WO2015010208A1 - Breathable laminated material - Google Patents

Breathable laminated material Download PDF

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Publication number
WO2015010208A1
WO2015010208A1 PCT/CA2014/050698 CA2014050698W WO2015010208A1 WO 2015010208 A1 WO2015010208 A1 WO 2015010208A1 CA 2014050698 W CA2014050698 W CA 2014050698W WO 2015010208 A1 WO2015010208 A1 WO 2015010208A1
Authority
WO
WIPO (PCT)
Prior art keywords
laminated material
material according
microporous film
adhesive
water vapor
Prior art date
Application number
PCT/CA2014/050698
Other languages
French (fr)
Inventor
Robert Milne
Original Assignee
Ibco Srl
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ibco Srl filed Critical Ibco Srl
Publication of WO2015010208A1 publication Critical patent/WO2015010208A1/en

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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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • 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
    • A61L15/42—Use of materials characterised by their function or physical properties
    • A61L15/425—Porous materials, e.g. foams or sponges
    • 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
    • A61L15/42—Use of materials characterised by their function or physical properties
    • A61L15/58—Adhesives
    • 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
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/582—Tearability
    • B32B2307/5825—Tear resistant
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • 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
    • B32B2419/00—Buildings or parts thereof
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/625—Sheets or foils allowing passage of water vapor but impervious to liquid water; house wraps
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
    • E04D12/002—Sheets of flexible material, e.g. roofing tile underlay

