专利摘要:
air permeable thermoplastic film, respective method of obtaining and laminated article. The invention relates to air permeable laminated thermoplastic films, and methods for obtaining films having a basis weight less than or equal to 15 gsm and a water vapor transmission rate of at least about 500 grams h2o/24 -hours/m2, where the film has a ratio of md load at break to cd load at break below about 10, and at least one of an elmendorf notched tear strength in the machine direction of at least about about 10 of 5 g or a notched trapezoidal tear strength in the machine direction of at least about 15 g.
公开号:BR112016025367B1
申请号:R112016025367-1
申请日:2015-05-13
公开日:2021-09-14
发明作者:Leopoldo V. Cancio;Frank Eschenbacher;Jerry Ford
申请人:Clopay Plastic Products Company, Inc;
IPC主号:
专利说明:

DESCRIPTIVE REPORT RELATED ORDERS
[0001] This application claims the priority benefit of US Provisional Patent Application No. 61/992,438, filed May 3, 2014, of US Provisional Patent Application No. 62/053,385, Filed September 22, 2014, and US provisional patent application no. 62/092,351, filed December 16, 2014. FIELD OF INVENTION
[0002] Thermoplastic films are widely used in personal care items, for example, as the outer layer of a diaper or other disposable personal care product. For a variety of reasons, including cost, comfort, resource conservation and minimizing waste, it is desirable to have as thin a film as possible while maintaining the other necessary film properties.
[0003] Desirable qualities of thermoplastic films include the fact that they are impermeable and liquid, permeable to vapor (eg, permeable to air), bondable to other layers of personal care items, and the fact that they have sufficient physical strength to be processed into a finished article. Strength is an important consideration when using thermoplastic films for packaging, for example, as an outer packaging for consumer goods. Air-permeable films having sufficient strength and basis weight can be particularly useful as packaging for products that need to release odors resulting from the manufacturing process.
[0004] Thermoplastic films can be formed by extrusion of a polymeric composition melted in a cold cylinder, where they are immediately cooled to obtain a solid film. Film processing includes a variety of steps including heating, cooling and stretching to produce a final film product having a thickness 72 times less than or less than the initial thickness. Machine direction stretching (MD) forms a highly oriented thin gauge film, which is called machine direction orientation (MDO). MDO can be useful, however, it can also result in qualities such as reduced shear strength (CD), impact strength, tear strength and low puncture strength, particularly in thinner films.
[0005] Current methods for obtaining thin gauge thermoplastic films include those described in US patent 7,442,332 (Cancio et al). In this process, a large part of the stretching (more than half) of the mesh takes place between the extruder and a first tooth (ie, in the ''cast curtain''). In such a molding process, two disadvantages are the phenomenon known as “stretch resonance”, which results in non-uniform film thickness, and the formation of holes in the film.
[0006] These problems increase with the speed of production, and furthermore limit the types of polymeric compositions that can be used. Overcoming these problems requires a reduction in production speed, which ultimately results in increased cost.
[0007] Thus there is a need for thin thermoplastic films, which have limited MDO and desirable properties such as absence of holes, good air permeability, good tensile strength and tear resistance properties, and which can be produced economically and efficient on high speed production lines. SUMMARY OF THE INVENTION
[0008] The present invention meets the needs mentioned above by providing thermoplastic films permeable to air having a low basis weight, which are substantially free of holes, which present physical properties characteristic of films having a much higher basis weight. The films of the present invention exhibit excellent tensile strength, tear strength and air permeability. While tear strength is proportional to film thickness, with thinner films generally exhibiting higher tear strengths, films obtained by the process of the present invention exhibit higher tear strengths than would be expected for equivalent films of similar thickness. In other words, films show an increased tear strength to thickness ratio.
[0009] The thermoplastic films of the present invention, which are believed to be unique, are obtained by a novel process in which the film is stretched on MD at a temperature that is high enough to prevent harmful MD orientation, and even below the melting point of thermoplastic polymer. This process takes place downstream of a cooled cylinder, in contrast to the process described in US patent 7,442,332. The method of the present invention allows the extrusion process to take place at normal production speeds, and without the need for additional equipment to reduce drawing resonance. As an added advantage, film qualities such as opacity can be controlled by further downstream MD stretching, which reduces or eliminates the need for adding opacifiers.
[0010] The following describes some of the non-limiting embodiments of the present invention. In one embodiment, an air-permeable thermoplastic film is provided, which has a basis weight less than or equal to about 15 gsm and a water vapor transmission rate (WVTR) of at least about 500 grams of H2O/24-hours/m2 and where said film has a ratio of MD load at break to CD load at break below about 10, and at least one of an Elmendorf tear strength machine direction notched at least about 5 g or a machine direction notched trapezoidal tear strength of at least about 15 g.
[0011] In another embodiment, a laminate is provided, comprising a first layer which in turn comprises an air permeable thermoplastic film having a basis weight less than or equal to 15 gsm and a water vapor transmission rate of fur minus about 500 grams H2O/24-hours/m2, and where said film has a ratio of MD load at break to CD load at break below about 10, and at least one of a tear strength of Machine direction notched Elmendorf of at least about 5 g or a machine direction notched trapezoidal tear strength of at least about 15 g, said first layer having a surface; and a substrate attached to the surface of the film.
