WO1998029246A1 - Breathable laminate of nonwoven and elastomeric film including metallocene catalyzed polyethylene elastomer and method for making the same - Google Patents
Breathable laminate of nonwoven and elastomeric film including metallocene catalyzed polyethylene elastomer and method for making the same Download PDFInfo
- Publication number
- WO1998029246A1 WO1998029246A1 PCT/US1997/023264 US9723264W WO9829246A1 WO 1998029246 A1 WO1998029246 A1 WO 1998029246A1 US 9723264 W US9723264 W US 9723264W WO 9829246 A1 WO9829246 A1 WO 9829246A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- film
- laminate
- length
- filler
- ethylene
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims description 35
- -1 polyethylene Polymers 0.000 title abstract description 14
- 239000004698 Polyethylene Substances 0.000 title abstract description 8
- 229920000573 polyethylene Polymers 0.000 title abstract description 8
- 229920001971 elastomer Polymers 0.000 title description 6
- 239000000806 elastomer Substances 0.000 title description 5
- 239000000945 filler Substances 0.000 claims abstract description 25
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 8
- 238000004519 manufacturing process Methods 0.000 claims abstract description 8
- 239000011148 porous material Substances 0.000 claims abstract description 6
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 26
- 239000005977 Ethylene Substances 0.000 claims description 26
- 230000008569 process Effects 0.000 claims description 26
- 229920001577 copolymer Polymers 0.000 claims description 20
- 238000011084 recovery Methods 0.000 claims description 17
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical group [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 14
- 239000002245 particle Substances 0.000 claims description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 229920000642 polymer Polymers 0.000 claims description 11
- 229920005989 resin Polymers 0.000 claims description 11
- 239000011347 resin Substances 0.000 claims description 11
- 230000002745 absorbent Effects 0.000 claims description 10
- 239000002250 absorbent Substances 0.000 claims description 10
- 230000005540 biological transmission Effects 0.000 claims description 10
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 claims description 7
- 206010021639 Incontinence Diseases 0.000 claims description 7
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 7
- 239000002952 polymeric resin Substances 0.000 claims description 7
- 229920003002 synthetic resin Polymers 0.000 claims description 7
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 claims description 6
- 239000007788 liquid Substances 0.000 claims description 5
- 230000001351 cycling effect Effects 0.000 claims description 4
- 238000012549 training Methods 0.000 claims description 4
- 239000002861 polymer material Substances 0.000 claims description 2
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 claims 2
- 238000005266 casting Methods 0.000 claims 1
- 239000013536 elastomeric material Substances 0.000 abstract 1
- 239000000463 material Substances 0.000 description 31
- 239000000835 fiber Substances 0.000 description 18
- 238000012360 testing method Methods 0.000 description 17
- 239000000523 sample Substances 0.000 description 15
- 239000000853 adhesive Substances 0.000 description 12
- 230000001070 adhesive effect Effects 0.000 description 12
- 239000000126 substance Substances 0.000 description 8
- 239000003054 catalyst Substances 0.000 description 7
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 6
- 230000004888 barrier function Effects 0.000 description 6
- 230000003111 delayed effect Effects 0.000 description 6
- 238000010030 laminating Methods 0.000 description 5
- 238000003475 lamination Methods 0.000 description 5
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 125000000058 cyclopentadienyl group Chemical group C1(=CC=CC1)* 0.000 description 4
- ZSWFCLXCOIISFI-UHFFFAOYSA-N endo-cyclopentadiene Natural products C1C=CC=C1 ZSWFCLXCOIISFI-UHFFFAOYSA-N 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 239000003963 antioxidant agent Substances 0.000 description 3
- 230000003078 antioxidant effect Effects 0.000 description 3
- 229910052796 boron Inorganic materials 0.000 description 3
- 239000012943 hotmelt Substances 0.000 description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 3
- CPOFMOWDMVWCLF-UHFFFAOYSA-N methyl(oxo)alumane Chemical compound C[Al]=O CPOFMOWDMVWCLF-UHFFFAOYSA-N 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 238000009864 tensile test Methods 0.000 description 3
- 239000012815 thermoplastic material Substances 0.000 description 3
- 229920002101 Chitin Polymers 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 2
- 125000005234 alkyl aluminium group Chemical group 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000003426 co-catalyst Substances 0.000 description 2
- UKMSUNONTOPOIO-UHFFFAOYSA-N docosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCCCCC(O)=O UKMSUNONTOPOIO-UHFFFAOYSA-N 0.000 description 2
- HEAMQYHBJQWOSS-UHFFFAOYSA-N ethene;oct-1-ene Chemical compound C=C.CCCCCCC=C HEAMQYHBJQWOSS-UHFFFAOYSA-N 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- KTWOOEGAPBSYNW-UHFFFAOYSA-N ferrocene Chemical group [Fe+2].C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 KTWOOEGAPBSYNW-UHFFFAOYSA-N 0.000 description 2
- 229910052736 halogen Inorganic materials 0.000 description 2
- 150000002367 halogens Chemical class 0.000 description 2
- 238000011068 loading method Methods 0.000 description 2
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 2
- 235000019341 magnesium sulphate Nutrition 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000012968 metallocene catalyst Substances 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 2
- NFHFRUOZVGFOOS-UHFFFAOYSA-N palladium;triphenylphosphane Chemical compound [Pd].C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1 NFHFRUOZVGFOOS-UHFFFAOYSA-N 0.000 description 2
- 125000000538 pentafluorophenyl group Chemical group FC1=C(F)C(F)=C(*)C(F)=C1F 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- HLWRUJAIJJEZDL-UHFFFAOYSA-M sodium;2-[2-[bis(carboxymethyl)amino]ethyl-(carboxymethyl)amino]acetate Chemical compound [Na+].OC(=O)CN(CC(O)=O)CCN(CC(O)=O)CC([O-])=O HLWRUJAIJJEZDL-UHFFFAOYSA-M 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- RSPAIISXQHXRKX-UHFFFAOYSA-L 5-butylcyclopenta-1,3-diene;zirconium(4+);dichloride Chemical compound Cl[Zr+2]Cl.CCCCC1=CC=C[CH-]1.CCCCC1=CC=C[CH-]1 RSPAIISXQHXRKX-UHFFFAOYSA-L 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 235000021357 Behenic acid Nutrition 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920013683 Celanese Polymers 0.000 description 1
- BGZIPDABODPYKI-UHFFFAOYSA-M Cl[Sc](C1C=CC=C1)C1C=CC=C1 Chemical compound Cl[Sc](C1C=CC=C1)C1C=CC=C1 BGZIPDABODPYKI-UHFFFAOYSA-M 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- 229920002633 Kraton (polymer) Polymers 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- JLTDJTHDQAWBAV-UHFFFAOYSA-N N,N-dimethylaniline Chemical compound CN(C)C1=CC=CC=C1 JLTDJTHDQAWBAV-UHFFFAOYSA-N 0.000 description 1
- 208000034809 Product contamination Diseases 0.000 description 1
- 241000220010 Rhode Species 0.000 description 1
- 235000021355 Stearic acid Nutrition 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 238000012644 addition polymerization Methods 0.000 description 1
- 230000002730 additional effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 description 1
- 229920013640 amorphous poly alpha olefin Polymers 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- AYJRCSIUFZENHW-DEQYMQKBSA-L barium(2+);oxomethanediolate Chemical compound [Ba+2].[O-][14C]([O-])=O AYJRCSIUFZENHW-DEQYMQKBSA-L 0.000 description 1
- 229940116226 behenic acid Drugs 0.000 description 1
- WXCZUWHSJWOTRV-UHFFFAOYSA-N but-1-ene;ethene Chemical compound C=C.CCC=C WXCZUWHSJWOTRV-UHFFFAOYSA-N 0.000 description 1
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 1
- CZQIDPLTQBOKMO-UHFFFAOYSA-L butylcyclopentane;dichlorotitanium Chemical compound Cl[Ti]Cl.CCCC[C]1[CH][CH][CH][CH]1.CCCC[C]1[CH][CH][CH][CH]1 CZQIDPLTQBOKMO-UHFFFAOYSA-L 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- ILZSSCVGGYJLOG-UHFFFAOYSA-N cobaltocene Chemical compound [Co+2].C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 ILZSSCVGGYJLOG-UHFFFAOYSA-N 0.000 description 1
- 239000013068 control sample Substances 0.000 description 1
- VYZZYIJFEPWENJ-UHFFFAOYSA-N cyclopenta-1,3-diene niobium(2+) Chemical compound [Nb++].c1cc[cH-]c1.c1cc[cH-]c1 VYZZYIJFEPWENJ-UHFFFAOYSA-N 0.000 description 1
- ZMMRKRFMSDTOLV-UHFFFAOYSA-N cyclopenta-1,3-diene zirconium Chemical compound [Zr].C1C=CC=C1.C1C=CC=C1 ZMMRKRFMSDTOLV-UHFFFAOYSA-N 0.000 description 1
- MKNXBRLZBFVUPV-UHFFFAOYSA-L cyclopenta-1,3-diene;dichlorotitanium Chemical compound Cl[Ti]Cl.C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 MKNXBRLZBFVUPV-UHFFFAOYSA-L 0.000 description 1
- CSEGCHWAMVIXSA-UHFFFAOYSA-L cyclopenta-1,3-diene;hafnium(4+);dichloride Chemical compound [Cl-].[Cl-].[Hf+4].C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 CSEGCHWAMVIXSA-UHFFFAOYSA-L 0.000 description 1
- KZPXREABEBSAQM-UHFFFAOYSA-N cyclopenta-1,3-diene;nickel(2+) Chemical compound [Ni+2].C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 KZPXREABEBSAQM-UHFFFAOYSA-N 0.000 description 1
- QOXHZZQZTIGPEV-UHFFFAOYSA-K cyclopenta-1,3-diene;titanium(4+);trichloride Chemical compound Cl[Ti+](Cl)Cl.C=1C=C[CH-]C=1 QOXHZZQZTIGPEV-UHFFFAOYSA-K 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- IVTQDRJBWSBJQM-UHFFFAOYSA-L dichlorozirconium;indene Chemical compound C1=CC2=CC=CC=C2C1[Zr](Cl)(Cl)C1C2=CC=CC=C2C=C1 IVTQDRJBWSBJQM-UHFFFAOYSA-L 0.000 description 1
- LOKCKYUBKHNUCV-UHFFFAOYSA-L dichlorozirconium;methylcyclopentane Chemical compound Cl[Zr]Cl.C[C]1[CH][CH][CH][CH]1.C[C]1[CH][CH][CH][CH]1 LOKCKYUBKHNUCV-UHFFFAOYSA-L 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 239000013013 elastic material Substances 0.000 description 1
- 238000011067 equilibration Methods 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000007871 hydride transfer reaction Methods 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 125000001449 isopropyl group Chemical group [H]C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 244000005700 microbiome Species 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 125000002524 organometallic group Chemical group 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- FZHCFNGSGGGXEH-UHFFFAOYSA-N ruthenocene Chemical compound [Ru+2].C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 FZHCFNGSGGGXEH-UHFFFAOYSA-N 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 230000037067 skin hydration Effects 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- ZWYDDDAMNQQZHD-UHFFFAOYSA-L titanium(ii) chloride Chemical compound [Cl-].[Cl-].[Ti+2] ZWYDDDAMNQQZHD-UHFFFAOYSA-L 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- 150000003624 transition metals Chemical class 0.000 description 1
