Film with Layered Segments and Apparatus and Method for Making the Same
A film having first segments and second segments arranged across the film's width direction is disclosed. The first and second segments are separated from each other by polymer interfaces. The first segments include a first polymeric composition and the second segments include a second polymeric composition. At least some of the second segments are layered second segments having first and second layers in the film's thickness direction, and one of the first or second layers includes a third polymeric composition different from the second polymeric composition. An extrusion die useful for making the film and a method for making the film using the extrusion die are also disclosed.
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Co-extrusion of multiple polymeric components into a single film is known in the art. For example, multiple polymeric flow streams have been combined in a die or feedblock in a layered fashion to provide a top to bottom multilayer film. It is also known to provide co-extruded film structures where the film is partitioned, not as coextensive layers in the thickness direction, but as stripes along the width dimension of the film. This has sometimes been called “side-by-side” co-extrusion. Extruded products with side-by-side oriented stripes are described, for example, in U.S. Pat. No. 6,245,401 (Ying et al.), U.S. Pat. No. 6,669,887 (Hilston et al.), and U.S. Pat. No. 7,897,081 (Ausen et al.), U.S. Pat. App. Pub. No. 2012/0022490 (Marche et al.), and Int. Pat. App. Pub. Nos. WO2011/097436 (Gorman et al.) and WO 2011/119323 (Ausen et al.). Films having multiple segmented flows within a matrix of another polymer are described, for example, in U.S. Pat. No. 5,773,374 (Wood et al.). Films having an arrangement of polymeric segments along the top surface that is different from the arrangement of polymeric segments along the bottom surface of the film are disclosed in Int. Pat. App. Pub. No. WO 2010/099148 (Hoium et al.).
SUMMARYAlthough products with side-by-side oriented stripes and extrusion devices for producing them are known, there is still a need for alternatives and improvements to such products and devices. The present disclosure provides a film having first segments and second segments arranged across the width of the film, in which at least the second segments are layered in the film's thickness direction, and an apparatus and method for making the film. In some embodiments, at least portions of the second segments are elastic while the first segments are relatively inelastic.
In one aspect, the present disclosure provides a film with first segments and second segments arranged across the film's width, separated from each other by polymer interfaces. The first segments and second segments each have first major surfaces that collectively form the first major surface of the film. The first segments include a first polymeric composition, and the second segments include a second polymeric composition. At least some of the second segments are layered second segments having first and second layers in the film's thickness direction, wherein one of the first or second layers includes a third polymeric composition different from the second polymeric composition. Neither the second or third polymeric composition extends through the entire thickness of a given layered second segment. At least two of the layered second segments have the second polymeric composition and the third polymeric composition in an identical arrangement. The film has a moisture vapor transmission rate of less than 800 g/m2/day. In embodiments where the first segments are layered in the film's thickness direction, the first major surfaces of the first segments and the first major surfaces of the second segments do not share a common polymeric composition. In embodiments where the layered second segments consist of the first and second layers and the third polymeric composition is the same as the first polymeric composition, the first polymeric composition extends through the entire thickness of the first segments.
In another aspect, the present disclosure provides a film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition that is more elastic than the first polymeric composition, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, and wherein the first segments have stretch-induced molecular orientation in a direction parallel to their lengths.
In another aspect, the present disclosure provides a film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition that is more elastic than the first polymeric composition, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, and wherein the time to failure in a hang shear evaluation is at least 100 minutes, wherein the hang shear evaluation is carried out by hanging a 200-gram weight on a 2.54 cm wide by 3.8 cm sample at 38° C. such that the second segments are stretched in the film's width direction.
In another aspect, the present disclosure provides a laminate that includes the aforementioned film according to one or more of the above aspects joined to a fibrous carrier.
In another aspect, the present disclosure provides a film with first segments and second segments arranged across the film's width, separated from each other by polymer interfaces. The first segments include a first polymeric composition, and the second segments include a second polymeric composition that is more elastic than the first polymeric composition. At least some of the second segments are layered second segments having first and second layers in the film's thickness direction, and one of the first or second layers comprises a third polymeric composition different from the second polymeric composition. Neither the second or third polymeric composition extends through the entire thickness of a given layered second segment. The second segments each have a width in the film's width direction of less than one millimeter. The first and second segments each have first major surfaces that collectively form the first major surface of the film. In embodiments where the first segments are layered in the film's thickness direction, the first major surfaces of the first segments and the first major surfaces of the second segments do not share a common polymeric composition.
In another aspect, the present disclosure provides a laminate including a film joined to a fibrous carrier. The film includes first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces. The first segments include a first polymeric composition, and the second segments include a second polymeric composition that is more elastic than the first polymeric composition. At least some of the second segments are layered second segments having first and second layers in the film's thickness direction, wherein one of the first or second layers including a third polymeric composition different from the second polymeric composition. Neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, and the second segments each have a width in the film's width direction of less than one millimeter.
The films according to any of the foregoing aspects or found in laminates according to any of the foregoing aspects can advantageously be formed by coextrusion of the first and second segments.
Accordingly, in another aspect, the present disclosure provides an extrusion die having at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot. A first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot, and a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot. The second slot segment and first slot segment are arranged side-by-side to provide a combined width. A third fluid passageway within the extrusion die extends from a die cavity within the extrusion die to the second slot segment, and the third fluid passageway meets the second fluid passageway from an area above the second fluid passageway at a point where the second fluid passageway enters the dispensing slot. The third fluid passageway has a width at a point where it meets the second fluid passageway that is less than the combined width of the first and second slot segments. In some embodiments, the fluid passageways are provided by a plurality of sequences of shims. Each sequence of shims includes at least one first shim that provides the first fluid passageway, at least one second shim that provides the second fluid passageway, and at least one third shim that provides the at least one third fluid passageway.
In another aspect, the present disclosure provides a method of extruding a film that includes providing the foregoing extrusion die and extruding a first polymeric composition from the first cavity, a second polymeric composition from the second cavity, and a third polymeric composition from the die cavity, wherein at the point where the second fluid passageway enters the dispensing slot, the third polymeric composition flows on top of the second polymeric composition to form a layer to provide a film having first segments comprising the first polymeric composition and second segments comprising a layer of the third polymeric composition on top of the second polymeric composition. In some embodiments, the third fluid passageway is diverted into branches that meet the second fluid passageway at areas above and below the second fluid passageways at the point where the second fluid passageway enters the dispensing slot.
In another aspect, the present disclosure provides a method of extruding a film according to any of the aspects described above. The method includes providing an extrusion die having at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot and extruding the first, second, and third polymeric compositions from the first, second, and third cavities, respectively, so as to form the film. A first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot. A second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot, and a third fluid passageway within the extrusion die extends from a die cavity within the extrusion die to the second slot segment. The third fluid passageway meets the second fluid passageway from an area above the second fluid passageway at a point where the second fluid passageway enters the dispensing slot. The third fluid passageway has a width at a point where it meets the second fluid passageway that is less than the combined width of the first and second slot segments.