[0012] In another embodiment, a method for obtaining a thermoplastic film product is provided, comprising extrusion of a cast mesh comprising a thermoplastic polymer from an extruder into a first cold cylinder, said first cold cylinder operating at a peripheral velocity V1 and a temperature T1, which is below the melting point of the thermoplastic polymer and which cools said mesh to form a film, and where a space between said extruder and the cold cylinder forms a first void space; advancing the film to a stretching cylinder downstream of said first cold cylinder, which operates at a peripheral speed V2 which is greater than V1, and at a temperature T2, and further stretches the film in the machine direction to produce a film exhibiting substantially uniform thickness and limited machine direction orientation, a ratio of MD load at break to CD load at break below about 10, and at least one of a notched Elmendorf tear strength in machine direction of at least 5 g or a machine direction notched trapezoidal tear strength of at least about 15 g.
[0013] In another embodiment, the above method is provided, where the thermoplastic film has an MD load at break of at least 2.0 N/cm and a CD load at break of at least 0.7 N/cm.
[0014] In another embodiment, the above method is provided, where the thickness of the thermoplastic film product is from about 5 gsm to about 20 g. In another embodiment, the above method is provided, where the cast mesh is molded, blown, calendered, mono-extruded, co-extruded, cold-formed, embossed by nip, or combinations thereof.
[0015] In another embodiment, the above method is provided, further comprising at least one additional cold cylinder operation at a temperature T and a peripheral velocity V.
[0016] In another embodiment, the above method is provided, further comprising the step of stretching the film in a transverse direction to produce an air permeable thermoplastic film product having a water vapor transmission rate of at least about 500 grams - H2O/24-hours/m2.
[0017] In another embodiment, the above method is provided, where the film is gradually stretched in the transverse direction using interdigitated cylinders.
[0018] In another embodiment the above method is provided, where the film is advanced by a first machine direction guiding section comprising at least one heated cylinder having a temperature T3 and at least one stretching cylinder.
[0019] In another embodiment the above method is provided, where the film is advanced by at least a second machine direction guide section comprising at least one heated cylinder and at least one stretching cylinder.
[0020] In another embodiment the above method is provided, where said second machine direction guidance section is located downstream from a cylinder section interdigitated in the transverse direction.
[0021] In another embodiment the above method is provided, where said second machine direction guidance section is located upstream from a cylinder section interdigitated in the transverse direction.
[0022] In another embodiment, the above method is provided, where T1 is from about 80°C to about 160°C.
[0023] In another embodiment the above method is provided, where T2 is from about 60°C to about 100°C.
[0024] In another embodiment the above method is provided, where T3 is from about 80°C to about 150°C.
[0025] In another embodiment, the above method is provided, where T is equal to T1.
[0026] In another embodiment the above method is provided, where T is different from T1.
[0027] In another embodiment, the above method is provided, where V is equal to V1.
[0028] In another embodiment the above method is provided, where V is different from V1.
[0029] In another embodiment, the above method is provided, where the cold cylinder and the stretch cylinder form a second empty space of about 7.5 cm to about 30 cm.
[0030] In another embodiment, the above method is provided, where the ratio of V2 to V1 is from about 2 to about 8.
[031] In another embodiment the above method is provided, where the film is a co-extruded multi-layer film.
[032] In another embodiment, the above method is provided, where the film is a mono-extruded film.
[033] In another embodiment, the above method is provided, where the film is a blown film.
[034] In another embodiment, the above method is provided, where the film has an opacity of at least about 50%.
[0035] In another embodiment, the above method is provided, wherein said film comprises an ethylene-based olefin block copolymer, propylene-based or combinations thereof.
[0036] In yet another embodiment, an air-permeable thermoplastic film is provided, which is produced by a process in which a cast mesh comprising a thermoplastic polymer is extruded into a cold cylinder having a temperature T1 to form a film, the film is advanced to a stretch cylinder having a temperature T2 downstream of said first cold cylinder, and further advanced by a first machine direction guiding section comprising at least one heated cylinder having a temperature T3 and at least one stretching cylinder, where a limited machine direction orientation is applied to the film, and where the film has a basis weight less than or equal to about 15 gsm, a water vapor transmission rate of at least about 500 grams H2O/24- hours/m2, and where said film has a ratio of MD load at break to CD load at break less than about 10.
[0037] In another embodiment, the film produced by the above process is provided, where the film has an Elmendorf tear strength in the machine direction of at least 5 g.
[0038] In another embodiment, the film produced by the above process is provided, where the film has a trapezoidal tear strength in the machine direction of at least 15 g.
[0039] In another embodiment, the film produced by the above process is provided, where the film has an MD load at break of at least 2.0 N/cm and a CD load at break of at least 0.7 N/ cm.
[0040] In another embodiment, the above film produced by the above process is provided, where the cast mesh is molded, blown, calendered, mono-extruded, co-extruded, cold-formed, made in relief by narrowing, or combinations thereof.
[0041] In another embodiment, the film produced by the above process is provided, where the film is a co-extruded multilayer film.
[0042] In another embodiment, the film produced by the above process is provided, where the film is a monolayer film.
[0043] In another embodiment, the film produced by the above process is provided, where the film has a hydrostatic head pressure of at least 200 psi.
[0044] In another embodiment, the film produced by the above process is provided, where the film is gradually stretched in the transverse direction using interdigitated cylinders.
[0045] In another embodiment, the film produced by the above process is provided, where the film has an opacity of at least about 50%. BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIGURE 1 shows a non-limiting embodiment of an apparatus suitable for obtaining the films of the present invention. DETAILED DESCRIPTION OF THE INVENTION
[0047] As used here:
[0048] "Activation defect", "activation holes" or "point holes" means small holes or tears in a film at the time the film is subjected to formation, lamination, activation or other manufacturing or processing steps, the which in turn can lead to reduced tear strength, increased porosity, increased leakage, or other undesirable characteristics.
[0049] “Gsm” means grams per square meter, and is a measure of basis weight, which is a standard industry term that quantifies the thickness or unit of mass of a film or laminate product.