- OBAJXDYVZBHCGT-UHFFFAOYSA-N tris(pentafluorophenyl)borane Chemical compound FC1=C(F)C(F)=C(F)C(F)=C1B(C=1C(=C(F)C(F)=C(F)C=1F)F)C1=C(F)C(F)=C(F)C(F)=C1F OBAJXDYVZBHCGT-UHFFFAOYSA-N 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
- VPGLGRNSAYHXPY-UHFFFAOYSA-L zirconium(2+);dichloride Chemical compound Cl[Zr]Cl VPGLGRNSAYHXPY-UHFFFAOYSA-L 0.000 description 1
- QMBQEXOLIRBNPN-UHFFFAOYSA-L zirconocene dichloride Chemical compound [Cl-].[Cl-].[Zr+4].C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 QMBQEXOLIRBNPN-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51456—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties
- A61F13/51464—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being stretchable or elastomeric
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51474—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure
- A61F13/51478—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure being a laminate, e.g. multi-layered or with several layers
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51474—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure
- A61F13/51478—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure being a laminate, e.g. multi-layered or with several layers
- A61F13/5148—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure being a laminate, e.g. multi-layered or with several layers having an impervious inner layer and a cloth-like outer layer
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
- A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
- A61L15/18—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons containing inorganic materials
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
- A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
- A61L15/22—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons containing macromolecular materials
- A61L15/24—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
- B32B27/327—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polyolefins obtained by a metallocene or single-site catalyst
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/04—Polyethylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2437/00—Clothing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2555/00—Personal care
- B32B2555/02—Diapers or napkins
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/08—Copolymers of ethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
- C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
Definitions
- the present invention is directed to breathable elastomeric films utilizing metallocene catalyzed polyethylene elastomers.
- the present invention is directed to a method of making such films.
- the invention also includes breathable laminates of the films to one or more substrates, and methods of making the laminates.
- the present invention is directed to breathable elastomeric films.
- Such materials have a wide variety of uses, especially in the areas of limited use and disposable items.
- Films have been traditionally used to provide barrier properties in limited use or disposable items.
- limited use or disposable it is meant that the product and/or component is used only a small number of times or possibly only once before being discarded.
- Examples of such products include, but are not limited to, surgical and health care related products such as surgical drapes and gowns, disposable work wear such as coveralls and lab coats and personal care absorbent products such as diapers, training pants, incontinence garments, sanitary napkins, bandages, wipes and the like.
- films are used as the outer covers with the purpose of preventing body wastes from contaminating the clothing, bedding and other aspects of the surrounding environment of use.
- films are used to prevent cross exchange of microorganisms between the wearer and the patient.
- Lamination of films have been used to create materials which are both impervious and somewhat cloth- like in appearance and texture.
- the outer covers on disposable diapers are but one example.
- Surgical gowns and drapes are other examples. See, in this regard, coassigned U.S. Patent No. 4,379,102 dated April 5, 1983.
- a primary purpose of the film in such laminations is to provide barrier properties.
- There is also a need for such laminates to be breathable so that they have the ability to transmit moisture vapor. Apparel made from laminations of these breathable or microporous films are more comfortable to wear by reducing the moisture vapor concentration and the consequent skin hydration underneath the apparel item.
- the present invention relates to a breathable elastomeric film that includes a metallocene catalyzed polyethylene polymeric resin material and at least 30% by weight of a filler having a particle size that contributes to pore formation.
- the polymeric resin material has a density of from about 0.850 to about 0.917 g/cc.
- the film includes from about 45 to about 60% filler by weight of the filled resin .
- the resin material is selected from copolymers of ethylene and 1-butene, copolymers of ethylene and 1-hexene, copolymers of ethylene and l-octene and combinations thereof.
- the breathable film has an immediate recovery length that is at least about 50% of its elongation following a stretch cycling that achieved a stretched length of about 160% of the unbiased length.
- the film of the present invention may have an immediate recovery length that is at least about 50% its elongation length following a stretch cycling that achieved a stretched length of about 200% of the unbiased length.
- the present invention also is directed to a process for preparing a breathable elastomeric film of the present invention, including providing a polymeric resin including a metallocene catalyzed polyethylene polymeric material; adding to the polymeric resin at least 30% by weight of a filler having a particle size that contributes to pore formation to form a filled resin; forming a film having a first length from the filled resin; and stretching the film to form a microporous film.
- the process of the invention is applicable to films formed by various processes, i.e., cast or blown films.
- the microporous film is stretched to a second length that is from about 160 to about 400% of the first length.
- the preferred film of the present invention has a water vapor transmission rate (WVTR) of from about 300 to about 4,500 grams per square meter per 24 hours (measured by ASTM Test E 96-80 with Celgard® 2500 as control) . More preferably, the film of the present invention has a WVTR of from about 1,000 to about 4,000 g/m 2 24 hrs.
- WVTR water vapor transmission rate
- Such films have a wide variety of uses including, but not limited to, applications in personal care absorbent articles including diapers, training pants, sanitary napkins, incontinence devices, bandages and the like. These same films also may be used in items such as surgical drapes and gowns as well as various articles of clothing either as the entire article or simply as a component thereof .
- Figure 1 is a schematic side view of a process for forming a laminate according to the present invention.
- Figure 2 is a cross-section side view of a film/nonwoven laminate according to the present invention.
- Figure 3 is a partially cut away top plan view of an exemplary personal care absorbent article, in this case a diaper, which may utilize a film made according to the present invention.
- the present invention is directed to breathable elastomeric films that include metallocene-catalyzed ethylene-based polymers.
- metallocene-catalyzed ethylene-based polymers includes those polymer materials that are produced by the polymerization of at least ethylene using metallocenes or constrained geometry catalysts, a class of organometallic complexes, as catalysts.
- a common metallocene is ferrocene, a complex with a metal sandwiched between two cyclopentadienyl (Cp) ligand ⁇ .
- Metallocene process catalysts include bis (n-butylcyclopentadienyl) titanium dichloride, bis (n-butylcyclopentadienyl) zirconium dichloride, bis (cyclopentadienyl) scandium chloride, bis(indenyl) zirconium dichloride, bis (methylcyclopentadieny1) titanium dichloride, bis(methylcyclopentadienyl) zirconium dichloride, cobaltocene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl (cyclopentadienyl, -1-flourenyl) zirconium dichloride, molybdocene dichloride, nickelocene, niobocene dichloride, ruthenocene, titanocene dichloride, zirconocene chloride hydride, zirconocen
- Co-catalysts are materials such as methylaluminoxane (MAO) which is the most common, other alkylaluminums and boron containing compounds like tris(pentafluorophenyl) boron, lithium tetrakis(pentafluorophenyl) boron, and dimethylanilinium tetrakis(pentafluorophenyl) boron.
- MAO methylaluminoxane
- the metallocene catalyst be activated or ionized to a cationic form for reaction with the monomer (s) to be polymerized.
- the metallocene-catalyzed ethylene-based polymers used in the present invention impart stretch and recovery properties to the film.
- the metallocene catalyzed ethylene-based polymer is selected from copolymers of ethylene and 1-butene, copolymers of ethylene and l-hexene, copolymers of ethylene and 1- octene and combinations thereof.
- preferred materials include AffinityTM brand elastomeric metallocene-derived copolymers of ethylene and 1-octene, both available from Dow Plastics of Freeport, Texas.
- Particularly preferred materials also include ExactTM brand elastomer metallocene-derived copolymers and terpolymers of ethylene and 1-butene and copolymers of ethylene and 1-hexene, available from Exxon Chemical Company of Houston, TX.
- the material used in the present invention has a density of from about 0.850 to about 0.899 g/cc. More preferably, the material used in the present invention has a density of from about 0.860 to about 0.899 g/cc, even more preferably from about 0.870 to about 0.899 g/cc.
- the melt index range of some useful materials is between about 1 to about 15 dg/min and advantageously may be in the range of from about 5 to about 10 dg/min. Specific examples of suitable materials can be found in U.S. Patent Nos. 5,472,775 and 5,272,236, both assigned to the Dow Chemical Company. The entire content of these patents is incorporated herein by reference.
- the film layer also includes a filler which enables development of micropores during orientation of the film.
- a "filler” is meant to include particulates and other forms of materials which can be added to the polymer and which will not chemically interfere with or adversely affect the extruded film but is able to be uniformly dispersed throughout the film.