Advantageously, the extrusion dies and methods disclosed herein allow the first and second segments to be made simultaneously in a single co-extrusion process. Patterns of first and second segments can also be separated by zones of the first polymeric composition (or a different polymeric composition) that are wider than the first segments. The arrangement of the first and second segments may be an arrangement in which the first and second segments alternate across the width of the film.
In some embodiments, the films according to the present disclosure include a significant amount of material that is relatively inelastic in combination with elastic material, but they still can have useful elongations when stretched in a direction transverse to the longitudinal direction of the first and second segments or in a direction parallel to the longitudinal direction of the first and second segments if stretched to the point of plastic deformation of the more inelastic segments. In these embodiments, relatively expensive elastic materials are used efficiently, and the films disclosed herein can be lower in cost than other elastic films, which typically include higher amounts of elastic materials. In some embodiments, in addition to exploiting efficient utilization of elastic polymeric compositions, the films disclosed herein can also be made to have very desirable hysteresis properties and may not require an “activation” step.
In this application, terms such as “a”, “an” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terms “a”, “an”, and “the” are used interchangeably with the term “at least one”. The phrases “at least one of” and “comprises at least one of” followed by a list refers to any one of the items in the list and any combination of two or more items in the list. All numerical ranges are inclusive of their endpoints and non-integral values between the endpoints unless otherwise stated.
The term “alternating” as used herein refers to embodiments in which one first segment is disposed between any two consecutive second segments (i.e., the second segments have only one first segment between them) and one second segment is disposed between any two consecutive first segments.
The term “elastic” refers to any material (such as a film that is 0.002 mm to 0 5 mm thick) that exhibits recovery from stretching or deformation. A material, film, or composition that is more elastic than another material, film, or composition exhibits at least one of higher elongation or lower hysteresis (usually both) than another material, film, or composition. In some embodiments, a material may be considered to be elastic if upon application of a stretching force, it can be stretched to a length that is at least about 25 (in some embodiments, 50) percent of its initial length and can recover at least 40 percent of its elongation upon release of the stretching force.
The term “inelastic” refers to any material (such as a film that is 0.002 mm to 0 5 mm thick) that does not exhibit recovery from stretching or deformation to a large extent. For example, an inelastic material that is stretched to a length that is at least about 50 percent greater than its initial length will recover less than about 40, 25, 20, or 10 percent of its elongation upon release of its stretching force. In some embodiments, an inelastic material may be considered to be a flexible plastic that is capable of undergoing permanent plastic deformation if it is stretched past its reversible stretching region.
“Elongation” in terms of percent refers to {(the extended length−the initial length)/the initial length} multiplied by 100. Unless otherwise defined, when a film or portion thereof is said herein to have an elongation of at least 100 percent, it is meant that the film has an elongation to break of at least 100 percent using the test method described in the Examples, below.
The term “extensible” refers to a material that can be extended or elongated in the direction of an applied stretching force without destroying the structure of the material or material fibers. An extensible material may or may not have recovery properties. For example, an elastic material is an extensible material that has recovery properties. In some embodiments, an extensible material may be stretched to a length that is at least about 5, 10, 15, 20, 25, or 50 percent greater than its relaxed length without destroying the structure of the material or material fibers.
The term “machine direction” (MD) as used above and below denotes the direction of a running, continuous web during the manufacturing of the film disclosed herein. When a portion is cut from the continuous web, the machine direction corresponds to the longitudinal “y” direction of the film. Accordingly, the terms machine direction and longitudinal direction may be used herein interchangeably. The term “cross-direction” (CD) as used above and below denotes the direction that is essentially perpendicular to the machine direction. When a portion of the film disclosed herein is cut from the continuous web, the cross-direction corresponds to the width “x” of the film.
The terms “first”, “second”, “third”, “fourth”, “fifth”, and “sixth” are used in this disclosure. It will be understood that, unless otherwise noted, these designations are used in their relative sense only. These designations may be applied to the components merely as a matter of convenience in the description of one or more of the embodiments. Likewise, “top”, “bottom”, “above”, and “below” are used in their relative sense only.
The above summary of the present disclosure is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The description that follows more particularly exemplifies illustrative embodiments. It is to be understood, therefore, that the drawings and following description are for illustration purposes only and should not be read in a manner that would unduly limit the scope of this disclosure.
The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings.
Referring now to
The first segments 110 include a first polymeric composition, and the second segments 104 include a second polymeric composition in first or second layer 106 or 108. The other layer of the first or second layer 106 or 108 that does not include the second polymeric composition includes a third polymeric composition different from the second polymeric composition. For example, the first layer 106 in
In the embodiment illustrated in
In films according to the present disclosure, including in the embodiments shown in
None of the first, fifth, or sixth polymeric composition, when present, extends through the thickness “z” of a given layered first segment. It may be understood from the embodiment illustrated in
As can be seen in the embodiments of
The first and second segments are arranged across the film's width “x” and are separated by polymer interfaces 105, 205, and 305, as shown in
The first and second segments may be overlapping or non-overlapping in the width “x” direction of the film. In some embodiments, for at least a portion of the film, the polymer interface separating the first and second segments is an interdigitated interface between the first and second polymeric compositions or other polymeric compositions in the first and second segments. In some embodiments, for at least a portion of the film, the polymeric interface separating the first and second segments is not an interdigitated interface between the first and second polymeric compositions. As described above, a portion of the first and/or second layers can extend over the first regions at one of the major surfaces of the film, but in some embodiments, a portion of the second polymeric composition does not intermix with the first polymeric composition to form a tip that is sandwiched between two portions of the first polymeric composition. While the polymer interfaces between the first and second segments may be linear or curved, generally the polymer interfaces are not formed by two linear segments that meet at a point.
The arrangement in the width “x” direction of polymer compositions on the first and second major surfaces of the film may be the same or different. In the embodiments shown in
Generally, the first and second segments are arranged side-by-side. Typically, each first segment is bonded alongside at least one second segment, and each second segment is bonded alongside at least one first segment. The arrangement in the width “x” direction of first and second segments may also include other, different segments. For example, the first and second segments may be arranged with a third segment to provide, for example, an ABCABCABC pattern on the first and optionally the second surface of the film. The film may also have four or more different segments that at least partially repeat across the film's width “x”. For some of these embodiments in which one first segment is disposed between any two consecutive second segments and one second segment is disposed between any two consecutive first segments, the films may be considered alternating with respect to the first and second segments. It is also possible that two first segments, both including the first polymeric composition and having the same arrangement of layers in the thickness direction if more than one layer is present, may be co-extruded side-by-side and arranged with the second segments. In these embodiments, a weld line or polymer interface may be visible, particularly upon stretching the film in the width direction, depending on the loading of pigment or other factors. In some of these embodiments, the film can have an AABAABAAB pattern on the first and optionally the second surface of the film.