[0050] “Hydrostatic head pressure” can be measured in accordance with AATCC method 127-2008, and can be expressed in units of pounds per square inch, or psi. The films of the present invention have a hydrostatic head pressure of at least 200 psi.
[0051] “Surface layer(s)” means one or both of the outer layers of a multi-layer film that functions as an outer surface of the film.
[0052] "Tear strength" or "tear strength" reflects the ease or difficulty with which the film can be torn, and is expressed in units of grams. Here, tear strength can be measured by the Elmendorf notched tear test, ASTM D-1922, incorporated herein by reference and/or by the trapezoidal tear test ("trap test"), as described herein or in accordance with ASTM D-5587. The test can be carried out with a notched or notched film and in the CD direction or in the MD direction. Unless otherwise specified, the tear strength here is the notched tear strength. It should be noted that tear strength is related to film thickness, and any comparison of tear strengths must consider the relative basis weights of the comparison samples.
[0053] “Tensile strength” means the load required to induce breakage (“break load”) on the film in both the CD and MD directions. Tensile strength is expressed in units of N/cm or equivalent units thereof, and is determined by ASTM method D822-02, using the following parameters: Sample direction = MD x CD; Sample Size = 1 inch wide x 6 inches long; Test speed = 20 in/min; Clamp Distance = 2 inches. Clamp size = 3 inches wide, rubber-faced clamps that hold the specimen evenly.
[0054] "WVTR" means "water vapor transmission rate" and is a measure of the air permeability of the film. WVTR is expressed in units of g H2O/24 hours/m2 or equivalent units thereof, and can be measured according to ASTM method D-6701-01. Film
The films of the present invention are thermoplastic monolayer or multilayer films and may have a basis weight of from about 5 gsm to about 20 gsm, alternatively from about 5 to about 15 gsm, alternatively from about 10 to about from 15 gsm, alternatively from about 8 to about 13 gsm, alternatively from about 10 gsm to about 12 gsm, alternatively less than about 15 gsm, alternatively less than 14 gsm, alternatively less than about 12 gsm, and alternatively less than about 10 gsm. The multilayer films of the present invention may comprise at least 2 layers, alternatively at least 3 layers, alternatively at least 5 layers, alternatively at least 7 layers, alternatively at least 9 layers, alternatively at least 11 layers, alternatively from 2 to about 20 layers, alternatively from 3 to about 11 layers, and alternatively from 5 to 11 layers. Films may or may not comprise a surface layer in order to reduce tackiness on one or both external surfaces.
[0056] The films of the present invention have a CD charge at break greater than 0.7 N/cm, alternatively greater than about 0.8 N/cm, alternatively greater than about 0.9 N/cm, alternatively of from about 0.7 N/cm to about 3.0 N/cm, and alternatively from about 0.7 N/cm to about 2.0. The films of the present invention have an MD load at break of at least about 2.0 N/cm, alternatively at least about 2.5 N/cm, alternatively at least about 3.0 N/cm, alternatively from about 2.0 N/cm to about 6.0 N/cm and alternatively from about 3.0 N/cm to about 6.0 N/cm.
[0057] An important and inventive aspect of the present invention, however, is the ratio of MD charge to CD charge at break, which is a measure of an improved balance between these properties and which is not present in previously described films . Without wanting to be limited to theory, it is believed that this advantageous proportion is achieved by reducing the machine direction orientation in films by the process described here. The films of the present invention have a ratio of MD charge at break to CD charge at break of about 1 to about 15, alternatively about 1 to about 10, alternatively about 1 to about 9, alternatively. from about 1 to about 8, alternatively from about 1 to about 5, alternatively from less than about 10, alternatively less than about 9, alternatively less than about 8, alternatively less than about 5, alternatively less of about 4, and alternatively of about 1.
[0058] The films of the present invention additionally feature a water vapor transmission rate (WVTR) of at least 500 grams H2O/24-hours/m2, alternatively at least 1000 grams H2O/24-hours/m2, alternatively by less 2000 grams H2O/24-hours/m2, alternatively at least 3500 grams H2O/24-hours/m2, alternatively at least 4500 grams H2O/24-hours/m2, alternatively at least about 6000 grams H2O/24- hours/m2, alternatively at least about 7000 grams H2O/24-hours/m2, alternatively at least about 9000 grams H2O/24-hours/m2, and alternatively about 1000 grams H2O/24-hours/m2 at about 10,000 grams H2O/24-hours/m2.
[0059] The films of the present invention further exhibit an Elmendorf tear strength in the machine direction of at least about 5 g, alternatively at least about 10 g, alternatively at least about 15 g, alternatively about about 5 g to about 50 g, alternatively from about 10 g to about 45 g, and alternatively from about 15 g to about 45 g.
[0060] The films of the present invention additionally exhibit a trapezoidal tear resistance ("trap") in the machine direction of at least about 15 g, alternatively at least about 20 g, alternatively at least about 25 g, alternatively from about 15 g to about 150 g, alternatively from about 15 g to about 100 g, and alternatively from about 15 g to about 85 g.