- the fillers will be in particulate form and usually will have somewhat of a spherical shape with average particle sizes in the range of about 0.5 to about 8 microns .
- the film will usually contain at least 30 percent (%) , preferably about 40 to about 70 percent, filler based upon the total weight of the film layer.
- filler More preferably, from about 45 to about 60 percent of filler is present in the film.
- organic and inorganic fillers are contemplated to be within the scope of the present invention provided that they do not interfere with the film formation process, the breathability of the resultant film or its ability to bond to another layer such as a fibrous polyolefin nonwoven web.
- fillers examples include calcium carbonate (CaC0 3 ) , various kinds of clay, silica (Si0 2 ) , alumina, barium sulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide, zeolites, aluminum sulfate, cellulose-type powders, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivative, polymer particles, chitin and chitin derivatives.
- the filler particles may optionally be coated with a fatty acid, such as stearic acid, and behenic acid which may facilitate the free flow of the particles (in bulk) and their ease of dispersion into the polymer matrix.
- the WVTR of the film of the present invention that may be used as a component in a limited-use or disposable item is from about 300 to about 4,500, more preferably from about 1,000 to about 4,000 g/m 2 /24 hrs.
- the preferred films of the present invention are also elastic.
- elastic is used herein to mean any material which, upon application of a biasing force, is stretchable, that is, elongatable, to a stretched, biased length which is at least about 150 percent of its relaxed unbiased length, and which will recover at least 50 percent of its elongation upon release of the stretching, elongating force.
- a hypothetical example would be a one (1) inch sample of a material which is elongatable to at least 1.50 inches and which, upon being elongated to 1.50 inches and released, will recover to a length of not more than 1.25 inches.
- Many elastic materials may be stretched by much more than 50 percent of their relaxed length, for example, 100 percent or more, and many of these will recover to substantially their original relaxed length, for example, to within 105 percent of their original relaxed length, upon release of the stretching force.
- filled film 10 is unwound and directed to a film stretching unit 44 such as a machine direction orienter, which is a commercially available device from vendors such as the Marshall and Williams Company of Buffalo, Rhode Island.
- a film stretching unit 44 such as a machine direction orienter, which is a commercially available device from vendors such as the Marshall and Williams Company of Buffalo, Rhode Island.
- Such an apparatus 44 has a plurality of stretching rollers 46 moving at progressively faster speeds relative to the pair disposed before it. These rollers 46 apply an amount stress and thereby progressively stretch filled film 10 to a stretch length in the machine direction of the film which is the direction of travel of filled film 10 through the process as shown in Figure 1.
- the stretch rollers 46 may be heated for better processing.
- unit 44 also include rollers (not shown) upstream and/or downstream from the stretch rollers 46 that can be used to preheat the film 10 before orienting and/or anneal (or cool) it after stretching.
- rollers (not shown) upstream and/or downstream from the stretch rollers 46 that can be used to preheat the film 10 before orienting and/or anneal (or cool) it after stretching.
- a plurality of micropores form in the film 10.
- the stretched length is from about 160 to about 500%, more preferably from about 200 to about 400% of the unbiased length of the film prior to stretching. If desired, film 10 is directed out of apparatus 44 so that the stress is removed to allow the stretched film 10 to relax.
- filled film 10 may be attached to one or more support layers 30 to form a laminate 32.
- a conventional fibrous nonwoven web forming apparatus 48 such as a pair of spunbond machines, is used to form the support layer 30.
- the long, essentially continuous fibers 50 are deposited onto a forming wire 52 as an unbonded web 54 and the unbonded web 54 is then sent through a pair of bonding rolls 56 to bond the fibers together and increase the tear strength of the resultant web support layer 30.
- One or both of the rolls are often heated to aid in bonding.
- the rolls 56 is also patterned so as to impart a discrete bond pattern with a prescribed bond surface area to the web 30.
- the other roll is usually a smooth anvil roll but this roll also may be patterned if so desired.
- the laminating rolls 58 may be heated.
- at least one of the rolls may be patterned to create a discrete bond pattern with a prescribed bond surface area for the resultant laminate 32. Generally, the maximum bond point surface area for a given area of surface on one side of the laminate 32 will not exceed about 50 percent of the total surface area.
- Suitable alternatives include, for example, adhesive bonding and the use of tackifiers.
- adhesive bonding an adhesive such as a hot melt adhesive is applied between the film and fiber to bind the film and fiber together.
- the adhesive can be applied by, for example, melt spraying, printing or meltblowing.
- Various types of adhesives are available, including those produced from amorphous polyalphaolefins, ethylene vinyl acetate-based hot melts, and Kraton® brand adhesives available from Shell Chemical of Houston, TX and RextacTM Brand Adhesives from Rexene of Odessa, TX.
- the tackifier When the film and support layer(s) is bonded with tackifiers, the tackifier may be incorporated into the film itself.
- the tackifier essentially serves to increase adhesion between the film and fiber layers.
- the film and fiber laminate may subsequently be thermally point-bonded, although generally very little heat is required since the tackifier tends to increase the pressure sensitivity of the film and a bond somewhat like and adhesive bond can be formed.
- useful tackifers include WingtackTM 95, available from Goodyear Tire & Rubber Co. of Akron, OH, and EscorezTM 5300, available from Exxon Chemical Company of Houston, TX.
- the direction of elasticity in the laminate may be tailored by the state of the film, i.e.
- the film is relaxed prior to bonding and the support layer is extensible in the cross-machine direction ("CD"), then a laminate with both CD and machine-direction (“MD”) stretch can be produced. Additionally, if the film is bonded to a support layer non-extensible in the CD direction while in a stretched state, then a laminate with a MD stretch can be produced.
- CD cross-machine direction
- MD machine-direction
- the support layers 30 as shown in Figure 2 are fibrous nonwoven webs.
- the manufacture of such fibrous nonwoven webs is known.
- Such fibrous nonwoven webs can add additional properties to filled film 10, such as a more soft, cloth-like feel. This is particularly advantageous when filled film 10 is being used as a barrier layer to liquids in such applications as outer covers for personal care absorbent articles and as barrier materials for hospital, surgical, and clean room applications such as, for example, surgical drapes, gowns and other forms of apparel.
- Attachment of the support layers 30 to the filled film 10 may be by the use of a separate adhesive such as hot-melt and solvent based adhesives or through the use of heat and/or pressure (also known as thermal bonding) as with heated bonding rolls.
- the support layer in a laminate containing the film layer of the present invention can be necked polypropylene spunbond, crimped polypropylene spunbond, bonded carded webs, elastomeric spunbond or meltblown fabrics produced from elastomeric resins.
- a particularly advantageous support layer is a fibrous nonwoven web.
- Such webs may be formed from a number of processes including, but not limited to, spunbonding, meltblowing and bonded carded web processes.
- Meltblown fibers are formed by extruding molten thermoplastic material through a plurality of fine, usually circular, capillaries as molten threads or filaments into a high velocity usually heated gas stream such as air, which attenuates the filaments of molten thermoplastic material to reduce their diameters.
- meltblown fibers are carried by the high velocity usually heated gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
- the meltblown process is well-known and is described in various patents and publications, including NRL Report 4364, "Manufacture of Super-Fine Organic Fibers" by B. A. Wendt, E. L. Boone and D. D. Fluharty; NRL Report 5265, "An Improved Device For The Formation of Super-Fine Thermoplastic Fibers" by K. D. Lawrence, R. T. Lukas, J. A. Young; U.S. Patent No. 3,676,242, issued July 11, 1972, to Prentice; and U.S. Patent No.
- Spunbond fibers are formed by extruding a molten thermoplastic material as filaments from a plurality of fine, usually circular, capillaries in a spinnerette with the diameter of the extruded filaments then being rapidly reduced, for example, by non-educative or educative fluid-drawing or other well-known spunbonding mechanisms.
- the production of spunbond nonwoven webs is illustrated in patents such as Appel et al., U.S. Patent No. 4,340,563; Matsuki, et al., U.S. Patent No. 3,802,817; Dorschner et al.
- a plurality of support layers 30 also may be used.
- Such materials can include, for example, spunbond/meltblown laminates and spunbond/meltblown/spunbond laminates such as are taught in Brock et al., U.S. Patent No. 4,041,203 which is incorporated herein by reference in its entirety.
- Bonded carded webs are made from staple fibers which are usually purchased in bales. The bales are placed in a picker which separates the fibers. Next the fibers are sent through a combing or carding unit which further breaks apart and aligns the staple fibers in the machine direction so as to form a machine direction-oriented fibrous nonwoven web. Once the web has been formed, it is then bonded by one or more of several bonding methods.
- One bonding method is powder bonding wherein a powdered adhesive is distributed throughout the web and then activated, usually by heating the web and adhesive with hot air.
- Another bonding method is pattern bonding wherein heated calender rolls or ultrasonic bonding equipment is used to bond the fibers together, usually in a localized bond pattern though the web can be bonded across its entire surface if so desired.
- heated calender rolls or ultrasonic bonding equipment is used to bond the fibers together, usually in a localized bond pattern though the web can be bonded across its entire surface if so desired.
- through-air bonding equipment is, for many applications, especially advantageous.
- the process shown in Figure 1 also may be used to create a three layer laminate.
- the only modification to the previously described process is to feed a supply 62 of a second fibrous nonwoven web support layer 30a into the laminating rolls 58 on a side of filled film 10 opposite that of the other fibrous nonwoven web support layer 30.
- one or both of the support layers may be formed directly in-line, as is support layer 30.
- the supply of one or both support layers may be in the form of a pre-formed roll 62, as is support layer 30a.
- the second support layer 30a is fed into the laminating rolls 58 and is laminated to filled film 10 in the same fashion as the first support layer 30.
- filled film 10 and the breathable laminate 32 may be used in a wide variety of applications not the least of which includes personal care absorbent articles such as diapers, training pants, incontinence devices and feminine hygiene products such as sanitary napkins.