Definitions

  • the invention pertains to materials that are permeable to water vapor and impermeable to water and air for use in applications where moisture transport is desired, but a gas or water barrier is required.
  • applications include building housewrap, building roofing membranes, building flashings, breathable apparel, and surgical barriers.
  • Moisture transport membranes are used where it is desirable to transmit moisture but avoid gross air or liquid transport.
  • such membranes when used as housewrap, such membranes insulate a house from air drafts and protect wooden and drywall substructure from liquid water.
  • Water vapor transport is desired to allow interior humidity to escape and protect the interior drywall, wood and insulation from water saturation.
  • a high water transport rate allows interior moisture or equilibrated exterior moisture to leave the structure or "breath" so that it is not trapped in the wood, drywall and insulation, causing decay and mold buildup.
  • the breathable membrane must also serve as weather protection against liquid water and air drafts.
  • Tyvek flash- spun high density polyethylene HDPE
  • microporous membranes microporous membranes
  • PP nonwoven polypropylene
  • perforated polymer films Tyvek flash-spun nonwoven has lightweight strength, high vapor transport and liquid hydrohead in one layer. Disadvantages of the product include high cost, tear propagation once a tear is introduced, and loss of
  • Microporous membranes are cast or extruded films with inorganic filler and laminated thermally or extrusion laminated on substrates, and subjected to stretching.
  • Perforated polymer film housewraps have microholes and offer low perm rating with high airflow.
  • a disadvantage is that deterioration of the membrane results in perforation distortions and may allow water to penetrate.
  • Membranes are selected based on perm rating, mechanical strength (tear strength, including wet tear strength), air penetration resistance and hydrostatic head. Both woven and non-woven types of housewraps are commonly used in the construction of buildings. Non- woven housewraps typically have higher water vapor permeabilities than woven housewraps. The strength properties of woven housewraps are typically much higher than those of non- woven housewraps. Some housewraps are translucent, which assists in locating the studs and window and door openings. Non- woven based housewraps are not perforated because the process used in manufacturing the housewrap results in a structure that inherently allows water vapor to pass through the wrap. Most woven housewrap are microperforated, having tiny holes incorporated in the woven coated product.
  • the invention provides a water- vapor permeable, water-impermeable and air-impermeable laminated material, comprising a fabric layer, a microporous film and an adhesive coating bonding the fabric layer and film together.
  • the breathability (water vapor transmission rate) of the laminated sheet material is controlled by the fabric layer openings, the breathability of the microporous film, and the adhesive coat weight applied during manufacture.
  • a water vapor- permeable, air-impermeable and water-impermeable laminated material having a selected water vapor transmission rate.
  • the laminated material comprises a microporous film comprising a resin and a filler, a woven or non-woven fabric layer bonded to the microporous film, and an adhesive bonding the microporous film and the fabric layer together.
  • the selected water vapor transmission rate of the laminated material is determined by a combination of the openings in the fabric layer, the water vapor transmission rate of the microporous film, and the coating weight of the adhesive.
  • a method of making a water vapor-permeable, air-impermeable and water- impermeable laminated material as aforesaid Values are selected for the openings in the fabric layer, the water vapor transmission rate of the microporous film, and the coating weight of the adhesive, the values being selected to provide the selected water vapor transmission rate of the laminated material.
  • a coating of adhesive is applied to one or both of the microporous film of the fabric, and the microporous film and the fabric are then bonded together by means of the adhesive.
  • the breathable, laminated sheet material comprises a fabric layer, a microporous film and an adhesive.
  • the fabric layer may be a woven or non- woven fabric, or combination of both, depending on the requirements of a particular application. These fabrics may be in the form of a film, natural or synthetic textile, woven scrim, non- woven and glass mat.
  • the woven fabric may comprise one or more of a polyolefin, (e.g.
  • the woven fabric comprises machine-direction and cross-direction tapes which may be made by a sheet extrusion process and followed by slitting, stretching, orientation and annealing of tapes.
  • the woven fabric has sufficient openings to achieve the finished product target breathability.
  • a weaving pattern in the range of 2x2 to 12x12 may be used.
  • the fabric layer is a non- woven fabric comprising randomly laid spun-bonded fibers.
  • the fibers may be polyolefin, including polyethylene and polypropylene, and polyester.
  • the fibrous fabrics can be used autonomously or in combination with one another using a tie layer to laminate the fabrics.
  • the microporous film comprises a blend of polymer resin and inorganic filler. Suitable resins include polyolefins (e.g. PE, PP), nylon, and blends thereof. Suitable fillers include mineral fillers such as calcium carbonate, talc, magnesium carbonate, and blends thereof.
  • the film may comprise in the range of 40% to 80% by weight of filler.
  • the microporous film may be made by a cast or blown extrusion process and stretched in the machine direction, the cross direction or both directions, to achieve the required breathability, for example, a WVTR in the range of 350 to 1,050 g/m 2 /day.
  • Representative weights for the microporous film are 25 to 150 g/m 2 .
  • Adhesive is used for bonding the microporous film and the fabric layer together.
  • Suitable adhesives include hot melt (e.g. pressure-sensitive hot melt), thermoplastic and acrylic based adhesives.
  • the adhesive may be applied with various spray patterns, using a slot die or a variety of nozzles. Representative adhesive weights are in the range of 2 to 25 grams per square meter.
  • the breathable laminated material has a WVTR in the range of 35 to 700 g/m 2 /day, alternatively greater than 600 g/m 2 /day.
  • the air resistance may be greater than 1,000 sec/100 cc.
  • the hydrostatic resistance may be at least 250 cm.
  • the material may have a tensile strength of 20 to 90 pounds/inch (3.51 to 15.80 kN/m), and a tear strength of 8 to 70 lbs (1.4 to 12.3 kN/m).
  • Representative product weights are in the range of 47 to 325 g/m 2 .
  • the WVTR of the laminated finished sheet product is controlled by a combination of the fabric layer openings, the microporous film
  • the openings are a function of weaving pattern and tape width.
  • the openings are a function of the density of the fabric.
  • the fabric layer or the microporous film or the adhesive coating will be the substantially limiting factor in determining the WVTR of the laminated material, i.e., where the breathability of two of the components far exceeds the breathability of the third component.
  • the WVTR of the laminated material is substantially determined by the WVTR of the microporous coating, with some effect from the adhesive and virtually none from the scrim.
  • the laminated sheet material is substantially impermeable to air and to liquid water, that is, sufficiently impermeable for practical purposes for its intended applications, e.g. as housewrap, roofing membranes, building flashings, breathable apparel and surgical barriers.
  • Reference in this specification to impermeability does not mean that absolute
  • a laminated sheet material according to the invention comprises a microporous film having a weight of 20 grams per square meter, an 8 x 8 woven scrim having a weight of 50 grams per square meter comprising tapes 3.1 mm in width, laminated together with an adhesive having a weight of 5 grams per square meter.
  • the laminated material has a WVTR of 20 metric perms.
  • the WVTR of the laminated material is substantially dictated by the WVTR of the microporous film.