[0061] The films of the present invention comprise one or more thermoplastic polymers. Suitable polymers for the films include, but are not limited to, polyolefins, e.g. polyethylene homopolymers and copolymers, polypropylene, polypropylene homopolymers and copolymers, functionalized polyolefins, polyesters, poly(ester-ether), polyamides, including nylons, poly (ether-amide), polyether sulfones, fluoropolymers, polyurethanes, and mixtures thereof. Polyethylene homopolymers include those of low, medium or high density and/or those formed by high pressure or low pressure polymerization. polyethylene and polypropylene copolymers include, but are not limited to, copolymers with C4 - C8 alpha-olefin monomers, including 1-octene, 1-butene, 1-hexene and 4-methyl pentene. Polyethylene can be substantially linear or branched, and can be formed by various processes known in the art using catalysts such as Ziegler-Natta catalysts, metallocene or single site catalysts or others widely known in the art. Examples of suitable copolymers include, but are not limited to, copolymers such as poly(ethylene-butene), poly(ethylene-hexene), poly(ethylene-octene), and poly(ethylene-propylene), poly(ethylene-vinylacetate) , poly(ethylene-methylacrylate), poly(ethylene-acrylic acid), poly(ethylene-butylacrylate), poly(ethylene-propylenediene), poly(methyl methacrylate) and/or polyolefin thermopolymers thereof. In one embodiment, the films comprise polyethylene, polypropylene, and combinations thereof. An example of a commercially available polyethylene-based resin is Exceed™ 3527PA produced by Exxon. An example of a suitable commercially available polypropylene copolymer is Borealis BD712 produced by Borealis.
[0062] Other non-limiting examples of olefinic polymeric compositions include olefinic block copolymers, random olefinic copolymers, polyurethanes, rubbers, vinyl arylenes and conjugated dienes, polyesters, polyamides, polyethers, polyisoprenes, polyneoprenes, copolymers of any of the above, and mixtures of these. In addition, the films of the present invention, or layers thereof, may comprise brittle polymers, limiting examples of which are described in US patent 7,879,452. In one embodiment, the films comprise an olefinic block copolymer.
[0063] In one embodiment, the olefinic block copolymer and the polypropylene base. Non-limiting examples of suitable polypropylene-based olefinic block copolymer are marketed under the tradename INFUSE™ from The Dow Chemical Company of Midland, MI, tradename V1STAMAXX® from ExxonMobil Chemical Company of Houston, TX, and tradename from Exxon Impact® Copolymers such as Exxon PD 7623. Polypropylene, as well as polyesters, is known to increase the melt temperature of a formed polymeric film, increasing the burn resistance of the film. In an alternative embodiment, the films of the present invention may comprise an ethylene-based olefinic block copolymer.
[0064] The thermoplastic polymers mentioned above may be present in the film or in individual layers of the film in an amount from 0% to about 95%, alternatively from about 0% to about 40%, alternatively from about 10% to about 50%, alternatively from about 35% to about 50%, alternatively from about 20% to about 40%, and alternatively from about 1% to about 10%. In one embodiment, the film, or one or more layers of a multilayer film, comprises from about 0.1% to about 90%, alternatively from about 1% to about 60%, alternatively from about 20% to about 50%, alternatively from about 20% to about 40%, and alternatively from about 1% to about 10% polypropylene, a composition or copolymer based on polypropylene, ethylene, a composition or copolymer based on polypropylene. of ethylene, or combinations thereof.
[0065] The films of the present invention, or individual layers thereof, may comprise one or more elastomeric polymers, including styrenic block copolymers, elastomeric olefinic block copolymer and combinations thereof. Non-limiting examples of styrenic block copolymers (SBC's) include the elastomeric block copolymers styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene- propylene (SEP), styrene-ethylene-propylene-styrene (SEPS), or styrene-ethylene-ethylene-propylene-styrene (SEEPS), polystyrene, and mixtures thereof. In one embodiment, the film comprises styrene-butadiene-styrene, polystyrene, and mixtures thereof. Suitable SBC resins are readily available from: KRATON® Polymers of Houston, TX; Dexco™ Polymers LP from Planquemine, LA; or Septon™ Company of America of Pasadena, TX.
[0066] The films of the present invention may include optional components such as fillers such as calcium carbonate, plasticizers, compatibilizers, stretch polymers, processing aids, anti-blocking agents, viscosity reducing polymers, and the like. Other additives can include pigments, dyes, antioxidants, antistatic agents, slip agents, foaming agents, heat or light stabilizers, UV stabilizers, and the like. Examples of suitable processing aids and anti-blocking agents, but not limited to, are Ampacet™, available from Ampacet Corporation. In one embodiment, the polymeric compositions can comprise from about 0% to about 75%, alternatively 1% to 30%, and alternatively from about 30% to about 60%, filler. In one embodiment, the polymeric compositions can comprise from about 0% to about 15%, and alternatively from about 0% to about 10%, and alternatively from about 0.5% to about 5%, of an auxiliary. proper processing.
[0067] In one embodiment, the films are substantially free of titanium dioxide, and alternatively comprise less than 0.1% titanium dioxide. Films may have an opacity above 50%, alternatively above 55%, and alternatively above about 60%. Device
[0068] Figure 1 shows exemplary drawings of a film forming apparatus (10) that is suitable for forming the films of the present invention. “Machine direction”, as applied to a film or non-woven material, means the direction that is parallel to the direction of displacement of the film or non-woven material as it is processed in the film forming apparatus. “Transverse direction” means the direction perpendicular to the machine direction. In a non-limiting embodiment, and as shown in Figure 1, the film forming apparatus (10) comprises a molding section (12), a machine direction orientation (MDO) section (14), and a molding section cylinder interdigitated in the transverse direction (CDI) (16). Optionally, the film forming apparatus (10) may comprise additional sections as would be clear to a person skilled in the art, such as an annealing section, a winder, an additional machine direction guidance section, and/or a machine direction section. crown treatment. In other embodiments, the order of sections or components may differ from that shown in Figure 1, as would be understood by a person skilled in the art.