- An exemplary article 80 in this case a diaper, is shown in Figure 4 of the drawings.
- most such personal care absorbent articles 80 include a liquid permeable top sheet or liner 82, a back sheet or outercover 84 and an absorbent core 86 disposed between and contained by the top sheet 82 and back sheet 84.
- Articles 80 such as diapers may also include some type of fastening means 88 such as adhesive fastening tapes or mechanical hook and loop type fasteners to maintain the garment in place on the wearer, stretch region 90 in the waist area may also be provided for greater comfort
- Filled film 10 by itself or in other forms such as the film/support layer laminate 32 may be used to form various portions of the article including, but not limited to, stretch region 90, the top and the back sheet 84. If the film or laminate is to be used as the liner 82, it will most likely have to be apertured or otherwise made to be liquid permeable. When using a film/nonwoven laminate as the outercover 84, it is usually advantageous to place the nonwoven side facing out away from the user. In addition, in such embodiments it may be possible to utilize the nonwoven portion of the laminate as the loop portion of the hook and loop combination.
- Other uses for the filled film and breathable film/support layer laminates according to the present invention include, but are not limited to, surgical drapes and gowns, wipers, barrier materials and articles of clothing or portions thereof including such items as workwear and lab coats.
- the sample is then held at zero elongation for one minute. At this time, the sample is elongated until a load is detected. This value is used as the final length to calculate delayed recovery.
- a 3 inch wide by 6 inch long strip of each sample is stretched to 160% of its unbiased length.
- the stretching apparatus was SINTECH Model 1/5 or Model 2/5 from Syntech Division of MTS Systems Corp., Research Triangle Park, NC 27709-4226. This cycle of 60% elongation was repeated two times. The % hysteresis loss was calculated in accordance to Equation III below.
- a 3 inch wide by 6 inch long strip of each sample was stretched with the Syntech equipment described above. Each strip was stretched to 160% the unbiased length and held at the stretched length for one minute.
- the zero load extension value which is the distance that the jaws of the tensile test equipment move at the beginning of the second cycle before a load is registered by the equipment, was obtained from the tensile test equipment. The zero load extension value was then used to calculate %set with Equation V below.
- the sample was held at 60% elongation for one minute. The sample is then returned to zero elongation. Upon this return, the length at which no load is initially detected is used as the final length for the Immediate Set calculation below:
- the sample is then held at zero elongation for one minute. At that time the sample is elongated until a load is detected. The length at which this load is detected is used to calculate Delayed Set:
- Recovery is defined as the difference between immediate set and delayed set. No recovery indicates that the two values were identical.
- WVTR Water Vapor Transmission Data
- the water vapor transmission rate (WVTR) for the sample materials was calculated in accordance with ASTM Standard E96-80. Circular samples measuring three inches in diameter were cut from each of the test materials and a control which was a piece of CELGARD® 2500 film from Hoechst Celanese Corporation of So merville, New Jersey. CELGARD® 2500 film is a microporous polypropylene film. Three samples were prepared for each material. The test dish was a number 60-1 Vapometer pan distributed by Thwing-Albert Instrument Company of Philadelphia, Pennsylvania. One hundred milliliters of water were poured into each Vapometer pan and individual samples of the test materials and control material were placed across the open tops of the individual pans.
- Screw-on flanges were tightened to form a seal along the edges of the pan, leaving the associated test material or control material exposed to the ambient atmosphere over a 6.5 centimeter diameter circle having an exposed area of approximately 33.17 square centimeters.
- the pans were placed in a forced air oven at 100°F (32 °C) for 1 hour to equilibrate.
- the oven was a constant temperature oven with external air circulating through it to prevent water vapor accumulation inside.
- a suitable forced air oven is, for example, a Blue M Power-O-Matic 60 oven distributed by Blue M Electric Company of Blue Island, Illinois.
- Test WVTR (grams weight loss over 24 hours) x 315.5 g / m 2 / 24hrs
- the relative humidity within the oven was not specifically controlled.
- the WVTR for the CELGARD® 2500 control has been defined to be 5000 grams per square meter for 24 hours. Accordingly, the control sample was run with each test and the preliminary test values were corrected to set conditions using equation II below:
- WVTR (Test WVTR / control WVTR) x (5000 g / m 2 / 24hrs.)
- the 20-inch wide 1.5 mils thick film was then stretch-oriented in the machine direction (MD) at a stretch ratio of 5.4X (fast niproll speed divided by the slow nip speed) , all rolls being at room temperature (65- 70°F) .
- Film inlet speed was 30 fpm, outlet speed 162 fp on the MDO, and the stretched film was wound up at about 98 fpm so that the film could be wound up under the lowest tension. This gives an effective stretch ratio of 3.25X from film inlet to the MDO to the winder.
- the film was completely whitened indicating porosity, with a measured WVTR of 1618 g/m 2 /day. The film displayed very good elastic behavior in both the CD and MD direction.
- the film so made was tested for its elastic behavior using tests which are described later following the examples. Testing the samples in the cross direction (CD) , that is, perpendicular to the direction of orientation, average of four specimens tested, resulted in the values listed in Table II below.
- EXXAIRETM XBF-511W A commercially available breathable film, EXXAIRETM XBF-511W, available from Exxon Chemical Company of Houston, TX, was also tested using some of the above test procedures.
- This film essentially inelastic, has an undisclosed amount of filler, it is a uniaxially oriented microporous LLDPE film with WVTR of 3840 g/m 2 /day as measured by the test procedure described above. Cycle testing was done perpendicular to the direction of orientation. The values obtained are listed in Table III below:
- a cast film of the following composition (% by weight) was extruded: 60% SupercoatTM calcium carbonate, as in Example 1
- the extruded 1.5-mil thick film was then stretch- oriented in the machine direction at a stretch ratio of 4X, the preheat rolls, slow and fast niprolls set at 170°F and the annealing roll at 200°F.
- Film inlet speed was 100 fpm, and the stretched film was wound up at about 400 fpm.
- the film was completely whitened, and the measured WVTR was 4590 g/m /day. This film was also tested perpendicular to the direction of orientation. The values obtained are listed in Table IV below.
- this film is made with a metallocene-type of copolymer, it is essentially inelastic because of the higher density of the copolymer.
- the 20-inch wide 1.5 mils thick film was then stretch-oriented in the machine direction (MD) on equipment commonly known in the art as MDO, at a stretch ratio of 5.
- MD machine direction
- MDO machine direction
- OX fast niproll speed divided by the slow niproll speed
- All rolls being at room temperature (about 70°F) , except the last roll which was set at 120°F to anneal the film.
- Film inlet speed was 60 fpm
- outlet speed from the MDO was 300 fpm
- the film was then directed to a winder whose speed was adjusted to allow the film to relax but without any slack or sag before the winder.
- a sheet of necked spunbond (previously stretched to neck to 40% of its original width, ending basis weight of 0.9 ounce per square yard) was then unwound, directed under a spray-head, which was positioned between the MDO and the winder, where the spunbond was sprayed with a molten hotmelt (RextacTM RT-2330, available from Rexene Corp. of Odessa, TX) at adhesive add-on level of 3 grams/m 2 , the so-sprayed spunbond was then directed to niprolls just before the winder where the film and the spunbond were contacted to consummate the lamination, and the laminate was wound up at a speed of 155 fpm.
- the laminate so made had a smooth, cloth-like appearance on one side, it was soft and elastic (extensible with snap- back) in the CD-direction withstanding repeated stretching without delamination.
- the laminate was breathable with WVTR measured at 1374 g/m 2 /day.
- the laminate so made was tested for its elastic behavior using tests described above Testing the sample in the cross direction (CD) , that is, in the direction of its extensibility and perpendicular to the direction of film orientation, average of four specimens tested, the values obtained are listed in Table V below:
- the films of the present invention have high water vapor transmission rate and elasticity that impart a wide variety of functionalities including vapor permeability, liquid impermeability, and comfort fit and stretch. Furthermore, such films can be attached to support layers to form laminates.
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Abstract
The present invention relates to a breathable laminate including a breathable film and a support layer. The film includes a metallocene derived polyethylene elastomeric material and filler that contributes to pore formation. The present invention is also directed to a method of making the breathable laminate that includes stretching the film to form micropores therein, and bonding the film to the support layer.
Description
BREATHABLE LAMINATE OP NONWOVEN AND ELASTOMERIC FILM
INCLUDING METALLOCENE CATALYZED POLYETHYLENE ELASTOMER AND METHOD FOR MAKING THE SAME
FIELD OF INVENTION
The present invention is directed to breathable elastomeric films utilizing metallocene catalyzed polyethylene elastomers. In addition, the present invention is directed to a method of making such films. The invention also includes breathable laminates of the films to one or more substrates, and methods of making the laminates.
BACKGROUND OF THE INVENTION
The present invention is directed to breathable elastomeric films. Such materials have a wide variety of uses, especially in the areas of limited use and disposable items. Films have been traditionally used to provide barrier properties in limited use or disposable items. By limited use or disposable, it is meant that the product and/or component is used only a small number of times or possibly only once before being discarded. Examples of such products include, but are not limited to, surgical and health care related products such as surgical drapes and gowns, disposable work wear such as coveralls and lab coats and personal care absorbent products such as diapers, training pants, incontinence garments, sanitary napkins, bandages, wipes and the like. In personal care absorbent products such as infant diapers and adult incontinence products, films are used as the outer covers with the purpose of preventing body wastes from contaminating the clothing, bedding and other aspects of the surrounding environment of use. In the area of protective apparel including hospital gowns,
films are used to prevent cross exchange of microorganisms between the wearer and the patient.