As shown in the embodiments illustrated in
In films according to the present disclosure, including in the embodiments shown in
In some embodiments, films according to the present disclosure have moisture vapor transmission rates of less than 800 g/m2/day. In some embodiments, both the first segments and the second segments of the film have moisture vapor transmission rates of less than 700 g/m2/day, 600 g/m2/day, 500 g/m2/day, 400 g/m2/day, 300 g/m2/day, 200 g/m2/day, or 100 g/m2/day. Moisture vapor transmission rates can be measured according to the method provided in the Examples, below, which is based on ASTM E96-80. In these embodiments, the films as extruded have moisture vapor transmission rates of less than 800 g/m2/day, which typically means they are not microporous. Microporosity may be observed, for example, by optical microscopy. It should be understood also that the films have moisture vapor transmission rates of less than 800 g/m2/day before and after stretching the film. The films are not designed to become microporous upon stretching. However, in some embodiments, the film may be apertured after it is extruded, for example, when it is laminated to a fibrous web as described below. Thus, the moisture vapor transmission rates of less than 800 g/m2/day applies to the films before any post-extrusion aperturing.
The films disclosed herein in any of their embodiments can conveniently be prepared by an extrusion die and/or method according to the present disclosure. The extrusion die according to the present disclosure has a variety of passageways from cavities within the die to a dispensing slot. The dispensing slot has a width, which is the dimension that corresponds to the width “x” of the resulting extruded film, and a thickness, which is the dimension that corresponds to the thickness “z” of the resulting extruded film. The extrusion die includes a first fluid passageway that extends from a first cavity to a first slot segment of the dispensing slot and a second fluid passageway that extends from a second cavity to a second slot segment of the dispensing slot. The first and second slot segments are arranged side-by-side along the width of the dispensing slot and have a combined width. A third fluid passageway within the extrusion die extends from a die cavity within the extrusion die to the second slot segment and meets the second fluid passageway from an area above the second fluid passageway at a point where the second fluid passageway enters the dispensing slot. That is, at least a portion of the third fluid passageway is on top of the second fluid passageway in the thickness direction at the point where the second fluid passageway enters the dispensing slot. The die cavity where the third fluid passageways begin may be the same cavity as the first cavity, or a third, different cavity may be useful depending on the desired construction of the film. The fluid passageways are capable of physically separating the polymers from the first and second cavities and optionally any further die cavities within the extrusion die until the fluid passageways enter the dispensing slot. The shape of the different passageways within the die may be identical or different. Examples of passageway cross-sectional shapes include round, square, and rectangular shapes.
In many embodiments, there are multiple first segments and multiple second slot segments arranged along the width of the dispensing slot. In some of these embodiments, the first and second slot segments alternate such that one first slot segment is disposed between any two adjacent second slot segments. Similarly, one second slot segment can be disposed between any two adjacent first slot segments. It should be understood that for multiple first slot segments, each is fed by a first passageway that extends from the same first cavity. Likewise, for multiple second slot segments, each is fed by a second passageway that extends from the same second cavity and a third passageway that extends from the same die cavity within the extrusion die. Although the second slot segments allow for polymeric compositions, one from the second cavity and one from the die cavity to which the third fluid passageways are connected, to be layered in the thickness “z” direction, the second slot segments are not further divided in the width “x” direction. That is, multiple fluid passageways do not enter the second slot segments of the dispensing slot in a side-by-side arrangement. Accordingly, the layered second segments of the film extruded from the second slot segments are uniform in composition across their widths.
The combined width of the first and second slot segments should be understood to be the width of the first slot segment added to the width of the second slot segment. The width of the third fluid passageway at a point where it meets the second fluid passageway is less than the combined width of the first and second slot segments. The third fluid passageway is therefore distinguished from a fluid passageway that extends across the width of the dispensing slot to provide, for example, a continuous skin layer of generally uniform composition on top of a side-by-side coextruded film. In some embodiments, the width of the third fluid passageway at a point where it meets the second fluid passageway is about the same as the width of the second slot segments.
The die may conveniently be comprised of a plurality of shims. The shims can include at least one first shim that provides the first fluid passageway and at least one second shim that provides the second fluid passageway. The shim that provides the second fluid passageway may also provide at least one third fluid passageway. Each of the shims in the plurality of shims typically defines a portion of the dispensing slot. In some embodiments, the plurality of shims comprises a plurality of sequences of shims that includes shims where each sequence provides at least first and second fluid passageways between a first and a second cavity and the dispensing slot. In some of these embodiments, there will be additional shims that provide a passageway between a third (fourth, fifth, sixth, etc.) cavity and the dispensing slot. A subsequence of shims can form a layered second segment, which is bonded to a first segment on one or both sides. Some examples of useful shim sequences and subsequences will be discussed with more particularity below in connection with
In some embodiments, the shims will be assembled according to a plan that provides a sequence of shims of diverse types. Since different applications may have different requirements, the sequences can have diverse numbers of shims. The sequence may be a repeating sequence that is not limited to a particular number of repeats in a particular zone. Or the sequence may not regularly repeat, but different sequences of shims may be used. In one embodiment, a twelve-shim sequence that when properly provided with molten polymer forms a segment of film of a single-material alternating with a layered segment is described below in connection with
In some embodiments, the shims that provide a passageway between one cavity and the dispensing slot might have a flow restriction compared to the shims that provide a passageway between another cavity and the dispensing slot. The width of the distal opening within, for example, different shims of the sequence of shims, may be identical or different. For example, the portion of the dispensing opening provided by the shims that provide a passageway between one cavity and the dispensing slot could be narrower than the portion of the dispensing opening provided by the shims that provide a passageway between another cavity and the dispensing slot.
In some embodiments, extrusion dies described herein include a pair of end blocks for supporting the plurality of shims. In these embodiments it may be convenient for one or all of the shims to each have one or more through-holes for the passage of connectors between the pair of end blocks. Bolts disposed within such through-holes are one convenient approach for assembling the shims to the end blocks although the ordinary artisan may perceive other alternatives for assembling the extrusion die. In some embodiments, the at least one end block has an inlet port for introduction of fluid material into one or more of the cavities.
In some embodiments, the assembled shims (conveniently bolted between the end blocks) further comprise a manifold body for supporting the shims. The manifold body has at least one (or more (e.g., two or three, four, or more)) manifold therein, the manifold having an outlet. An expansion seal (e.g., made of copper or alloys thereof) is disposed so as to seal the manifold body and the shims, such that the expansion seal defines a portion of at least one of the cavities (in some embodiments, a portion of the first, second, and third cavities), and such that the expansion seal allows a conduit between the manifold and the cavity.
In some embodiments, the shims for dies described herein have thicknesses (in the narrowest dimension of the shim) in the range from 50 micrometers to 125 micrometers. Typically, the fluid passageways have dimension in the width direction of the extrusion die in a range from 50 micrometers to 750 micrometers, and heights in the thickness dimension less than 5 mm (with generally a preference for smaller heights for decreasingly smaller passageway widths), although widths and heights outside of these ranges may also be useful. In some embodiments, the fluid passageways can have heights in a range from 10 micrometers to 1.5 millimeters. For fluid passageways with large widths or diameters, several smaller thickness shims may be stacked together, or single shims of the desired passageway width may be used. Widths of the first and second slot segments can correspond to the widths of the fluid passageways described above. The first and second slot segments may have widths within 10 percent of the widths of the fluid passageways.