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  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • General Health & Medical Sciences (AREA)
  • Materials Engineering (AREA)
  • Epidemiology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Hematology (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Textile Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

A water vapor-permeable, air-impermeable and water-impermeable laminated material having a selected moisture vapor transmission rate comprises a microporous film comprising a resin and filler, a woven or non-woven fabric layer bonded to the film, and an adhesive bonding the microporous film and the fabric layer together. The selected moisture vapor transmission rate of the laminated material is determined by a combination of the openings in the fabric layer, the water vapor transmission rate of the microporous film, and the coating weight of the adhesive. The laminated material is useful as housewrap, roofing membranes, building flashing, breathable apparel and surgical barriers.

Description

BREATHABLE LAMINATED MATERIAL
Field of the Invention
The invention pertains to materials that are permeable to water vapor and impermeable to water and air for use in applications where moisture transport is desired, but a gas or water barrier is required. Such
applications include building housewrap, building roofing membranes, building flashings, breathable apparel, and surgical barriers.
Background of the Invention Moisture transport membranes are used where it is desirable to transmit moisture but avoid gross air or liquid transport. For example, when used as housewrap, such membranes insulate a house from air drafts and protect wooden and drywall substructure from liquid water. Water vapor transport is desired to allow interior humidity to escape and protect the interior drywall, wood and insulation from water saturation. A high water transport rate allows interior moisture or equilibrated exterior moisture to leave the structure or "breath" so that it is not trapped in the wood, drywall and insulation, causing decay and mold buildup. The breathable membrane must also serve as weather protection against liquid water and air drafts.
Materials commonly used as housewrap include Tyvek (trademark) flash- spun high density polyethylene (HDPE), microporous membranes, nonwoven polypropylene (PP) and perforated polymer films. Tyvek flash-spun nonwoven has lightweight strength, high vapor transport and liquid hydrohead in one layer. Disadvantages of the product include high cost, tear propagation once a tear is introduced, and loss of
hydrophobicity when exposed to surfactant. Microporous membranes are cast or extruded films with inorganic filler and laminated thermally or extrusion laminated on substrates, and subjected to stretching. Perforated polymer film housewraps have microholes and offer low perm rating with high airflow. A disadvantage is that deterioration of the membrane results in perforation distortions and may allow water to penetrate.
Membranes are selected based on perm rating, mechanical strength (tear strength, including wet tear strength), air penetration resistance and hydrostatic head. Both woven and non-woven types of housewraps are commonly used in the construction of buildings. Non- woven housewraps typically have higher water vapor permeabilities than woven housewraps. The strength properties of woven housewraps are typically much higher than those of non- woven housewraps. Some housewraps are translucent, which assists in locating the studs and window and door openings. Non- woven based housewraps are not perforated because the process used in manufacturing the housewrap results in a structure that inherently allows water vapor to pass through the wrap. Most woven housewrap are microperforated, having tiny holes incorporated in the woven coated product.
There remains a need for an effective membrane material while avoiding one or more of the disadvantages of existing products.
Summary of the Invention
The invention provides a water- vapor permeable, water-impermeable and air-impermeable laminated material, comprising a fabric layer, a microporous film and an adhesive coating bonding the fabric layer and film together. The breathability (water vapor transmission rate) of the laminated sheet material is controlled by the fabric layer openings, the breathability of the microporous film, and the adhesive coat weight applied during manufacture.
According to one aspect of the invention, there is provided a water vapor- permeable, air-impermeable and water-impermeable laminated material having a selected water vapor transmission rate. The laminated material comprises a microporous film comprising a resin and a filler, a woven or non-woven fabric layer bonded to the microporous film, and an adhesive bonding the microporous film and the fabric layer together. The selected water vapor transmission rate of the laminated material is determined by a combination of the openings in the fabric layer, the water vapor transmission rate of the microporous film, and the coating weight of the adhesive. According to another aspect of the invention, there is provided a method of making a water vapor-permeable, air-impermeable and water- impermeable laminated material as aforesaid. Values are selected for the openings in the fabric layer, the water vapor transmission rate of the microporous film, and the coating weight of the adhesive, the values being selected to provide the selected water vapor transmission rate of the laminated material. A coating of adhesive is applied to one or both of the microporous film of the fabric, and the microporous film and the fabric are then bonded together by means of the adhesive. Further aspects of the invention and features of specific embodiments of the invention are described below. Detailed Description