[0069] The molding section (12) comprises an extruder (24) followed by at least one cold cylinder (28) with a first void (26) between them. As will be understood by one skilled in the art, the position of the extruder (24) relative to the cold cylinder (28) may vary from that shown in Figure 1 to a position slightly further downstream from that shown, with the extruder (24) still being in a position for depositing a cast curtain comprising the extrudate in the cold cylinder (28). Downstream of the cold cylinder (28), which has a temperature T1 and rotates at a speed V1, there is a stretch cylinder (30), having a temperature T2 and rotating at a speed V2. The cold cylinder (28) is separated from the drawing cylinder (30) by a second void (32). In operation, the extruder (24) melts and extrudes an extrudate through the void (26) into the cold cylinder (28), forming a mesh, or film, (15). The film (15) moves through the second void (32) to the nip (33) formed between the slave cylinder (34) and the stretch cylinder (30). The film (15) then passes over a tension cylinder (39) to the machine steer guidance section (14).
[0070] The meshes, or films, of the present invention can be formed by a variety of means that should be understood by the person skilled in the art, and can be molded, blown, calendered, mono-extruded, co-extruded, cold molded, embossed by nip, or any other method that results in a film compatible with the process described here.
[0071] In one embodiment, the thermoplastic polymer film formulation can be mixed in the extruder (24), for example, at a temperature of about 210°C to about 280°C. The exact temperature will depend on the formulation of the polymeric compositions. The mesh, or "fused curtain", comprising the polymeric composition may be extruded (or co-extruded if a multilayer film is being formed) into the cold cylinder (28). The temperature T1 of the cold cylinder (28) is carefully controlled such that the film (15), as it leaves the cold cylinder (28), is at a high enough temperature to be able to be stretched to the desired thickness without MD molecular orientation. significantly, still below the melting temperature of the polymer composition. Thus, the temperatures T1 and T2 depend on the composition of the film. T1 may be greater than 80°C, alternatively from about 80°C to about 160°C, alternatively is from 90°C to about 160°C, alternatively is from about 100°C to about 140°C , alternatively from about 80°C to about 120°C, alternatively from about 100°C to about 120°C, and alternatively less than about 160°C. The temperature, T2, of the drawing cylinder (30), may be above 40°C, alternatively from about 40°C to about 100°C, alternatively from about 60°C to about 100°C, alternatively from about 60°C to about 90°C, alternatively from about 85°C to about 90°C, and alternatively less than about 100°C.
[0072] It should be noted that in the present invention, the temperature T1 of the cold cylinder (28) and the temperature T2 of the stretch cylinder (30), are significantly higher than in any other MDO process previously described. In prior patent applications, T1 typically is from about 10°C to about 60°C, and T2 typically is from about 10°C to about 40°C. The present invention uses a temperature that balances the need for film processability and still allows control of the amount of MDO.
[0073] In one embodiment, at least two cold cylinders are present, each having a velocity V and a temperature T. The speeds and temperatures of the cold cylinders can be the same or different, however, they will be sufficient for the film to be stretched to the desired thickness without significant MD molecular orientation, still below the melting temperature of the polymer composition. By way of non-limiting example only, temperatures may differ by 5°C, by 10°C, or more. Cold rolls can be individually smooth, textured, coated (eg with a release treatment), which can be the same or different on each roll.
[0074] The length of the first void (26) between the extruder (24) and the cold cylinder (28) is the shortest distance between the extruder (24) and the cold cylinder (28), and is longer than in the processes Previous molding MDO. In one embodiment, the length of the first void (26) is greater than 2.5 cm, alternatively is from about 2.5 cm to about 25 cm, alternatively from about 3 cm to about 15 cm, and alternatively it is about 3 cm to about 3 cm. The extrudate can be subjected to a stretch of the cast curtain, with a corresponding reduction in thickness, into a void (26) from 10 times to about 25 times (about 10X to about 25X).
[0075] In one embodiment, the apparatus may include an additional barrel and a nip between the extruder (24) and the cold barrel (28), as shown in US patent 7,442,332. In another embodiment, the apparatus can include one or more additional cold cylinders. In yet another embodiment, the cold cylinder (28) can be replaced by two cylinders, where the cylinders form an additional nip. The cylinders can be a metal cylinder and a rubber cylinder, and the metal cylinder can optionally be embossed. The film temperature at the nip is about 120°C or less, and alternatively is about 100°C or less. After passing through the additional nip, the film is advanced through the nip (33) and further through the process described here.
[0076] The ratio of the speeds of the V2/V1 cylinders provides the relative length that a film is stretched. In this way, a 1/1 (1x) aspect ratio indicates that the film has not been stretched. A ratio of 5/1 (5x) indicates that a film has been stretched 5 times its length before stretching with a corresponding reduction in film thickness, i.e., 0.2 times its thickness before stretching. In one embodiment, the ratio of V2/V1 is at least 2, alternatively is at least 5, alternatively is from about 2 to about 8, alternatively is from about 3 to about 8, and alternatively is less than 5.
[0077] The length of the second void (32) between the cold cylinder (28) and the nip (33) in the stretch cylinder (30) is the shortest distance between the cold cylinder (28) and the stretch cylinder (30 ), and in one embodiment it is at least about 7.5 cm, alternatively it is about 7.5 to about 30 cm, alternatively it is about 7.5 to about 20 cm, alternatively it is about 7.5 cm to about 10 cm, alternatively is about 30 cm, alternatively is about 20 cm, alternatively is about 15 cm, alternatively is about 15 cm, and alternatively is less than 10 cm. The film (15), after being stretched between the cold cylinder (28) and the stretching cylinder (30), is essentially a non-porous film showing limited molecular orientation in MD.