The shims are tightly compressed to prevent gaps between the shims and polymer leakage. For example, 12 mm (0.5 inch) diameter bolts are typically used and tightened, at the extrusion temperature, to their recommended torque rating. It may be desirable to press the shims together with force while tightening the bolts. Also, the shims are aligned to provide uniform extrusion out the dispensing slot, as misalignment can lead to first and second segments extruding at an angle out of the die which may inhibit bonding between these segments. To aid in alignment, an indexing groove can be cut into the shims to receive a key. Also, a vibrating table can be useful to provide a smooth surface alignment of the extrusion tip.
The size of the various segments and layers in the film can be adjusted, for example, by the composition of the extruded polymers (e.g., materials, melt viscosities, additives, and molecular weight), pressure in the cavities, flow rate of the polymer stream, and/or the dimensions of the passageways.
In practicing methods described herein, the polymeric compositions might be solidified simply by cooling. This can be conveniently accomplished by, for example, quenching the extruded film or article on a chilled surface (e.g., a chilled roll). In some embodiments, it is desirable to maximize the time to quenching to increase the weld line strength.
A plurality of shims that is useful for providing a layered second segment in which layers on the first and second major surfaces are fed from the same cavity is shown in
Referring now to
Shim 500 has several holes 547 to allow the passage of, for example, bolts to hold shim 500 and others to be described below into an assembly. Shim 500 has dispensing opening 556 in dispensing surface 567. Dispensing opening 556 may be more clearly seen in the expanded view shown in
Referring now to
Referring now to
Referring now to
Referring now to
Referring now to
Extrusion dies according to the present disclosure, which are useful for extruding the films disclosed herein, have a dispensing slot. The embodiment of
Referring now to
In this embodiment, inlet fittings 2250a, 2250b, and 2250c provide a flow path for three streams of molten polymer through end blocks 2244a and 2244b to cavities 562a, 562b, and 562c. Compression blocks 2204 have a notch 2206 that conveniently engages the shoulders on the shims (e.g., 590 and 592 on 500). When mount 2000 is completely assembled, compression blocks 2204 are attached by, e.g. machine bolts to backplates 2208. Holes are conveniently provided in the assembly for the insertion of cartridge heaters 52.
Referring now to
Another embodiment of a plurality of shims useful for an extrusion die according to the present disclosure is illustrated in
Shim 1500 has several holes 1547 to allow the passage of, for example, bolts to hold shim 1500 and others to be described below into an assembly Shim 1500 has dispensing opening 1556 in dispensing surface 1567. Dispensing opening 1556 may be more clearly seen in the expanded view shown in
Referring now to
Referring now to
Referring now to
Modifications of the shims shown in
Extrusion dies that include a repeating sequence of the shims shown in
While each of
In some embodiments of the film or the method of making the film according to the present disclosure, the film may be stretched in at least one direction. When the film or extruded article disclosed herein is a web of indefinite length, for example, monoaxial stretching in the machine direction, which is typically the direction parallel to the longitudinal direction of the first and second segments, can be performed by propelling the web over rolls of increasing speed. Means such as diverging rails and diverging disks are useful for cross-direction stretching, which is typically the film width “x” direction. A versatile stretching method that allows for monoaxial, sequential biaxial, or simultaneous biaxial stretching of a thermoplastic web employs a flat film tenter apparatus. Such an apparatus grasps the thermoplastic web using a plurality of clips, grippers, or other film edge-grasping means along opposing edges of the thermoplastic web in such a way that monoaxial, sequential biaxial, or simultaneous biaxial stretching in the desired direction is obtained by propelling the grasping means at varying speeds along divergent rails. Increasing clip speed in the machine direction generally results in machine-direction stretching. Monoaxial and biaxial stretching can be accomplished, for example, by the methods and apparatus disclosed in U.S. Pat. No. 7,897,078 (Petersen et al.) and the references cited therein. Flat film tenter stretching apparatuses are commercially available, for example, from Brückner Maschinenbau GmbH, Siegsdorf, Germany.
Films according to and/or made according to the present disclosure may have stretch-induced molecular orientation (e.g., in the first segments) after being stretched in at least one of the machine direction or cross-direction. Whether the first or second segments or other portions of the film have stretch-induced molecular orientation can be determined by standard spectrographic analysis of the birefringent properties of the oriented polymer forming the segments. The first or second segments or other portions of the film having stretch-induced molecular orientation may also be said to be birefringent, which means that the polymer in the oriented portion of the film has different effective indexes of refraction in different directions. In the present application, whether the first or second segments or other portions of the film have stretch-induced molecular orientation is measured with a retardance imaging system available from Lot-Oriel GmbH & Co., Darmstadt, Germany, under the trade designation “LC-PolScope” on a microscope available from Leica Microsystems GmbH, Wetzlar, Germany, under the trade designation “DMRXE” and a digital CCD color camera available from QImaging, Surrey, BC, Canada, under the trade designation “RETIGA EXi FAST 1394”. The microscope is equipped with a 546.5 nm interference filter obtained from Cambridge Research & Instrumentation, Inc., Hopkinton, Mass., and a 10×/0.25 objective. The degree of birefringence in an oriented film portion is typically observed to be higher in a film that has been stretched to the point of plastic deformation than in a film that only has melt-induced orientation in the machine direction. The difference in degree of birefringence between stretch-induced molecular orientation and melt-induced orientation would be understood by a person skilled in the art.
The extrusion die according to the present disclosure may be useful for making a variety of film constructions including, for example, two, three, or more different polymeric compositions. A variety of different polymeric compositions may be selected to provide first segments in side-by-side arrangement with second segments where the first segments and first and second layers of the second segments are each made, for example, from different polymeric compositions. The different polymeric compositions may be selected for their surface properties or their bulk properties (e.g., tensile strength, elasticity, color, etc). Furthermore, polymeric compositions can be selected to provide specific functional or aesthetic properties in the extruded article such as elasticity, softness, hardness, stiffness, bendability, roughness, colors, textures, or patterns.
In some embodiments, the extrusion die disclosed herein is useful for making film constructions including two different polymeric compositions. In some embodiments, the same polymeric composition may be in two different cavities. For example, in the apparatus illustrated in
In some instances, it may be useful to reduce the flow channel sizes in the third fluid passageways, for example, so that the flow velocity for the second and third polymeric compositions is more similar to the flow velocity of the first polymeric composition, which exits from flow channels formed by shims 500 shown in
A variety of polymeric compositions are useful for practicing the present disclosure. The mass flow (or volume flow) of the different polymeric compositions can be equal or unequal as they are respectively extruded. In some embodiments, it is desirable for the melt strengths of the different polymeric compositions to be similar. Polymeric compositions useful for the first segments and first and second layers of the second segments may be selected, for example, based on their compatibility and mutual adhesion properties.
In some embodiments, the polymeric compositions that may be extruded in the die disclosed herein are thermoplastic polymeric compositions (e.g., polyolefins (e.g., polypropylene, polypropylene copolymers, polyethylene, and polyethylene copolymers), polyvinyl chloride, polystyrenes and polystyrene block copolymers, nylons, polyesters (e.g., polyethylene terephthalate), polyurethanes, polyacrylates, silicone polymers, and copolymers and blends thereof). However, the die and method according to the present disclosure may also be useful for co-extruding polymeric materials that can be crosslinked (e.g., by heat or radiation). When a heat curable resin is used, the die can be heated to start the cure so as to adjust the viscosity of the polymeric material and/or the pressure in the corresponding die cavity.