While these films can be effective barriers, they are not aesthetically pleasing because their surfaces are smooth and either feel slick or tacky. They are also visually flat and "plasticy" thereby making them less desirable in apparel applications and other uses where they are in contact with human skin. It would be more preferable if these items were more cloth-like from both a tactile and visual standpoint. For example, infant diapers that have the feel and appearance of traditional cloth undergarments are perceived as premium products and may, in some cases, overcome the tendency to believe that they need to be covered by outer garments for aesthetic reasons. Garment-like adult incontinence products could improve the self-image of the incontinent individual. In addition, more garment-like isolation gowns would help the hospital environment feel less foreign and threatening to the patient and increase the comfort of the wearer. It is also preferable to have films that can make an outercover material with more elastic give and recovery to provide better fit and comfort.
Lamination of films have been used to create materials which are both impervious and somewhat cloth- like in appearance and texture. The outer covers on disposable diapers are but one example. In this regard, reference may be had to coassigned U.S. Patent No. 4,818,600 dated April 4, 1989 and U.S. Patent No. 4,725,473 dated February 16, 1988. Surgical gowns and drapes are other examples. See, in this regard, coassigned U.S. Patent No. 4,379,102 dated April 5, 1983. A primary purpose of the film in such laminations is to provide barrier properties. There is also a need for such laminates to be breathable so that they have the ability to transmit moisture vapor. Apparel made from laminations of these breathable or microporous films are
more comfortable to wear by reducing the moisture vapor concentration and the consequent skin hydration underneath the apparel item.
There is therefore a need for an elastic breathable film and process that provides a film with both the cloth-like aesthetics and the fit and comfort that are desired.
SUMMARY OF THE INVENTION The present invention relates to a breathable elastomeric film that includes a metallocene catalyzed polyethylene polymeric resin material and at least 30% by weight of a filler having a particle size that contributes to pore formation. Preferably, the polymeric resin material has a density of from about 0.850 to about 0.917 g/cc. Preferably, the film includes from about 45 to about 60% filler by weight of the filled resin .
In one embodiment of the present invention, the resin material is selected from copolymers of ethylene and 1-butene, copolymers of ethylene and 1-hexene, copolymers of ethylene and l-octene and combinations thereof. For certain applications of the present invention, the breathable film has an immediate recovery length that is at least about 50% of its elongation following a stretch cycling that achieved a stretched length of about 160% of the unbiased length. In yet other applications, the film of the present invention may have an immediate recovery length that is at least about 50% its elongation length following a stretch cycling that achieved a stretched length of about 200% of the unbiased length.
The present invention also is directed to a process for preparing a breathable elastomeric film of the present invention, including providing a polymeric resin including a metallocene catalyzed polyethylene polymeric material; adding to the polymeric resin at least 30% by
weight of a filler having a particle size that contributes to pore formation to form a filled resin; forming a film having a first length from the filled resin; and stretching the film to form a microporous film. The process of the invention is applicable to films formed by various processes, i.e., cast or blown films. In one embodiment of the invention, the microporous film is stretched to a second length that is from about 160 to about 400% of the first length. The preferred film of the present invention has a water vapor transmission rate (WVTR) of from about 300 to about 4,500 grams per square meter per 24 hours (measured by ASTM Test E 96-80 with Celgard® 2500 as control) . More preferably, the film of the present invention has a WVTR of from about 1,000 to about 4,000 g/m2 24 hrs.
Such films have a wide variety of uses including, but not limited to, applications in personal care absorbent articles including diapers, training pants, sanitary napkins, incontinence devices, bandages and the like. These same films also may be used in items such as surgical drapes and gowns as well as various articles of clothing either as the entire article or simply as a component thereof .
Having thus described the invention in detail, it should be appreciated that various modifications and changes can be made to the present invention without departing from the spirit and scope of the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic side view of a process for forming a laminate according to the present invention.
Figure 2 is a cross-section side view of a film/nonwoven laminate according to the present invention.
Figure 3 is a partially cut away top plan view of an exemplary personal care absorbent article, in this case a diaper, which may utilize a film made according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to breathable elastomeric films that include metallocene-catalyzed ethylene-based polymers. The term "metallocene-catalyzed ethylene-based polymers" as used herein includes those polymer materials that are produced by the polymerization of at least ethylene using metallocenes or constrained geometry catalysts, a class of organometallic complexes, as catalysts. For example, a common metallocene is ferrocene, a complex with a metal sandwiched between two cyclopentadienyl (Cp) ligandε. Metallocene process catalysts include bis (n-butylcyclopentadienyl) titanium dichloride, bis (n-butylcyclopentadienyl) zirconium dichloride, bis (cyclopentadienyl) scandium chloride, bis(indenyl) zirconium dichloride, bis (methylcyclopentadieny1) titanium dichloride, bis(methylcyclopentadienyl) zirconium dichloride, cobaltocene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl (cyclopentadienyl, -1-flourenyl) zirconium dichloride, molybdocene dichloride, nickelocene, niobocene dichloride, ruthenocene, titanocene dichloride, zirconocene chloride hydride, zirconocene dichloride, among others. A more exhaustive list of such compounds is included in U.S. Patent No. 5,374,696 to Rosen et al. and assigned to the Dow Chemical Company. Such compounds are also discussed in U.S. Patent No. 5,064,802 to Stevens et al. and also assigned to Dow. The metallocene process, and particularly the catalysts and catalyst support systems are the subject of
a number of patents. U.S. Patent No. 4,542,199 to Kaminsky et al. describes a procedure wherein MAO is added to toluene, the metallocene catalyst of the general formula (cyclopentadienyl) 2MeRHal wherein Me is a transition metal, Hal is a halogen and R is cyclopentadienyl or a Cl to C6 alkyl radical or a halogen, is added, and ethylene is then added to form polyethylene. U.S. Patent No. 5,189,192 to LaPointe et al. and assigned to Dow Chemical describes a process for preparing addition polymerization catalysts via metal center oxidation. U.S. Patent No. 5,352,749 to Exxon Chemical Patents, Inc. describes a method for polymerizing monomers in fluidized beds. U.S. Patent No. 5,349,100 describes chiral metallocene compounds and preparation thereof by creation of a chiral center by enantioselective hydride transfer.
Co-catalysts are materials such as methylaluminoxane (MAO) which is the most common, other alkylaluminums and boron containing compounds like tris(pentafluorophenyl) boron, lithium tetrakis(pentafluorophenyl) boron, and dimethylanilinium tetrakis(pentafluorophenyl) boron. Research is continuing on other co-catalyst systems or the possibility of minimizing or even eliminating the alkylaluminums because of handling and product contamination issues. The important point is that the metallocene catalyst be activated or ionized to a cationic form for reaction with the monomer (s) to be polymerized.
The metallocene-catalyzed ethylene-based polymers used in the present invention impart stretch and recovery properties to the film. Preferably, the metallocene catalyzed ethylene-based polymeris selected from copolymers of ethylene and 1-butene, copolymers of ethylene and l-hexene, copolymers of ethylene and 1- octene and combinations thereof. In particular, preferred materials include Affinity™ brand elastomeric
metallocene-derived copolymers of ethylene and 1-octene, both available from Dow Plastics of Freeport, Texas. Particularly preferred materials also include Exact™ brand elastomer metallocene-derived copolymers and terpolymers of ethylene and 1-butene and copolymers of ethylene and 1-hexene, available from Exxon Chemical Company of Houston, TX.
Useful metallocene catalyzed polyethylene elastomers are available in a variety of densities. Preferably, the material used in the present invention has a density of from about 0.850 to about 0.899 g/cc. More preferably, the material used in the present invention has a density of from about 0.860 to about 0.899 g/cc, even more preferably from about 0.870 to about 0.899 g/cc. The melt index range of some useful materials is between about 1 to about 15 dg/min and advantageously may be in the range of from about 5 to about 10 dg/min. Specific examples of suitable materials can be found in U.S. Patent Nos. 5,472,775 and 5,272,236, both assigned to the Dow Chemical Company. The entire content of these patents is incorporated herein by reference.
In addition to the polymeric material, the film layer also includes a filler which enables development of micropores during orientation of the film. As used herein, a "filler" is meant to include particulates and other forms of materials which can be added to the polymer and which will not chemically interfere with or adversely affect the extruded film but is able to be uniformly dispersed throughout the film. Generally, the fillers will be in particulate form and usually will have somewhat of a spherical shape with average particle sizes in the range of about 0.5 to about 8 microns . In addition, the film will usually contain at least 30 percent (%) , preferably about 40 to about 70 percent, filler based upon the total weight of the film layer. More preferably, from about 45 to about 60 percent of
filler is present in the film. Both organic and inorganic fillers are contemplated to be within the scope of the present invention provided that they do not interfere with the film formation process, the breathability of the resultant film or its ability to bond to another layer such as a fibrous polyolefin nonwoven web.
Examples of fillers include calcium carbonate (CaC03) , various kinds of clay, silica (Si02) , alumina, barium sulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide, zeolites, aluminum sulfate, cellulose-type powders, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivative, polymer particles, chitin and chitin derivatives. The filler particles may optionally be coated with a fatty acid, such as stearic acid, and behenic acid which may facilitate the free flow of the particles (in bulk) and their ease of dispersion into the polymer matrix.
Generally, it has been possible to produce films with a water vapor transmission rate (WVTR) of at least about 300 grams per square meter per 24 hours, measured by the ASTM E-96-80 WVTR test. In general, factors that affect the amount of breathability include the amount of filler, the film stretching conditions (e.g. , whether it is performed at ambient or elevated temperatures) , orientation ratio, and film thickness. Preferably, the WVTR of the film of the present invention that may be used as a component in a limited-use or disposable item is from about 300 to about 4,500, more preferably from about 1,000 to about 4,000 g/m2/24 hrs. In addition, the preferred films of the present invention are also elastic.
The term "elastic" is used herein to mean any material which, upon application of a biasing force, is stretchable, that is, elongatable, to a stretched, biased length which is at least about 150 percent of its relaxed unbiased length, and which will recover at least 50 percent of its elongation upon release of the stretching, elongating force. A hypothetical example would be a one (1) inch sample of a material which is elongatable to at least 1.50 inches and which, upon being elongated to 1.50 inches and released, will recover to a length of not more than 1.25 inches. Many elastic materials may be stretched by much more than 50 percent of their relaxed length, for example, 100 percent or more, and many of these will recover to substantially their original relaxed length, for example, to within 105 percent of their original relaxed length, upon release of the stretching force.