[0078] Here, "giving limited machine direction orientation to the film" means to produce an MD orientation sufficient to give the film an MD load at break of at least 2.0 N/cm with a CD load at hair break minus 0.7 N/cm. In addition, the film will exhibit a ratio of MD charge at break to CD charge at break of from about 1 to about 15. Although the amount of MDO cannot be directly quantified, the amount of MDO is correlated with the properties of the film. A film that exhibits limited MDO will, in particular, exhibit improved CD properties, such as Elmendorf's CD and trapezoidal tear strength, CD tensile strength at break, and an improved balance of CD and MD tensile strengths relative to films previously described.
[0079] Downstream of the molding section (12), the film (15) can pass from the stretch cylinder (30) around the tension cylinder (39) to a first machine direction orientation section (MDO) (14 ). The purpose of this section is to further stretch the film in machine direction, while still avoiding significant MD orientation. The MDO section (14) may include heated cylinders (35a) and (35b), followed by stretch cylinders (36a) and (36b) and/or cooling cylinder (37). In heated rolls (35a, 35b), the film (15) is heated to a temperature T3. T3 will depend on the composition of the film, and will be sufficient to avoid significant MD orientation. In one embodiment, T3 is from about 80°C to about 150°C, alternatively is above 95°C and alternatively is above 120°C.
[0080] As should be understood by the person skilled in the art, the number of stretching cylinders, heated cylinders and cold cylinders in the first MDO section (14) may vary, as well as the number of MDO sections. Thus, in an alternative embodiment, the apparatus may comprise one or more additional sets of stretching rollers, heated rollers, and/or cooling rollers to impart desired physical and aesthetic characteristics, such as porosity and opacity. As an example, a second set of heated cylinders, stretching cylinders and/or cooling cylinder may be located in the first MDO section (14), downstream of the drawing cylinders (36a) and (36b) and upstream of the cooling (37). In an alternative embodiment, a second set of heated cylinders, stretching cylinders and/or cooling cylinder is located downstream of the CDI section (16) in a second MDO section.
[0081] The film (15) moves downstream of the MDO section (14) at a speed of V3. In one embodiment, the ratio of V3/V1 is greater than 1, alternatively greater than 2, alternatively less than 25, alternatively about 2 to about 25, alternatively about 5 to about 15, alternatively about 5 to about 25. In one embodiment, the ratio of V3/V2 and/or V2/V1 is greater than 1, alternatively is greater than 2, alternatively is less than 5, alternatively is from about 1 to about 5, and alternatively it is from about 2 to about 5.
[0082] The transverse direction interdigitated cylinder (CDI) section (16), if present, may include a tension cylinder (38) followed by interdigitation cylinders (40, 42). In the present invention, the interdigitation rollers (40, 42) are designed to stretch the film in the transverse direction, resulting in additional film activation and imparting air permeability. In one embodiment, machine direction interdigitation cylinders are used in place of, or in addition to, interdigitation cylinders (40, 42) in the transverse direction, before or after the CDI section (16). Suitable transverse direction interdigitated cylinders are described in US patent 7,442,332.
[0083] In place of the MDO section and/or the CDI section or in addition to these sections, the film can be stretched by using a stretch frame (not shown). This can be used to perform both MDO and CDO.
[0084] The film (15) may move from the CDI section (16) to other optional components including, but not limited to, a crown treatment section, an annealing section, a second MDO section and/ or a winder, where it is then ready for its intended use. The films of the present invention are useful for a variety of purposes, including, for example, use in personal care products such as disposable absorbent products. Non-limiting examples include, training pants, adult incontinence pads and pants, swimwear, sanitary napkins, tampons, sanitary towels, etc. In one embodiment, the present invention is related to an absorbent article comprising the films described herein. In one embodiment, the absorbent article is a diaper.
[0085] The present invention further describes laminates comprising the films of the present invention. The laminates comprise a first layer comprising the air permeable thermoplastic films described herein, and a substrate affixed to one or both surfaces of the film. The substrate can be any woven or non-woven material suitable for use with thermoplastic films, and in one embodiment is a woven non-woven. The substrate may have a basis weight of 100 gsm or less, alternatively 50 gsm or less, alternatively 25 gsm or less, alternatively 15 gsm or less, and alternatively 10 gsm or less. The substrate can be fixed to the film by a variety of means such as adhesive lamination, ultrasound bonding, extrusion bonding, etc.
[0086] The films and/or laminates of the present invention are suitable for use as diaper or ear backsheets (closing flap), and can be formed into pouches for packaging, wrapping products such as hygiene items, as well as food such as sandwiches, fruits, vegetables and the like, air permeable poly pouches such as air permeable diapers. Other non-limiting examples of articles in which the laminates of the present invention can be used include construction applications such as roofing and wall coverings, and backsheets for flooring and carpeting.
[0087] The invention will be further presented in light of the following detailed examples. Opacity
[0088] The opacity of the film is measured as follows: The method uses the ratio of the reflectance of the sample combined with a white background, for the same sample combined with a black background. A Hunterlab D25A colorimeter is calibrated and standardized to the manufacturer's specifications. Samples are cut large enough to cover the meter inlet opening. The sample is placed in the port with the rubber cylinder side or wavy side up. The sample is covered with an uncalibrated white tile. “Read” and “xyz” are pressed. The white tile is removed. The sample is covered with a black glass tile. “100%” is pressed. The “y” value of the sample will be shown, along with the percentage opacity value. In all examples, samples were subjected to incremental CD stretching (CDI).