The first segments in a film according to and/or made according to the present disclosure include a first polymeric composition. In some embodiments, any combination of the second layers of the layered second segments, at least a portion of the first segments, or a second region of the film (not having second segments side-by-side with first segments) are made from the first polymeric composition. In some embodiments, the first polymeric composition in the films according to the present disclosure is relatively less elastic than the second polymeric composition in the second segments. The first polymeric composition can also be inelastic as defined above. The first polymeric composition can be formed, for example, of semicrystalline or amorphous polymers or blends. Inelastic polymers can be polyolefinic, formed predominantly of polymers such as polyethylene, polyethylene copolymers, polypropylene, polypropylene copolymers, polybutylene, or polyethylene-polypropylene copolymers. In some embodiments, the first polymeric composition comprises polypropylene, polyethylene, polypropylene-polyethylene copolymer, or blends thereof.
In some embodiments of the films according to and/or made according to the present disclosure, the second polymeric composition in the second segments is relatively more elastic than the first polymeric composition described above. In some embodiments, the first segments are made from a first polymeric composition, the second layers of the layered second segments are made from a third polymeric composition, and the first layer of the layered second segments is made from a second polymeric composition that is more elastic than either the first or third polymeric composition. Examples of elastic polymeric compositions useful in the second segments include thermoplastic elastomers such as ABA block copolymers, polyurethane elastomers, polyolefin elastomers (e.g., metallocene polyolefin elastomers), olefin block copolymers, polyamide elastomers, ethylene vinyl acetate elastomers, and polyester elastomers. An ABA block copolymer elastomer generally is one where the A blocks are polystyrenic, and the B blocks are prepared from conjugated dienes (e.g., lower alkylene dienes). The A block is generally formed predominantly of substituted (e.g., alkylated) or unsubstituted styrenic moieties (e.g., polystyrene, poly(alphamethylstyrene), or poly(t-butylstyrene)), having an average molecular weight from about 4,000 to 50,000 grams per mole. The B block(s) is generally formed predominantly of conjugated dienes (e.g., isoprene, 1,3-butadiene, or ethylene-butylene monomers), which may be substituted or unsubstituted, and has an average molecular weight from about 5,000 to 500,000 grams per mole. The A and B blocks may be configured, for example, in linear, radial, or star configurations. An ABA block copolymer may contain multiple A and/or B blocks, which blocks may be made from the same or different monomers. A typical block copolymer is a linear ABA block copolymer, where the A blocks may be the same or different, or a block copolymer having more than three blocks, predominantly terminating with A blocks. Multi-block copolymers may contain, for example, a certain proportion of AB diblock copolymer, which tends to form a more tacky elastomeric film segment. Other elastic polymers can be blended with block copolymer elastomers, and various elastic polymers may be blended to have varying degrees of elastic properties.
Many types of thermoplastic elastomers are commercially available, including those from BASF, Florham Park, N.J., under the trade designation “STYROFLEX”, from Kraton Polymers, Houston, Tex., under the trade designation “KRATON”, from Dow Chemical, Midland, Mich., under the trade designation “PELLETHANE”, “INFUSE”, VERSIFY”, or “NORDEL”, from DSM, Heerlen, Netherlands, under the trade designation “ARNITEL”, from E. I. duPont de Nemours and Company, Wilmington, Del., under the trade designation “HYTREL”, from ExxonMobil, Irving, Tex. under the trade designation “VISTAMAXX”, and more.
As described above, the first and second polymeric compositions can be selected based at least partially on their compatibility and mutual adhesion properties. Compatibility and adhesion between segments can be evaluated by a hang shear evaluation as described in the Examples, below. The hang shear evaluation is carried out by hanging a 200-gram weight on a 2.54 cm long sample (measured in the longitudinal direction of the segments) having 3.8 cm exposed sample in the width direction. The evaluation is carried out at 100° F. (38° C.), and the time until the static load breaks the film is determined. The film is positioned so that the load is applied in the film width or cross-direction (that is, in a direction transverse to the longitudinal direction of the first and second segments). In some embodiments, the time to failure in a hang shear evaluation is at least 100 minutes, in some embodiments, at least 500 minutes, and in some embodiments, at least 1000 minutes. The time to failure in a hang shear evaluation may be influenced by a variety of factors. For example, for different first polymeric compositions, the second polymeric compositions that will provide the desired hang shear strength may be different. The presence of any plasticizers or compatibilizers may affect the hang shear strength. At least for these reasons, it is impractical to describe each composition that may provide a hang shear time of at least 100 minutes although guidance is provided in the following description and in the Examples, below. A time to failure in a hang shear evaluation of at least 100 minutes (in some embodiments at least 500 or 1000 minutes) may be useful for evaluating, for example, films according to the present disclosure which are designed to be extended in the width or cross-direction of the film during use. However, lower time to failure may be useful in films, for example, which are designed to be extended in the longitudinal direction of the film after the film undergoes plastic deformation of relatively inelastic segments as described in further detail below.
For some embodiments, the first polymeric composition comprises polypropylene, and the second polymeric composition is selected such that it bonds well to polypropylene. In some of these embodiments, the second polymeric composition is a thermoplastic elastomer, for example, an ABA triblock copolymer elastomer or an ABAD tetrablock copolymer. In some embodiments, the second polymeric composition is an ABA triblock copolymer of styrene or substituted styrene as the A blocks and hydrogenated polybutadiene, hydrogenated polyisoprene, or a combination of hydrogenated polybutadiene and polyisoprene as the B block. The hydrogenated B block can therefore include polyethylene, polypropylene, and polybutylene moieties. Typically the time to failure in a hang shear evaluation of a film having second segments including such a second polymeric composition and first segments comprising polypropylene is at least 100 minutes (in some embodiments at least 500 or 1000 minutes). The polystyrene units in the ABA triblock copolymer may be present in a range from 20 to 60 percent or in a range from 25 to 45 percent by weight, based on the total weight of the ABA triblock copolymer. The hydrogenated conjugated diene units in the ABA triblock copolymer may be present in a range from 40 to 80 percent or in a range from 55 to 75 percent by weight, based on the total weight of the ABA triblock copolymer. The hydrogenated polyisoprene, when present, may be present in an amount up to 15, 10, or 5 percent by weight, based on the total weight of the ABA triblock copolymer. The weight average molecular weight of the ABA triblock copolymer may be in a range from 75,000 to 250,000 grams per mole, or 150,000 to 220,000 grams per mole. The number average molecular weight of the ABA triblock copolymer may be in a range from 50,000 to 200,000 grams per mole, or 120,000 to 200,000 grams per mole. Weight and number average molecular weights can be measured, for example, by gel permeation chromatography (i.e., size exclusion chromatography) using techniques known to one of skill in the art.