In this patent application, reference to certain measured properties of the laminated sheet material or its components means measurement according to the following standard test methods: (1) water vapor transmission rate (WVTR) is measured in accordance with ASTM E-96; air resistance is measured in accordance with TAPPI-460; hydrostatic resistance is measured in accordance with AATCC-127; tensile strength is measured in accordance with ASTM D5034; and tear strength is measured in accordance with ASTM D4533. The breathable, laminated sheet material comprises a fabric layer, a microporous film and an adhesive. The fabric layer may be a woven or non- woven fabric, or combination of both, depending on the requirements of a particular application. These fabrics may be in the form of a film, natural or synthetic textile, woven scrim, non- woven and glass mat. The woven fabric may comprise one or more of a polyolefin, (e.g.
polyethylene and polypropylene), polyester, polyamide, polyethylene terephthalate (PET), nylon, glass mat, and combinations thereof. The woven fabric comprises machine-direction and cross-direction tapes which may be made by a sheet extrusion process and followed by slitting, stretching, orientation and annealing of tapes. The woven fabric has sufficient openings to achieve the finished product target breathability. A weaving pattern in the range of 2x2 to 12x12 may be used.
In other embodiments, the fabric layer is a non- woven fabric comprising randomly laid spun-bonded fibers. The fibers may be polyolefin, including polyethylene and polypropylene, and polyester. The fibrous fabrics can be used autonomously or in combination with one another using a tie layer to laminate the fabrics. The microporous film comprises a blend of polymer resin and inorganic filler. Suitable resins include polyolefins (e.g. PE, PP), nylon, and blends thereof. Suitable fillers include mineral fillers such as calcium carbonate, talc, magnesium carbonate, and blends thereof. The film may comprise in the range of 40% to 80% by weight of filler. The microporous film may be made by a cast or blown extrusion process and stretched in the machine direction, the cross direction or both directions, to achieve the required breathability, for example, a WVTR in the range of 350 to 1,050 g/m2/day. Representative weights for the microporous film are 25 to 150 g/m2.
Adhesive is used for bonding the microporous film and the fabric layer together. Suitable adhesives include hot melt (e.g. pressure-sensitive hot melt), thermoplastic and acrylic based adhesives. The adhesive may be applied with various spray patterns, using a slot die or a variety of nozzles. Representative adhesive weights are in the range of 2 to 25 grams per square meter.
The breathable laminated material has a WVTR in the range of 35 to 700 g/m2/day, alternatively greater than 600 g/m2/day. The air resistance may be greater than 1,000 sec/100 cc. The hydrostatic resistance may be at least 250 cm. The material may have a tensile strength of 20 to 90 pounds/inch (3.51 to 15.80 kN/m), and a tear strength of 8 to 70 lbs (1.4 to 12.3 kN/m). Representative product weights are in the range of 47 to 325 g/m2. The WVTR of the laminated finished sheet product is controlled by a combination of the fabric layer openings, the microporous film
breathability, and the adhesive coat weight used to laminate the layers. For embodiments in which the fabric layer is a woven, the openings are a function of weaving pattern and tape width. For embodiments in which the fabric layer is a non- woven, the openings are a function of the density of the fabric. In some embodiments, the fabric layer or the microporous film or the adhesive coating will be the substantially limiting factor in determining the WVTR of the laminated material, i.e., where the breathability of two of the components far exceeds the breathability of the third component. For example, where the fabric layer is a woven scrim with significant openings between the tapes, and the adhesive coating weight is low, the WVTR of the laminated material is substantially determined by the WVTR of the microporous coating, with some effect from the adhesive and virtually none from the scrim.
The laminated sheet material is substantially impermeable to air and to liquid water, that is, sufficiently impermeable for practical purposes for its intended applications, e.g. as housewrap, roofing membranes, building flashings, breathable apparel and surgical barriers. Reference in this specification to impermeability does not mean that absolute
impermeability is required. Example
A laminated sheet material according to the invention comprises a microporous film having a weight of 20 grams per square meter, an 8 x 8 woven scrim having a weight of 50 grams per square meter comprising tapes 3.1 mm in width, laminated together with an adhesive having a weight of 5 grams per square meter. The laminated material has a WVTR of 20 metric perms. In the example, the WVTR of the laminated material is substantially dictated by the WVTR of the microporous film. As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the following claims.