[0089] Alternatively, the opacity of the film can be measured in accordance with ASTM D1746. Hydrostatic head pressure
[0090] The hydrostatic head pressure can be measured according to the method described in AATCC 127-2008. Specifically, a Textest FX 3000 Hydrotester III instrument, 7/05 s/n 597 or above may be used. The standard test gradient is 60 mbar/min, and a standard bond 70 gsm woven polypropylene nonwoven is used as the support. The test endpoint is the third drop, and the pressure in mbar is recorded when the first, second and third drops penetrate the sample and/or the pressure when the sample is ruptured. If no water penetration is observed, the maximum test pressure is recorded. Trap Tear Resistance
[0091] A mold sample is cut to 3" x 6" dimensions. From this mold, a trapezoidal mold is marked having a 4" long side, a 1" parallel short side, and a height (distance between the parallel sides, measured perpendicular to the sides) of 3". Starting in the middle of the edge of the short side, a slit perpendicular to the short side having a length of 5/8” is cut. The mold is placed in clamps of an Instron Model 1122, 4301, or equivalent tension test unit showing a constant rate of extension. The distance between the clamps is set to 1”. The load cell is adjusted and standardized according to the instructions. For Voltage Testers equipped with Series IX software, the appropriate Series IX test method is selected from the “method” menu in the software.
[0092] The load range of the test unit is adjusted such that the maximum load occurs at 85% of full load scale. Transverse displacement is set at twelve inches (12”) per minute. The mold is secured to the upper and lower brackets along the non-parallel marked side of the trapezoid such that one end edge of the brackets is in line with the one inch (1”) side of the trapezoid and the cut is midway between the clamps. The test unit starts and records the tear strength of the samples. EXAMPLE 1:
[0093] A film was formed according to the method previously described. The polymer formulation by weight included 48% polyethylene, 45% calcium carbonate, 6% polypropylene and 1% processing aids. This formulation was melt blended and extruded as a monolayer at a temperature of about 260°C and extruded into a cold cylinder rotating at approximately 45.7 meters per minute and a temperature of 116°C. The film was stretched on a stretching cylinder operating at a V2 speed of 149 meters per minute and a temperature of 88°C. It was then stretched in an MDO operating at a speed of 278 meters per minute and a temperature below 95°C. The formed film had a basis weight of 11.4 gsm and a CD load at break of 1.14 Newtons/cm. The elongation in the transverse direction at break was 446%. In machine direction, the breaking load was 3.16 Newtons/cm. The elongation in machine direction at breakout was 269%. The opacity was 59.4%, and no TiO2 was added. The water vapor transmission rate (WVTR) was 9,083 grams H2O/24 hours/m2. All of this data exceeds the specifications for a 16 gsm basis weight film with a reduction in materials. EXAMPLES 2 TO 11:
[0094] By using the method described in Example 1, additional molded films were formed. The samples contained 1% processing aids, polypropylene and fillers as indicated below, with the remainder of the composition comprising polyethylene. The physical characteristics of the films are shown in Table 1. Unless otherwise indicated, the films contained 50% calcium carbonate and did not contain titanium dioxide.
[0095] According to Example 2, a three-layer film was formed, where the surface layers contained polyethylene with 4% polypropylene and the core layer contained polyethylene with 33% polypropylene. The percent thickness of layers A/B/A was 15/70/15.
[0096] In Example 3, a monolayer film is formed comprising polyethylene, 11% polypropylene and 47% calcium carbonate as filler.
[0097] In Example 4, a monolayer film comprising 9% polypropylene was formed. The V2/V1 ratio was 2.2 and the V3/V2 ratio is 2.0.
[0098] In Example 5, a monolayer film comprising 16% polypropylene was formed. The V2/V1 ratio was 3.2 and the V3/V2 ratio is 2.5.
[0099] In Examples 6 and 7, monolayer films comprising 33% polypropylene were formed. The V2/V1 ratio was 4.0 and 3.5, respectively, and the V3/V2 ratio was 1.5 and 1.3, respectively.
[0100] In Example 8, a multilayer film comprising three layers was formed, in which the outer layers contained 0% polypropylene and the inner layer contained 33% polypropylene. The ratio of V2/V1 was 3.2 and V3/V2 is 2.0. The percent thickness of layers A/B/A was 15/70/15.
[0101] In Examples 9 and 10, a monolayer film comprising 33% polypropylene as well as a rubber additive was formed. The ratio of V2/V1 was 3.5 V3/V2, eg 9 is 1.3 and eg 10 is 1.5.
[0102] In Example 11, a monolayer film is formed, comprising 21% polypropylene and 46% calcium carbonate. The V2/V1 ratio is 3 and the V3/V2 ratio is 2. TABLE 1

[0103] In all embodiments of the present invention, all tracks are inclusive and combinable. It is understood that all numerical quantities may be modified by the term "about" unless specifically indicated. When the terms "includes", "including", "contains" or "containing" are used in the Report or Claims, it is intended to be inclusive in a manner similar to the term "comprising" insofar as the term is interpreted when used as a transitional word in a Claim.
[0104] All documents cited in the Detailed Description of the Invention are, in the relevant parts, incorporated herein by reference; citation of any document is not to be construed as an admission that it is prior art in relation to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, it is the meaning or definition associated with that term in this document that shall prevail.
[0105] Although particular embodiments of the present invention have been illustrated and described, it should be clear to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Thus, it is intended to cover in these Claims all such changes and modifications that fall within the scope of this invention.
权利要求:
Claims (20)
[0001]
1. Method for Making Film Product (15), Thermoplastic, is provided, characterized in that it comprises extruding a cast mesh comprising a thermoplastic polymer from an extruder (24) into a first cold cylinder (28), said first cold cylinder (28) operating at a peripheral velocity V1 and a temperature T1, which is below the melting point of the thermoplastic polymer and which cools said molten mesh to form a film (15); advancing the film (15) to a first stretching cylinder (36a) operating at a peripheral velocity V2 which is greater than the peripheral velocity V1 and at a temperature T2; advancing the film (15) to a first machine direction guiding section (14) comprising at least one heated cylinder (35a, 35b) having a temperature T3 and a second stretching cylinder (36b); and stretching the film (15) at the first machine direction orientation section (14) in the machine direction to produce a film (15) having limited machine direction orientation and a ratio of MD load at break to a load of CD on break less than 10.