A third polymeric composition, which may be at one or both major surfaces of the second segments, may be the same as or different from the first polymeric composition. In embodiments in which the second polymeric composition is more elastic than the first polymeric composition, the third polymeric composition may be selected so that the second polymeric composition is also more elastic than the third polymeric composition. The third polymeric composition can be useful, for example, for protecting the elastic, second polymeric composition during manufacture or use and/or providing a less tacky surface on the elastic polymeric composition. If the third polymeric composition is selected such that it is softer than the first polymeric composition, the force required to initially stretch the film in the width “x” direction may be less than when the third polymeric compositions is a relatively more inelastic matrix. For example, as shown in Examples 5 and 7, the initial load at 50% elongation in a film having third polymeric composition comprising a mixture of an elastic resin and polypropylene (Example 7) was lower than the initial load at 50% elongation in a film having a third polymeric composition comprising polypropylene resin and no elastic resin (Example 5).
In embodiments of the film or method disclosed herein that include a first polymeric composition, a second polymeric composition, and a third polymeric composition that is different from the first polymeric composition, blending may be useful for making a third polymeric composition that is relatively more elastic than the first polymeric composition but relatively less elastic than the second polymeric composition from which at least the first layers of the layered second segments are made. In some embodiments, the third polymeric composition comprises a blend of the first polymeric composition and the second polymeric composition. In these embodiments, the third polymeric composition generally has good compatibility with and good adhesion to both the first polymeric composition and the second polymeric composition. In some embodiments, the third polymeric composition may be a blend of an elastic resin and an inelastic resin but may not contain the resins in the first or second polymeric compositions.
In some embodiments, compatibilizers added to at least one of the second or third polymeric compositions may be useful. A compatibilizer may be useful, for example, for increasing the elongation of an elastic film, lowering the force required to stretch the film, and modifying the thicknesses of the second segments. Examples of suitable compatibilizers include hydrogenated cycloaliphatic resins, hydrogenated aromatic resins, and combinations thereof. For example, some compatibilizers are hydrogenated C9-type petroleum resins obtained by copolymerizing a C9 fraction produced by thermal decomposition of petroleum naphtha, hydrogenated C5-type petroleum resins obtained by copolymerizing a C5 fraction produced by thermal decomposition of petroleum naphtha, or hydrogenated C5/C9-type petroleum resins obtained by polymerizing a combination of a C5 fraction and C9 fraction produced by thermal decomposition of petroleum naphtha. The C9 fraction can include, for example, indene, vinyl-toluene, alpha-methylstyrene, beta-methylstyrene, or a combination thereof. The C5 fraction can include, for example, pentane, isoprene, piperine, 1,3-pentadiene, or a combination thereof. Other compatibilizers include hydrogenated poly(cyclic olefin) polymers. Examples of hydrogenated poly(cyclic olefin) polymers include hydrogenated petroleum resins; hydrogenated terpene-based resins (for example, resins commercially available under the trade designation “CLEARON”, in grades P, M and K, from Yasuhara Chemical, Hiroshima, Japan); hydrogenated dicyclopentadiene-based resins (for example, those available from Kolon Industries, South Korea, under the trade designation “SUKOREZ”; a hydrogenated C5-type petroleum resin obtained by copolymerizing a C5 fraction such as pentene, isoprene, or piperine with 1,3-pentadiene produced through thermal decomposition of petroleum naphtha available, for example, from Exxon Chemical Co., Irving, Tex., under the trade designations “ESCOREZ 5300” or “ESCOREZ 5400”; and from Eastman Chemical Co., Kingsport, Tenn., under the trade designation “EASTOTAC H”); partially hydrogenated aromatic modified dicyclopentadiene-based resins commercially available, for example, from Exxon Chemical Co. under the trade designation “ESCOREZ 5600”; resins resulting from hydrogenation of a C9-type petroleum resin obtained by copolymerizing a C9 fraction such as indene, vinyltoluene and α- or β-methylstyrene produced by thermal decomposition of petroleum naphtha available, for example, from Arakawa Chemical Industries Co., Ltd. under the trade designations “ARCON P” or “ARCON M”; and resins resulting from hydrogenation of a copolymerized petroleum resin of the above-described C5 fraction and C9 fraction available, for example, from Idemitsu Petrochemical Co., Tokyo, Japan, under the trade designation “IMARV”. In some embodiments, the hydrogenated poly(cyclic olefin) is a hydrogenated poly(dicyclopentadiene). Other examples of useful compatibilizers can be found in U.S. Pat. No. 4,787,897 (Torimae et al.) and U.S. Pat. No. 6,669,887 (Hilston et al.). The compatibilizer is typically amorphous and has a weight average molecular weight up to 5000 grams per mole to preserve compatibility with the elastomeric resin. The molecular weight is often up to 4000 grams per mole, 2500 grams per mole, 2000 grams per mole, 1500 grams per mole, 1000 grams per mole, or up to 500 grams per mole. In some embodiments, the molecular weight is in the range of 200 to 5000 gram per mole, in the range of 200 to 4000 grams per mole, in the range of 200 to 2000 grams per mole, or in the range of 200 to 1000 gram per mole. When present, the compatibilizer may be in the second or third polymeric composition in a range from 15 percent to 30 percent by weight (in some embodiments, 15 to 25 percent by weight) based on the total weight of the second or third polymeric composition.
The second polymeric composition for use in the second segments may be selected such that a film of the second polymeric composition (such as a film that is 0.002 mm to 0 5 mm thick) has an elongation of at least 200 percent at room temperature. The third polymeric composition for use in the second segments, when it is different from the first polymeric composition, may be selected such that a film (e.g., 0.002 mm to 0 5 mm thick) of the third polymeric composition, which may be a blend of polymers, has an elongation of at least 5% at room temperature. In some embodiments, the first, second, and third polymeric compositions may be selected such that the force required to stretch the second segments in the film's width “x” direction is less that the force required to stretch the first segments.
In some embodiments, at least one of the third, fourth, fifth, or sixth polymeric composition is a hot melt adhesive. In some embodiments of the second segments, at least one of the second or third layers comprises a hot melt adhesive. In some embodiments, the first segments include fourth, fifth, and optionally sixth layers, and at least one of the fifth or sixth layers is a hot melt adhesive. Including a hot melt adhesive on the second segments that are relatively more elastic than the first segments may serve to protect the elastic and provide bondability, for example, to fibrous carriers. Hot melt adhesives are typically non-tacky at room temperature, and use of hot melts can decrease contamination on equipment during the handling of the film and lamination. Including a hot melt adhesive on segments that are relatively less elastic than other segments in the film may allow for selective bonding (e.g., to fibrous carriers) in these regions. In some of these embodiments, the first polymeric composition in the first segments may be more elastic than the second polymeric composition in the second segments. The second segments may have first, second, and optionally third layers in which at least one of the second or third layers is a hot melt adhesive. The first segments may be elastic segments that may be uniform in composition from the first major surface to the second major surface. In other words, in these embodiments, the first segments may not be layered segments.