As used herein, the term "nonelastic" refers to any material which does not fall within the definition of "elastic," above.
These properties can be obtained by first preparing a polymeric resin of a metallocene catalyzed ethylene- based polymer filling the resin with filler, extruding a film from the filled resin and thereafter stretching or orienting the filled film in at least one direction, usually, the machine direction. As explained in greater detail below, the resultant film is microporous and has increased strength properties in the orientation direction. Processes for forming filled films and orienting them are well-known to those skilled in the art. Figure 1 illustrates a general approach in orienting a filled film 10, such as one of the present invention. Referring to Figure 1, filled film 10 is unwound and directed to a film stretching unit 44 such as a machine direction orienter, which is a commercially available device from
vendors such as the Marshall and Williams Company of Providence, Rhode Island. Such an apparatus 44 has a plurality of stretching rollers 46 moving at progressively faster speeds relative to the pair disposed before it. These rollers 46 apply an amount stress and thereby progressively stretch filled film 10 to a stretch length in the machine direction of the film which is the direction of travel of filled film 10 through the process as shown in Figure 1. The stretch rollers 46 may be heated for better processing. Preferably, unit 44 also include rollers (not shown) upstream and/or downstream from the stretch rollers 46 that can be used to preheat the film 10 before orienting and/or anneal (or cool) it after stretching. At the stretched length, a plurality of micropores form in the film 10. Preferably, the stretched length is from about 160 to about 500%, more preferably from about 200 to about 400% of the unbiased length of the film prior to stretching. If desired, film 10 is directed out of apparatus 44 so that the stress is removed to allow the stretched film 10 to relax.
Oftentimes it may be desirable to laminate filled film 10 to one or more substrates or support layers 20 such as is shown in Figure 2. Lamination of film may enhance the strength and thus durability of the film. If desired, filled film 10 may be attached to one or more support layers 30 to form a laminate 32. Referring again to Figure 1, a conventional fibrous nonwoven web forming apparatus 48, such as a pair of spunbond machines, is used to form the support layer 30. The long, essentially continuous fibers 50 are deposited onto a forming wire 52 as an unbonded web 54 and the unbonded web 54 is then sent through a pair of bonding rolls 56 to bond the fibers together and increase the tear strength of the resultant web support layer 30. One or both of the rolls are often heated to aid in bonding. Typically, one of
- li ¬
the rolls 56 is also patterned so as to impart a discrete bond pattern with a prescribed bond surface area to the web 30. The other roll is usually a smooth anvil roll but this roll also may be patterned if so desired. Once filled film 10 has been sufficiently stretched and the support layer 30 has been formed, the two layers are brought together and laminated to one another using a pair of laminating rolls or other means 58. As with the bonding rolls 56, the laminating rolls 58 may be heated. Also, at least one of the rolls may be patterned to create a discrete bond pattern with a prescribed bond surface area for the resultant laminate 32. Generally, the maximum bond point surface area for a given area of surface on one side of the laminate 32 will not exceed about 50 percent of the total surface area. There are a number of discrete bond patterns which may be used. See, for example, Brock et al., U.S. Patent No. 4,041,203 which is incorporated herein by reference in its entirety. Once the laminate 32 exists the laminating rolls 58, it may be wound up into a roll 60 for subsequent processing. Alternatively, the laminate 32 may continue in-line for further processing or conversion.
While the support layers 30 and film 10 shown in Figure 1 were bonded together through thermal point bonding, other bonding means can also be used. Suitable alternatives include, for example, adhesive bonding and the use of tackifiers. In adhesive bonding, an adhesive such as a hot melt adhesive is applied between the film and fiber to bind the film and fiber together. The adhesive can be applied by, for example, melt spraying, printing or meltblowing. Various types of adhesives are available, including those produced from amorphous polyalphaolefins, ethylene vinyl acetate-based hot melts, and Kraton® brand adhesives available from Shell Chemical
of Houston, TX and Rextac™ Brand Adhesives from Rexene of Odessa, TX.
When the film and support layer(s) is bonded with tackifiers, the tackifier may be incorporated into the film itself. The tackifier essentially serves to increase adhesion between the film and fiber layers. The film and fiber laminate may subsequently be thermally point-bonded, although generally very little heat is required since the tackifier tends to increase the pressure sensitivity of the film and a bond somewhat like and adhesive bond can be formed. Examples of useful tackifers include Wingtack™ 95, available from Goodyear Tire & Rubber Co. of Akron, OH, and Escorez™ 5300, available from Exxon Chemical Company of Houston, TX. The direction of elasticity in the laminate may be tailored by the state of the film, i.e. , whether it is relaxed or stretched, during the bonding with the support layer, as well as the physical property of the support layer material. For example, if the film is relaxed prior to bonding and the support layer is extensible in the cross-machine direction ("CD"), then a laminate with both CD and machine-direction ("MD") stretch can be produced. Additionally, if the film is bonded to a support layer non-extensible in the CD direction while in a stretched state, then a laminate with a MD stretch can be produced.
The support layers 30 as shown in Figure 2 are fibrous nonwoven webs. The manufacture of such fibrous nonwoven webs is known. Such fibrous nonwoven webs can add additional properties to filled film 10, such as a more soft, cloth-like feel. This is particularly advantageous when filled film 10 is being used as a barrier layer to liquids in such applications as outer covers for personal care absorbent articles and as barrier materials for hospital, surgical, and clean room applications such as, for example, surgical drapes, gowns
and other forms of apparel. Attachment of the support layers 30 to the filled film 10 may be by the use of a separate adhesive such as hot-melt and solvent based adhesives or through the use of heat and/or pressure (also known as thermal bonding) as with heated bonding rolls.
The support layer in a laminate containing the film layer of the present invention can be necked polypropylene spunbond, crimped polypropylene spunbond, bonded carded webs, elastomeric spunbond or meltblown fabrics produced from elastomeric resins. A particularly advantageous support layer is a fibrous nonwoven web. Such webs may be formed from a number of processes including, but not limited to, spunbonding, meltblowing and bonded carded web processes. Meltblown fibers are formed by extruding molten thermoplastic material through a plurality of fine, usually circular, capillaries as molten threads or filaments into a high velocity usually heated gas stream such as air, which attenuates the filaments of molten thermoplastic material to reduce their diameters. Thereafter, the meltblown fibers are carried by the high velocity usually heated gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. The meltblown process is well-known and is described in various patents and publications, including NRL Report 4364, "Manufacture of Super-Fine Organic Fibers" by B. A. Wendt, E. L. Boone and D. D. Fluharty; NRL Report 5265, "An Improved Device For The Formation of Super-Fine Thermoplastic Fibers" by K. D. Lawrence, R. T. Lukas, J. A. Young; U.S. Patent No. 3,676,242, issued July 11, 1972, to Prentice; and U.S. Patent No. 3,849,241, issued November 19, 1974, to Buntin, et al. The foregoing references are incorporated herein by reference in their entirety. Spunbond fibers are formed by extruding a molten thermoplastic material as filaments from a plurality of
fine, usually circular, capillaries in a spinnerette with the diameter of the extruded filaments then being rapidly reduced, for example, by non-educative or educative fluid-drawing or other well-known spunbonding mechanisms. The production of spunbond nonwoven webs is illustrated in patents such as Appel et al., U.S. Patent No. 4,340,563; Matsuki, et al., U.S. Patent No. 3,802,817; Dorschner et al. , U.S. Patent No. 3,692,618; Kinney, U.S. Patent Nos. 3,338,992 and 3,341,394; Levy, U.S. Patent No. 3,276,944; Peterson, U.S. Patent No. 3,502,538;
Hartman, U.S. Patent No. 3,502,763; Dobo et al. , U.S. Patent No. 3,542,615; and Harmon, Canadian Patent No. 803,714. All of the foregoing references are incorporated herein by reference in their entirety. A plurality of support layers 30 also may be used.
Examples of such materials can include, for example, spunbond/meltblown laminates and spunbond/meltblown/spunbond laminates such as are taught in Brock et al., U.S. Patent No. 4,041,203 which is incorporated herein by reference in its entirety.
Bonded carded webs are made from staple fibers which are usually purchased in bales. The bales are placed in a picker which separates the fibers. Next the fibers are sent through a combing or carding unit which further breaks apart and aligns the staple fibers in the machine direction so as to form a machine direction-oriented fibrous nonwoven web. Once the web has been formed, it is then bonded by one or more of several bonding methods. One bonding method is powder bonding wherein a powdered adhesive is distributed throughout the web and then activated, usually by heating the web and adhesive with hot air. Another bonding method is pattern bonding wherein heated calender rolls or ultrasonic bonding equipment is used to bond the fibers together, usually in a localized bond pattern though the web can be bonded across its entire surface if so desired. When using
bico ponent staple fibers, through-air bonding equipment is, for many applications, especially advantageous.
The process shown in Figure 1 also may be used to create a three layer laminate. The only modification to the previously described process is to feed a supply 62 of a second fibrous nonwoven web support layer 30a into the laminating rolls 58 on a side of filled film 10 opposite that of the other fibrous nonwoven web support layer 30. As shown in Figure 1, one or both of the support layers may be formed directly in-line, as is support layer 30. Alternatively, the supply of one or both support layers may be in the form of a pre-formed roll 62, as is support layer 30a. In either event, the second support layer 30a is fed into the laminating rolls 58 and is laminated to filled film 10 in the same fashion as the first support layer 30.