[0002]
Method for Making Film Product (15), Thermoplastic, according to Claim 1, characterized in that the ratio of MD load at break to CD load at break is 8.
[0003]
Method for Making Film Product (15), Thermoplastic, according to Claim 1, characterized in that the ratio of MD load at break to CD load at break is 5.
[0004]
Method for Making Thermoplastic Film Product (15) according to Claim 1, characterized in that the cast mesh is molded, blown, calendered, mono-extruded, co-extruded or combinations thereof.
[0005]
Method for Making Thermoplastic Film Product (15) according to Claim 1, characterized in that it further comprises the step of advancing the film (15) to at least one additional cold cylinder operating at a temperature T and a a peripheral velocity V.
[0006]
Method for Making Film Product (15), Thermoplastic, according to Claim 1, characterized in that it further comprises the step of stretching the film (15) in the transverse direction.
[0007]
Method for Making Film Product (15), Thermoplastic, according to Claim 6, characterized in that the film (15) has a water vapor transmission rate of at least 500 grams - H2O/24- hours/m2.
[0008]
A method for making thermoplastic film product (15) according to claim 6, characterized in that the film (15) is stretched in the transverse direction using interdigitated cylinders (40, 42).
[0009]
A method for making thermoplastic film product (15) according to claim 1, characterized in that the film (15) is advanced through at least a second machine direction guiding section comprising at least one cylinder additional heating and at least one additional stretch cylinder.
[0010]
10. Method for Making Film Product (15), Thermoplastic, according to Claim 9, characterized in that the second machine direction orientation section is located downstream from a cylinder section interdigitated in the transverse direction ( 16).
[0011]
Method for Making Film Product (15), Thermoplastic, according to Claim 9, characterized in that the second machine direction orientation section is located upstream from a cylinder section interdigitated in the transverse direction ( 16).
[0012]
Method for Making Thermoplastic Film Product (15) according to Claim 1, characterized in that the temperature T1 is from 80°C to 160°C.
[0013]
Method for Making Film Product (15), Thermoplastic, according to Claim 1, characterized in that the temperature T2 is from 60°C to 100°C.
[0014]
Method for Making Film Product (15), Thermoplastic, according to Claim 1, characterized in that the temperature T3 is from 80°C to 150°C.
[0015]
A method for making thermoplastic film product (15) according to claim 1, characterized in that the film (15) has a basis weight of 15 gsm or less.
[0016]
Method for Making Thermoplastic Film Product (15) according to Claim 1, characterized in that the film (15) has a basis weight of 5gsm to 15gsm.
[0017]
A method for making thermoplastic film product (15) according to claim 1, characterized in that the film (15) has a basis weight of 8gsm to 13gsm.
[0018]
Method for Making the Thermoplastic Film Product (15) according to Claim 1, characterized in that the film (15) has a notched Elmendorf tear strength in the machine direction of at least 5 g.
[0019]
A method for making thermoplastic film product (15) according to claim 1, characterized in that the film (15) has a notched trapezoidal tear strength in the machine direction of at least 15 g.
[0020]
Method for Making Thermoplastic Film Product (15) according to Claim 1, characterized in that the thermoplastic polymer is an olefin block copolymer, an ethylene-based polymer, a propylene-based polymer or combinations thereof.
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同族专利:
公开号 | 公开日
EP3351380A1|2018-07-25|
HK1258015A1|2019-11-01|
US20170020740A1|2017-01-26|
KR20170009901A|2017-01-25|
KR102108157B1|2020-05-28|
USRE48555E1|2021-05-18|
US10398605B2|2019-09-03|
JP2020122159A|2020-08-13|
BR112016025367A2|2017-08-15|
CN106459525A|2017-02-22|
SA516380252B1|2020-03-22|
US10398606B2|2019-09-03|
KR20200051047A|2020-05-12|
AU2015259236B2|2019-05-23|
US9492332B2|2016-11-15|
AU2015259236A1|2016-11-03|
CN109705437A|2019-05-03|
US20190240075A1|2019-08-08|
EP3142858A1|2017-03-22|
US20180140470A1|2018-05-24|
AU2019213370A1|2019-08-29|
WO2015175593A1|2015-11-19|
JP6702888B2|2020-06-03|
CN112852040A|2021-05-28|
AU2015259236C1|2020-10-15|
CL2016002863A1|2017-02-17|
US20150328058A1|2015-11-19|
JP2017515952A|2017-06-15|
KR102159539B1|2020-09-25|
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法律状态:
2019-12-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
2021-04-13| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
2021-07-27| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
2021-08-17| B350| Update of information on the portal [chapter 15.35 patent gazette]|
2021-09-14| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 13/05/2015, OBSERVADAS AS CONDICOES LEGAIS. |
优先权:
申请号 | 申请日 | 专利标题
US201461992438P| true| 2014-05-13|2014-05-13|
US61/992,438|2014-05-13|
US201462053385P| true| 2014-09-22|2014-09-22|
US62/053,385|2014-09-22|
US201462092351P| true| 2014-12-16|2014-12-16|
US62/092,351|2014-12-16|
PCT/US2015/030463|WO2015175593A1|2014-05-13|2015-05-13|Breathable and microporous thin thermoplastic film|
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