Suitable hot melt adhesives include those based on ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, polyolefins, polyamides, polyesters, polyurethanes, styrene block copolymers, polycaprolactone, and polycarbonates and may include a variety of tackifying resins, plasticizers, pigments, fillers, and stabilizers. Examples of suitable hot melt adhesives include those available from 3M Company, St. Paul, Minn., under the trade designation “3M SCOTCH-WELD” hot melt adhesives (e.g., products 3731 B and 3764 PG).
In some embodiments, polymeric materials used to make films described herein may comprise a colorant (e.g., pigment and/or dye) for functional (e.g., optical effects) and/or aesthetic purposes (e.g., each has different color/shade). Suitable colorants are those known in the art for use in various polymeric compositions. Examples of colors imparted by the colorant include white, black, red, pink, orange, yellow, green, aqua, purple, and blue. In some embodiments, it is desirable level to have a certain degree of opacity for one or more of the polymeric compositions. The amount of colorant(s) to be used in specific embodiments can be readily determined by those skilled in the art (e.g., to achieve desired color, tone, opacity, transmissivity, etc.). The polymeric compositions such as the first, second, and third polymeric compositions may be formulated to have the same or different colors. In some embodiments, the first segments and at least portions of the second segments are different colors. In some of these embodiments, the first segments the first layer of the second segments are different colors. In some embodiments, each of the first segments and the first and second layers in the second segments are different colors.
In some embodiments, the films may be provided with apertures after they are extruded, which may be useful, for example, for increasing the breathability of the film. In some embodiments, the first segments may include apertures. In some embodiments in which the film includes a second region that does not have second segments side-by-side with first segments, the second region includes apertures. Apertures can be made in the film by a variety of methods including needle-punching, vacuum forming, die cutting, laser techniques, or other methods to introduce apertures into the film after it is extruded. The film may also be provided with apertures during lamination as described in further detail, below.
Films disclosed herein are typically extensible in the film's width “x” direction (which is typically transverse to the direction of the first and second segments). In some embodiments, the film disclosed herein has an elongation of at least 75 (in some embodiments, at least 100, 200, 250, or 300) percent and up to 1000 (in some embodiments, up to 750 or 500) percent in the film's width direction. In some embodiments, films disclosed herein will sustain only small permanent set following deformation and relaxation (in some embodiments, less than 25, 20, or even less than 10 percent) of the original length after 100% elongation at room temperature. As used herein, elongation and permanent set are determined using the test method described in the Examples, below.
In some embodiments, the widths of the second segments, which may include an elastic polymeric composition, in films disclosed herein are less than 1 millimeter (mm) (in some embodiments, up to 750 micrometers, 650 micrometers, 500 micrometers, or 400 micrometers). The width of the first and second segments is typically at least 100 micrometers (in some embodiments, at least 150 micrometers or 200 micrometers). For example, the second segments may be in a range from 100 micrometers to less than 1 mm, 100 micrometers to 750 micrometers, 150 micrometers to 750 micrometers, 150 micrometers to 500 micrometers, or 200 micrometers to 600 micrometers wide.
In some embodiments, the films disclosed herein have first segments with widths up to 2 mm (in some embodiments, up to 1.5 mm, 1 mm or 750 micrometers). In some embodiments, the first segments are at least 250 micrometers, 350 micrometers, 400 micrometers, or 500 micrometers wide. For example, the first segments may be in a range from 250 micrometers to 1.5 mm, 250 micrometers to 1 mm, or 350 micrometers to 1 mm wide. As used herein, the width of the first and second segments is the dimension measured in the film's width direction “x”.
While the apparatus and method according to the present disclosure are capable of extruding segments with widths up to 2 mm or 1 mm, such films could not practically be achieved by extrusion from apparatuses having continuous width flow channels up to 2 mm or 1 mm wide and at least 5 cm or 7.5 cm in length such as those described in Int. Pat. App. Pub. No. WO 2010/099148 (Hoium et al.). The pressure drop at the dispensing edge would limit the extrusion rates to less than 0.1 meters per minute, at least ten times slower than the extrusion rates achievable from the apparatus and method disclosed herein.
In some embodiments of the film disclosed herein, the distance between midpoints of two first segment separated by one second segment is up to 3 mm, 2.5 mm, or 2 mm. In some embodiments, the distance between midpoints of two first segments separated by one second segment is at least 300 micrometers, 350 micrometers, 400 micrometers, 450 micrometers, or 500 micrometers. In some embodiments, the distance between midpoints of two first segments separated by one second segment is in a range from 300 micrometers to 3 mm, 400 micrometers to 3 mm, 500 micrometers to 3 mm, 400 micrometers to 2.5 mm, or 400 micrometers to 2 mm.
The films disclosed herein may have a variety of useful thicknesses, depending on the desired use. In some embodiments, the film may be up to about 250 micrometers, 200 micrometers, 150 micrometers, or 100 micrometers thick. In some embodiments, the film may be at least about 10 micrometers, 25 micrometers, or 50 micrometers thick. For example, the thickness of the film may be in a range from 10 micrometers to 250 micrometers, from 10 micrometers to 150 micrometers, or from 25 micrometers to 100 micrometers thick. In some embodiments, the thickness of the first segments is within about 20%, 10%, or 5% of the thickness of the second segments. In these cases, the first segments may be said to have substantially the same thickness as the second segments. This may be useful, for example, for lowering the force to initially stretch the film, to maximize the elongation, and to lower the hysteresis of the film. In other embodiments, particularly embodiments in which the second polymeric composition is more elastic than the first polymeric composition, the thickness of the second segments may be at least 50%, 100%, 150%, or more higher than the first segments. This may be useful, for example, to provide a pleasing tactile ribbed texture to the film surface. Variations in the thicknesses of the first and second segments in a film according to the present disclosure can be seen in the photomicrograph of
In the layered segments, including the layered second segments or the layered first segments, the second, third, fifth, and sixth layers, when present, may be in a range from 0.2 micrometers to 20 micrometers, from 1 micrometers to 15 micrometers, or from 3 micrometers to 10 micrometers thick. Layers at the major surfaces of the second segments, for example, having these dimensions may be useful, for example, to allow facile elongation of the film according to the present disclosure. In some embodiments, the thicknesses of these layers are not uniform across the width of the layered segments.
In some embodiments of the films disclosed herein, the density of the second segments, which may include a relatively more elastic polymeric composition, can vary across the web. This can be accomplished, for example, if sequences of shims in the die described herein include varying frequency of shim sequences providing the second segments. In some embodiments, it may be desirable to have a higher density of such second segments toward the center of the film. In other words, the distance between midpoints of successive first segments may or may not be identical. Measuring the distance between midpoints between successive first segments is convenient; however, distance could also be measured between any point of one first segment to a corresponding point in the next first segment of the film. In some embodiments, across a film there is an average of distances between midpoints of two first segments separated by one second segment, and for any two given first segments separated by one second segment, the distance is within 20 (in some embodiments, 15, 10, or 5) percent of the average of these distances across the film.