As has been stated previously, filled film 10 and the breathable laminate 32 may be used in a wide variety of applications not the least of which includes personal care absorbent articles such as diapers, training pants, incontinence devices and feminine hygiene products such as sanitary napkins. An exemplary article 80, in this case a diaper, is shown in Figure 4 of the drawings. Referring to Figure 4, most such personal care absorbent articles 80 include a liquid permeable top sheet or liner 82, a back sheet or outercover 84 and an absorbent core 86 disposed between and contained by the top sheet 82 and back sheet 84. Articles 80 such as diapers may also include some type of fastening means 88 such as adhesive fastening tapes or mechanical hook and loop type fasteners to maintain the garment in place on the wearer, stretch region 90 in the waist area may also be provided for greater comfort
Filled film 10 by itself or in other forms such as the film/support layer laminate 32 may be used to form various portions of the article including, but not
limited to, stretch region 90, the top and the back sheet 84. If the film or laminate is to be used as the liner 82, it will most likely have to be apertured or otherwise made to be liquid permeable. When using a film/nonwoven laminate as the outercover 84, it is usually advantageous to place the nonwoven side facing out away from the user. In addition, in such embodiments it may be possible to utilize the nonwoven portion of the laminate as the loop portion of the hook and loop combination. Other uses for the filled film and breathable film/support layer laminates according to the present invention include, but are not limited to, surgical drapes and gowns, wipers, barrier materials and articles of clothing or portions thereof including such items as workwear and lab coats.
The advantages and other characteristics of the present invention are best illustrated by the following examples :
EXAMPLES
For Examples 1 and 2 and comparative Examples 1 and 2 , the best procedures described below were used to evaluate the films and laminate.
Cvcle Test
A 3" wide by 6" long strip of the sample material was pulled to an elongated length of 160% and 200% of the original grip distance of 3 inches. The sample is elongated at a rate of 20 in/min for two cycles. Upon return after the second cycle, the elongation at which no load is first detected is recorded. This value is used as the final length in the immediate recovery calculation below.
Maximum Length - Final Length
(I) immediate Recovery = — — : ; ; τ . . ,-■ x 100% v Maximum Length - Initial Length
The sample is then held at zero elongation for one minute. At this time, the sample is elongated until a load is detected. This value is used as the final length to calculate delayed recovery.
Maximum Length - Final Length ^ ' Maximum Length - Initial Length
Hysteresis Loss
A 3 inch wide by 6 inch long strip of each sample is stretched to 160% of its unbiased length. The stretching apparatus was SINTECH Model 1/5 or Model 2/5 from Syntech Division of MTS Systems Corp., Research Triangle Park, NC 27709-4226. This cycle of 60% elongation was repeated two times. The % hysteresis loss was calculated in accordance to Equation III below.
area under loading stress / strain curve - area under unloading stress / strain curve \
(πi) Hysteresis = 100% I ; ) area under loading curve Tensile Test
A 3" wide by 6" long strip of each sample was elongated at a rate of 20 in/min until it broke. Peak load and elongation at peak load were acquired.
Permanent Elongation
An evaluation was performed to determine the amount of permanent elongation of the film and comparative materials.
A 3 inch wide by 6 inch long strip of each sample was stretched with the Syntech equipment described above. Each strip was stretched to 160% the unbiased length and held at the stretched length for one minute. The zero
load extension value, which is the distance that the jaws of the tensile test equipment move at the beginning of the second cycle before a load is registered by the equipment, was obtained from the tensile test equipment. The zero load extension value was then used to calculate %set with Equation V below.
zero load extension after one cycle
(IV) % set = r-— : ; — x l00% initial sample gauge length
After the second cycle, the sample was held at 60% elongation for one minute. The sample is then returned to zero elongation. Upon this return, the length at which no load is initially detected is used as the final length for the Immediate Set calculation below:
Final Length - Initial Length (V) Immediate Set = — — — -
Final Length
The sample is then held at zero elongation for one minute. At that time the sample is elongated until a load is detected. The length at which this load is detected is used to calculate Delayed Set:
Final Length - Initial Length (VI ) Delayed Set = Final Length
Recovery is defined as the difference between immediate set and delayed set. No recovery indicates that the two values were identical.
Water Vapor Transmission Data The water vapor transmission rate (WVTR) for the sample materials was calculated in accordance with ASTM Standard E96-80. Circular samples measuring three inches in diameter were cut from each of the test materials and
a control which was a piece of CELGARD® 2500 film from Hoechst Celanese Corporation of So merville, New Jersey. CELGARD® 2500 film is a microporous polypropylene film. Three samples were prepared for each material. The test dish was a number 60-1 Vapometer pan distributed by Thwing-Albert Instrument Company of Philadelphia, Pennsylvania. One hundred milliliters of water were poured into each Vapometer pan and individual samples of the test materials and control material were placed across the open tops of the individual pans. Screw-on flanges were tightened to form a seal along the edges of the pan, leaving the associated test material or control material exposed to the ambient atmosphere over a 6.5 centimeter diameter circle having an exposed area of approximately 33.17 square centimeters. The pans were placed in a forced air oven at 100°F (32 °C) for 1 hour to equilibrate. The oven was a constant temperature oven with external air circulating through it to prevent water vapor accumulation inside. A suitable forced air oven is, for example, a Blue M Power-O-Matic 60 oven distributed by Blue M Electric Company of Blue Island, Illinois. Upon completion of the equilibration, the pans were removed from the oven, weighed and immediately returned to the oven. After 24 hours, the pans were removed from the oven and weighed again. The preliminary test water vapor transmission rate values were calculated with Equation (I) below:
( I ) Test WVTR = (grams weight loss over 24 hours) x 315.5 g / m2 / 24hrs
The relative humidity within the oven was not specifically controlled.
Under predetermined set conditions of 100°F (32 °C) and ambient relative humidity, the WVTR for the CELGARD® 2500 control has been defined to be 5000 grams per square meter for 24 hours. Accordingly, the control sample was
run with each test and the preliminary test values were corrected to set conditions using equation II below:
( II ) WVTR = (Test WVTR / control WVTR) x (5000 g / m2 / 24hrs.)
EXAMPLE 1
A blown film of the composition (% by weight) listed in Table I below was extruded:
Table I
55% Supercoat™ calcium carbonate,
average particle size of 1 micron, available from English China Clay Company of America, Sylacauga, AL,
45% Affinity™ 8200 resin (0.870 g/cc, 5 MI),
an (ethylene 1-octene) copolymer made with a single-site catalyst, available from Dow Chemical Co. of Midland, MI, and
600± pp of an antioxidant package.
The 20-inch wide 1.5 mils thick film was then stretch-oriented in the machine direction (MD) at a stretch ratio of 5.4X (fast niproll speed divided by the slow nip speed) , all rolls being at room temperature (65- 70°F) . Film inlet speed was 30 fpm, outlet speed 162 fp on the MDO, and the stretched film was wound up at about 98 fpm so that the film could be wound up under the lowest tension. This gives an effective stretch ratio of 3.25X from film inlet to the MDO to the winder. The film was completely whitened indicating porosity, with a measured WVTR of 1618 g/m2/day. The film displayed very good elastic behavior in both the CD and MD direction.
The film so made was tested for its elastic behavior using tests which are described later following the examples. Testing the samples in the cross direction (CD) , that is, perpendicular to the direction of orientation, average of four specimens tested, resulted in the values listed in Table II below.
Table II
COMPARATIVE EXAMPLE 1
A commercially available breathable film, EXXAIRE™ XBF-511W, available from Exxon Chemical Company of Houston, TX, was also tested using some of the above test procedures. This film, essentially inelastic, has an undisclosed amount of filler, it is a uniaxially oriented microporous LLDPE film with WVTR of 3840 g/m2/day as measured by the test procedure described above. Cycle testing was done perpendicular to the direction of orientation. The values obtained are listed in Table III below:
Table III
Pronertv at 60% elongation immediate recovery 39.9% delayed recovery 73.5 first cycle hysteresis loss 86.7% 2nd cycle hysteresis loss 67.9% peak (breaking) tensile load 975 grams peak (breaking) elongation 245%
COMPARATIVE EXAMPLE 2
A cast film of the following composition (% by weight) was extruded:
60% Supercoat™ calcium carbonate, as in Example 1
40% Exceed® 357C80, a metallocene-catalyzed (ethylene 1-butene) copolymer (0.917 g/cc, 3.4 MI) available from Exxon Chemical Co. of Houston, TX, and
lOOO± ppm of an antioxidant package.
The extruded 1.5-mil thick film was then stretch- oriented in the machine direction at a stretch ratio of 4X, the preheat rolls, slow and fast niprolls set at 170°F and the annealing roll at 200°F. Film inlet speed was 100 fpm, and the stretched film was wound up at about 400 fpm. The film was completely whitened, and the measured WVTR was 4590 g/m /day. This film was also tested perpendicular to the direction of orientation. The values obtained are listed in Table IV below.
Table IV
Pronertv at 60% elongation immediate recovery 51.6% delayed recovery 70.4% first cycle hysteresis loss 79.25% 2M cycle hysteresis loss 57.4% peak (breaking) tensile load 394.0 grams peak (breaking) elongation 269%
Although this film is made with a metallocene-type of copolymer, it is essentially inelastic because of the higher density of the copolymer.
EXAMPLE 2
A blown film of the following composition (% by weight) was extruded:
55% Supercoat™ calcium carbonate, average particle size of 1 micron, available from English China Clay Company of America, Sylacauga, AL,
45% Affinity™ 8200 resin (0.870 g/cc, 5 MI), an (ethylene 1-octene) copolymer made with a single- site catalyst, available from Dow Chemical Co. of Midland, MI, and
600± ppm of an antioxidant package.
