Strength of greater than about 90 grams, and a strain at peak machine direction of at least about 125%.
  • 18. The process of claim 1, comprising laminating the multi-layer breathable barrier film to a support.
  • 19. The process of claim 1 wherein the MD stretching and the CD-IMG stretching occur in a separate manufacturing process that is not in-line with formation of the quenched film.
  • 20. The process of claim 17 wherein the MD stretching and the CD-IMG stretching occur in a separate manufacturing process that is not in-line with formation of the quenched film.
  • 21. The process of claim 1 wherein the molten web is configured to hit the surface of the chill roll within a distance of less than or equal to about 1 inch.
  • 22. The process of claim 17 wherein the molten web is configured to hit the surface of the chill roll within a distance of less than or equal to about 1 inch.
  • 23. The process of claim 1 wherein the hygroscopic polymer is selected from the group consisting of hygroscopic elastomers, polyesters, polyamides, polyetherester copolymers, polyetheramide copolymers, polyurethanes, polyurethane copolymers, poly(etherimide) ester copolymers, polyvinyl alcohols, ionomers, celluloses, nitrocelluloses, and/or the like, and combinations thereof.
  • 24. The process of claim 17 wherein the hygroscopic polymer is selected from the group consisting of hygroscopic elastomers, polyesters, polyamides, polyetherester copolymers, polyetheramide copolymers, polyurethanes, polyurethane copolymers, poly(etherimide) ester copolymers, polyvinyl alcohols, ionomers, celluloses, nitrocelluloses, and/or the like, and combinations thereof.
  • 25. The process of claim 1 wherein the second composition further comprises an adhesive.
  • 26. The process of claim 25 wherein the adhesive comprises polyethylene/acrylate copolymer, ethylene/methyl acrylate copolymer, acid-modified acrylate, anhydride-modified acrylate, ethylene vinyl acetate, acid/acrylate-modified ethylene vinyl acetate, anhydride-modified ethylene vinyl acetate, or a combination thereof.
  • 27. The process of claim 17 wherein the second composition further comprises an adhesive.
  • 28. The process of claim 27 wherein the adhesive comprises polyethylene/acrylate copolymer, ethylene/methyl acrylate copolymer, acid-modified acrylate, anhydride-modified acrylate, ethylene vinyl acetate, acid/acrylate-modified ethylene vinyl acetate, anhydride-modified ethylene vinyl acetate, or a combination thereof.
  • 29. The process of claim 1 wherein the multi-layer breathable barrier film does not contain a tie resin.
  • 30. The process of claim 17 wherein the multi-layer breathable barrier film does not contain a tie resin.
  • 31. The process of claim 1 wherein the multi-layer breathable barrier film comprises micropores that permit passage of water vapor but do not permit passage of liquid water.
RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/233,128, filed Sep. 25, 2015, and U.S. Provisional Application No. 62/191,010, filed Jul. 10, 2015. The entire contents of both of these priority documents are 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.

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Related Publications (1)
Number Date Country
20170008211 A1 Jan 2017 US
Provisional Applications (2)
Number Date Country
62233128 Sep 2015 US
62191010 Jul 2015 US