Claims

1. A water vapor-permeable, air-impermeable and water-impermeable laminated material having a selected water vapor transmission rate, comprising:
(a) a microporous film comprising a resin and a filler;
(b) a woven or non- woven fabric layer bonded to the
microporous film; and
(c) an adhesive bonding the microporous film and the fabric layer together; wherein the selected water vapor transmission rate of the laminated material is determined by a combination of:
(i) openings in the fabric layer;
(ii) the water vapor transmission rate of the microporous film; and
(iii) a coating weight of the adhesive.
2. A laminated material according to claim 1, wherein the water vapor transmission rate of the laminated material is in the range of 35 to 700 grams per square meter per day.
3. A laminated material according to claim 1 or 2, wherein the water vapor transmission rate of the laminated material is greater than 600 grams per square meter per day.
4. A laminated material according to any one of claims 1-3, wherein the laminated material has an air resistance greater than 1,000 sec/100 cc.
5. A laminated material according to any one of claims 1-4, wherein the laminated material has a hydrostatic resistance of at least 250 cm.
6. A material according to any one of claims 1-5, wherein the material has a tensile strength in the range of 3.51 kN/m to 15.80 kN/m.
7. A laminated material according to any one of claims 1-6, wherein the laminated material has tear strength in the range of 1.4 kN/m to 12.3 kN/m.
8. A laminated material according to any one of claims 1-7, wherein the laminated material has a weight in the range of 47 to 325 grams per square meter.
9. A laminated material according to any one of claims 1-8, wherein the fabric layer is one of woven or nonwoven.
10. A laminated material according to any one of claims 1-9, wherein the fabric layer comprises one of a polyolefin, polyester, polyamide, polyethylene terephthalate, nylon, glass mat, and combinations thereof.
11. A laminated material according to claim 10, wherein the polyolefin is one of polyethylene and polypropylene.
12. A laminated material according to any one of claims 1-11, wherein the fabric layer is a woven scrim.
13. A laminated material according to claim 12, wherein the woven scrim has a weaving pattern in the range of 2x2 to 12x12.
14. A laminated material according to any one of claims 1-11, wherein the fabric layer is a non-woven.
15. A laminated material according to any one of claims 1-14, wherein the fabric layer has a weight in the range of 20 to 150 grams per square meter.
16. A laminated material according to any one of claims 1-15, wherein the microperforated film comprises a resin that is one of a polyolefin, nylon, or blends thereof.
17. A laminated material according to any one of claims 1-16, wherein the filler comprises a mineral filler.
18. A laminated material according to claim 17, wherein the mineral filler comprises calcium carbonate, talc or magnesium carbonate, or blends thereof.
19. A laminated material according to any one of claims 1-18, wherein the filler comprises in the range of 40% to 80% by weight of the microporous film.
20. A laminated material according to any one of claims 1-19, wherein the microporous film is stretched in the machine direction, the cross direction, or both the machine and cross directions.
21. A laminated material according to any one of claims 1-20, wherein the microporous film has a water vapor transmission rate in the range of 350 to 1,050 grams per square meter per day.
22. A laminated material according to any one of claims 1-21, wherein the microporous film has a weight in the range of 20 to 150 grams per square meter.
23. A laminated material according to any one of claims 1-22, wherein the adhesive comprises a pressure-sensitive hot melt adhesive.
24. A laminated material according to any one of claims 1-22, wherein the adhesive comprises one of a thermoplastic and an acrylic adhesive.
25. A laminated material according to any one of claims 1-24, wherein the adhesive has a coating weight in the range of 2 to 25 grams per square meter.
26. A method of making a water vapor-permeable, air-impermeable and water-impermeable laminated material according to any one of claims 1-25, comprising the steps of:
(a) selecting values of:
(i) openings in the fabric layer;
(ii) the water vapor transmission rate of the microporous film; and
(ii) the coating weight of the adhesive; said values being selected to provide the selected water vapor transmission rate of the laminated material;
(b) applying a coating of adhesive to one or both of the microporous film and the fabric; and
(c) bonding the microporous film and the fabric together by means of the adhesive.
PCT/CA2014/050698 2013-07-24 2014-07-24 Breathable laminated material WO2015010208A1 (en)