The 20-inch wide 1.5 mils thick film was then stretch-oriented in the machine direction (MD) on equipment commonly known in the art as MDO, at a stretch ratio of 5. OX (fast niproll speed divided by the slow niproll speed) , all rolls being at room temperature (about 70°F) , except the last roll which was set at 120°F to anneal the film. Film inlet speed was 60 fpm, outlet speed from the MDO was 300 fpm, and the film was then directed to a winder whose speed was adjusted to allow the film to relax but without any slack or sag before the winder. A sheet of necked spunbond (previously stretched to neck to 40% of its original width, ending basis weight of 0.9 ounce per square yard) was then unwound, directed under a spray-head, which was positioned between the MDO and the winder, where the spunbond was sprayed with a molten hotmelt (Rextac™ RT-2330, available from Rexene Corp. of Odessa, TX) at adhesive add-on level of 3 grams/m2 , the so-sprayed spunbond was then directed to niprolls just before the winder where the film and the spunbond were contacted to consummate the lamination, and the laminate was wound up at a speed of 155 fpm. The laminate so made had a smooth, cloth-like appearance on one side, it was soft and elastic (extensible with snap- back) in the CD-direction withstanding repeated stretching without delamination. The laminate was breathable with WVTR measured at 1374 g/m2/day.
The laminate so made was tested for its elastic behavior using tests described above Testing the sample in the cross direction (CD) , that is, in the direction of
its extensibility and perpendicular to the direction of film orientation, average of four specimens tested, the values obtained are listed in Table V below:
Table V
Therefore, the films of the present invention have high water vapor transmission rate and elasticity that impart a wide variety of functionalities including vapor permeability, liquid impermeability, and comfort fit and stretch. Furthermore, such films can be attached to support layers to form laminates.
Of course, it should be understood that a wide range of changes and modifications can be made to the embodiments described above. It is therefore intended that the foregoing description illustrates rather than limits this invention, and that it is the following claims, including all equivalents, which define this invention.
Claims
1. A breathable laminate comprising: an elastomeric film including a metallocene catalyzed ethylene-based polymer having a density of from about 0.850 to 0.899 g/cc and at least 30% by weight of a filler having a particle size that contributes to pore formation; and at least one support layer bonded to said film layer.
2. The laminate of claim 1 wherein said metallocene catalyzed ethylene-based polymer is selected from copolymers of ethylene and butylene, copolymers of ethylene and hexene, copolymers of ethylene and octene and combinations thereof.
3. The laminate of claim 1 wherein said film has an unbiased length, a stretched length of about 160% said unbiased length and an immediate recovery length; said immediate recovery length is at least about 55% said unbiased length following a stretch cycling that achieved said stretched length.
4. The laminate of claim 1 wherein said film has an unbiased length, a stretched length of about 200% said unbiased length and an immediate recovery length; said immediate recovery length is at least about 50% said unbiased length following a stretch cycling that achieved said stretched length.
5. The laminate of claim 1 wherein said density is from about 0.860 to about 0.899 g/cc.
6. The laminate of claim 1 wherein said density is from about 0.870 to about 0.899 g/cc.
7. The laminate of claim 1 wherein said filler is present in an amount of from about 40 to about 70% by weight of said film.
8. The laminate of claim 1 wherein said filler is present in an amount of from about 45 to about 60% by weight of said film.
9. The laminate of claim 1 wherein said filler is calcium carbonate.
10. The laminate of claim 1 wherein said filler particle size is from about 0.5 to about 8 microns.
11. The laminate of claim 1 wherein said film has a water vapor transmission rate of at least about 300 g/m2- 24 hr.
12. The laminate of claim 1 wherein said film has a water vapor transmission rate of from about 1,000 to about 4,500 g/m2-/24 hr.
13. A personal care absorbent article comprising a liquid permeable top sheet and a back sheet with an absorbent core disposed therebetween, at least one of said back sheet of said top sheet including the laminate of claim 1.
14. The article of claim 13 further including at least one stretch region peripherally disposed on said article, at least one of said back sheet, said top sheet and said stretch region including the laminate of claim 1.
15. The article of claim 13 wherein said article is a diaper.
16. The article of claim 13 wherein said article is a training pant.
17. The article of claim 13 wherein said article is a sanitary napkin.
18. The article of claim 13 wherein said article is a incontinence device.
19. A process for preparing a breathable laminate comprising: providing a polymeric resin including a metallocene catalyzed ethylene-based polymer having a density of from about 0.850 to about 0.899 g/cc; adding to said polymeric resin at least 30% by weight of a filler having a particle size that contributes to pore formation to form a filled resin; casting a film from said filled resin, said film having a first length; stretching said film to form a microporous film having a second length; and bonding at least one support layer to said film to form a laminate.
20. The process of claim 19 wherein said ethylene-based polymer material is selected from copolymers of ethylene and butylene, copolymers of ethylene and hexene, copolymers of ethylene and octene and combinations thereof.
21. The process of claim 19 wherein said density is from about 0.860 to about 0.899 g/cc.
22. The process of claim 19 wherein said density is from about 0.870 to about 0.899 g/cc.
23. The process of claim 19 wherein said film is stretched in a machine direction.
2 . The process of claim 19 wherein said second length is from about 160% to about 450% said first length.
25. The process of claim 19 wherein said filler is present in an amount of from about 40 to about 70% by weight of said film.
26. The process of claim 19 wherein said filler is present in an amount of from about 45 to about 60% by weight of the film.
27. The process of claim 19 wherein said filler is calcium carbonate.
28. The process of claim 19 wherein said filler particle size is from about 0.5 to about 8 microns.
29. The process of claim 19 wherein said microporous film has a water vapor transmission rate of at least about 1000 g/m2-24 hrs.
30. The process of claim 19 wherein said film has a water vapor transmission rate of from about 300 to about 4,500 g/m2-24 hr.
31. A breathable laminate prepared by the process of claim 19.
32. A medical garment comprising a breathable laminate including a breathable elastomeric film and a support layer, said film comprising:
a metallocene catalyzed ethylene-based polymer having a density of from about 0.850 to about 0.899 g/cc at least 30% by weight of a filler having a particle size that contributes to pore formation.
33. The medical garment of claim 32 wherein the support layer is bonded to one surface of said elastomeric film.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AU55292/98A AU5529298A (en) | 1996-12-27 | 1997-12-15 | Breathable laminate of nonwoven and elastomeric film including metallocene catalyzed polyethylene elastomer and method for making the same |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US77485296A | 1996-12-27 | 1996-12-27 | |
US08/774,852 | 1996-12-27 | ||
US85465897A | 1997-05-12 | 1997-05-12 | |
US08/854,658 | 1997-05-12 |
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WO1998029246A1 true WO1998029246A1 (en) | 1998-07-09 |
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ID=27118964
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PCT/US1997/023264 WO1998029246A1 (en) | 1996-12-27 | 1997-12-15 | Breathable laminate of nonwoven and elastomeric film including metallocene catalyzed polyethylene elastomer and method for making the same |
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WO1999033498A2 (en) * | 1997-12-31 | 1999-07-08 | Kimberly-Clark Worldwide, Inc. | Adhesive for use in disposable absorbent products |
WO2000020208A1 (en) * | 1998-10-02 | 2000-04-13 | Kimberly-Clark Worldwide, Inc. | Nonwoven web and film laminate with improved tear strength and method of making the same |
US6063981A (en) * | 1998-01-20 | 2000-05-16 | Kimberly-Clark Worldwide, Inc. | Adhesive for use in disaposable absorbent products |
EP1053728A1 (en) * | 1998-12-02 | 2000-11-22 | Nichiban Company Limited | Pressure-sensitive adhesive tape for pasting on skin and base material for use therein |
SG79305A1 (en) * | 1999-04-13 | 2001-03-20 | Uni Charm Corp | Disposable diaper |
US6277479B1 (en) | 1997-12-19 | 2001-08-21 | Kimberly-Clark Worldwide, Inc. | Microporous films having zoned breathability |
US6350399B1 (en) | 1999-09-14 | 2002-02-26 | Kimberly-Clark Worldwide, Inc. | Method of forming a treated fiber and a treated fiber formed therefrom |
WO2002034511A1 (en) * | 2000-10-27 | 2002-05-02 | Kimberly-Clark Worldwide, Inc. | Biaxial stretch, breathable laminate with cloth-like aesthetics and method for making same |
WO2002034512A1 (en) * | 2000-10-27 | 2002-05-02 | Kimberly-Clark Worldwide, Inc. | Elastomeric, breathable laminate with enhanced breathability upon extension |
US6383431B1 (en) | 1997-04-04 | 2002-05-07 | The Procter & Gamble Company | Method of modifying a nonwoven fibrous web for use as component of a disposable absorbent article |
US6410129B2 (en) | 1999-09-17 | 2002-06-25 | The Procter & Gamble Company | Low stress relaxation elastomeric materials |
US6706942B1 (en) | 2003-05-08 | 2004-03-16 | The Procter & Gamble Company | Molded or extruded articles comprising polyhydroxyalkanoate copolymer compositions having short annealing cycle times |
US6808795B2 (en) | 2001-03-27 | 2004-10-26 | The Procter & Gamble Company | Polyhydroxyalkanoate copolymer and polylactic acid polymer compositions for laminates and films |
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US6617016B2 (en) | 1999-09-17 | 2003-09-09 | The Procter & Gamble Company | Low stress relaxation elastomeric materials |
US6410129B2 (en) | 1999-09-17 | 2002-06-25 | The Procter & Gamble Company | Low stress relaxation elastomeric materials |
KR100837017B1 (en) * | 2000-10-27 | 2008-06-10 | 킴벌리-클라크 월드와이드, 인크. | Elastomeric, Breathable Laminate with Enhanced Breathability upon Extension |
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KR100848750B1 (en) * | 2000-10-27 | 2008-07-25 | 킴벌리-클라크 월드와이드, 인크. | Biaxial Elastic Stretch, Breathable Laminate, and Laminate Fluid Barrier with Cloth-like Aesthetics |
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JP2004530571A (en) * | 2000-10-27 | 2004-10-07 | キンバリー クラーク ワールドワイド インコーポレイテッド | Biaxially stretchable breathable laminate having a cloth-like appearance and method for producing the same |
US6808795B2 (en) | 2001-03-27 | 2004-10-26 | The Procter & Gamble Company | Polyhydroxyalkanoate copolymer and polylactic acid polymer compositions for laminates and films |
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