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US61/858,000 2013-07-24

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EP3124242B1 (en) 2015-07-28 2018-09-19 SML Maschinengesellschaft m.b.H. Method and device for producing a water vapour permeable web
EP3513961A1 (en) * 2018-01-19 2019-07-24 K.L. Kaschier- und Laminier GmbH Construction foil
US11105099B2 (en) 2018-01-08 2021-08-31 Low & Bonar Inc. Extruded mat
US11365328B2 (en) 2017-02-23 2022-06-21 3M Innovative Properties Company Air and water barrier article including inelastic porous layer
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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3124242B1 (en) 2015-07-28 2018-09-19 SML Maschinengesellschaft m.b.H. Method and device for producing a water vapour permeable web
US10384430B2 (en) 2015-07-28 2019-08-20 Sml Maschinengesellschaft M. B. H. Method and device for the production of a water vapor permeable laminar sheet
WO2017031275A1 (en) * 2015-08-18 2017-02-23 3M Innovative Properties Company Self-sealing articles including elastic porous layer
CN107923176A (en) * 2015-08-18 2018-04-17 3M创新有限公司 Self sealss product including elastic cellular layer
US11105089B2 (en) 2015-08-18 2021-08-31 3M Innovative Properties Company Self-sealing articles including elastic porous layer
US11512463B2 (en) 2015-08-18 2022-11-29 3M Innovative Properties Company Air and water barrier article with porous layer and liner
US11365328B2 (en) 2017-02-23 2022-06-21 3M Innovative Properties Company Air and water barrier article including inelastic porous layer
US11105099B2 (en) 2018-01-08 2021-08-31 Low & Bonar Inc. Extruded mat
US11821214B2 (en) 2018-01-08 2023-11-21 Low & Bonar Inc. Extruded mat
EP3513961A1 (en) * 2018-01-19 2019-07-24 K.L. Kaschier- und Laminier GmbH Construction foil
DE102018000411A1 (en) * 2018-01-19 2019-07-25 K. L. Kaschier- Und Laminier Gmbh Films building
WO2023170612A1 (en) * 2022-03-09 2023-09-14 Masons Plastabrick Limited Pliable insulation sheet

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