Measurements of the widths and/or thicknesses of first and second segments (e.g., including the first, second, and optionally third layers) or distances between two corresponding points on successive first or second segments may be made, for example, by optical microscopy. Optical microscopy is also useful to determine volume percentage of the first and second segments. In some embodiments, the first segments make up a higher volume percentage than the second segments. In some embodiments, the first segments make up a range of about 51% to 85% of the volume of the film, and the second segments make up a range of about 15% to 49% of the volume of the film. In some embodiments, the first segments make up a range of about 55% to 80% of the volume of the film, and the second segments make up a range of about 20% to 45% of the volume of the film.
Films according to and/or prepared using the method according to the present disclosure can be made with a variety of basis weights. For example, the basis weight of the film may be in a range from 15 grams per square meter to 100 grams per square meter. In some embodiments, the basis weight of the film is in a range from 20 grams per square meter to 60 grams per square meter. It is useful that in these films, elastomeric polymers can make a relatively low contribution to the basis weight and yet useful elastic properties are achieved in the films and film articles. In some embodiments, the elastomeric polymers contribute up to 25, 20, 15, or 10 grams per square meter to the basis weight of the film. In some embodiments, elastomeric polymers contribute in a range from 5 to 10 grams per square meter to the basis weight of the film. The typically low amount of elastomeric polymer in the films and film articles described herein provides a cost advantage over elastic films in which elastomeric polymers make a higher contribution to the basis weight of the films.
In some embodiments of the films disclosed herein, the first segments, which contain the first polymeric composition that is relatively less elastic than the second polymeric composition, have molecular orientation resulting from stretching. In some of these embodiments, the first segments have stretch-induced molecular orientation in a width direction “x” caused by permanent plastic deformation. To achieve the permanent deformation, the film may be stretched to at least 500 (in some embodiments, at least 600 or 750) percent, depending on the elongation of the film. In these embodiments, the films disclosed herein can provide a “dead-stop” elastic film, in which the force required for extension rises rapidly during the last portion of extension.
In some embodiments, the films disclosed herein are stretched-activated in the longitudinal direction of the first and second segments. In some of these embodiments, the first segments have stretch-induced molecular orientation in a longitudinal direction “y” caused by permanent plastic deformation. To achieve the permanent deformation, the film may be stretched to at least 200 (in some embodiments, at least 300, 400, or 500) percent or more. When the elastic second segments relax after stretching, the stretched first segments are shirred to form a textured surface. Such texture may eliminate the need for laminating the elastic film to a fibrous (e.g., nonwoven) carrier, especially if soft-feeling resins are used to make the film. Accordingly, in some embodiments, the film disclosed herein is not joined to a carrier. Furthermore, after stretching in the “y” direction, the films are remarkably strong in this direction. The process of stretching the relatively inelastic first segments in the machine direction can orient or tensilize those segments, offering strength and robustness during manufacturing line processing and in the end-use applications of the films.
In some embodiments where the film disclosed herein is not joined to a carrier, particles may be applied to one or both major surfaces of the film to provide a matte finish. In some embodiments, the film disclosed herein may be flocked with a fibrous material, such as any of those described below, to give the film a soft feeling without joining it to a carrier. In other embodiments, pattern-embossing the film on one or both major surfaces can provide an appearance or feeling of a fibrous material.
In laminates according to the present disclosure, the film disclosed herein is joined to a carrier. One or both major surfaces of the film may be joined to a carrier. The method disclosed herein further comprises joining a surface of the film to a carrier or joining both major surfaces of the film to a carrier. The carrier on opposite sides of the film may be the same or different. The film may be joined to a carrier, for example, by lamination (e.g., extrusion lamination), adhesives (e.g., hot melt or pressure sensitive adhesives), or other bonding methods (e.g., ultrasonic bonding, thermal bonding, compression bonding, or surface bonding).
The film and the carrier may be substantially continuously bonded or intermittently bonded. “Substantially continuously bonded” refers to being bonded without interruption in space or pattern. Substantially continuously bonded laminates can be formed by laminating a carrier to a substantially continuous film upon extrusion of the film; passing the film and the fibrous web between a heated smooth surfaced roll nip if at least one of them is thermally bondable; or applying a substantially continuous adhesive coating or spray to one of the film or carrier before bringing it in contact with the other of the film or carrier. “Intermittently bonded” can mean not continuously bonded and refers to the film and the carrier being bonded to one another at discrete spaced apart locations or being substantially unbonded to one another in discrete, spaced apart areas. Intermittently bonded laminates can be formed, for example, by passing the film and the carrier through a heated patterned embossing roll nip if at least one of them is heat bondable, or by applying discrete, spaced apart areas of adhesive to one of the film or the carrier before bringing it into contact with the other of the film or the carrier. An intermittently bonded laminate can also be made by feeding an adhesively coated aperture ply or scrim between the film and the carrier.
In some embodiments, the chemical compositions in the first and second segments differ at the surface of the film. The ability to select different compositions for the second and third layers of the second segments, for example, and the first segments offers the ability to bond selectively to either the first or second segments as desired. For example, a hot melt adhesive in at least one of the second and third layers in the second segments or fifth and sixth layers of the first segments can offer selective bonding to the desired segments. In some embodiments, the carrier is bonded predominantly to the first segments, which may be relatively less elastic than the first segments. When a carrier is said to bond predominantly to either the first or second segments, it means that greater than 50, 60, 75, or 90 percent of the bonded area of the film is found in one of these locations but not in the other. Bonding predominantly to the first segments can be achieved, for example, through the selected materials for the first and second segments, through the geometry of the first and second segments, or a combination of these. The first polymeric composition may be selected, for example, to have a similar chemical composition and/or molecular weight as the carrier to be bonded. Matching chemical composition and/or molecular weight for the bonding of two materials may be useful, for example, for thermal bonding, ultrasonic bonding, and compression bonding methods among others. An additive to the second or third layers in the second segments could be used to make it less receptive to bonding. For example, extrudable release materials, or lower surface energy materials than in the first segments, could be employed. In some embodiments, the first segments include fifth and sixth layers comprising a hot melt adhesive, and the second segments include second and third layers comprising a material that may be a non-adhesive or a material resistant to bonding (e.g., a soft polypropylene). The ability to preferentially bond to either the first or second segments using selection of materials is not possible in films, for example, in which multiple strands of one polymer are embedded within a continuous matrix of another polymer.
In laminates according to the present disclosure, the carrier may comprise a variety of suitable materials including woven webs, non-woven webs (e.g., spunbond webs, spunlaced webs, airlaid webs, meltblown web, and bonded carded webs), textiles, nets, and combinations thereof. In some embodiments, the carrier is a fibrous material (e.g., a woven, nonwoven, or knit material). The term “nonwoven” when referring to a carrier or web means having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs can be formed from various processes such as meltblowing processes, spunbonding processes, spunlacing processes, and bonded carded web processes. In some embodiments, the carrier comprises multiple layers of nonwoven materials with, for example, at least one layer of a meltblown nonwoven and at least one layer of a spunbonded nonwoven, or any other suitable combination of nonwoven materials. For example, the carrier may be a spunbond-meltbond-spunbond, spunbond-spunbond, or spunbond-spunbond-spunbond multilayer material. Or, the carrier may be a composite web comprising a nonwoven layer and a dense film layer.
Fibrous materials that provide useful carriers may be made of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., thermoplastic fibers), or a combination of natural and synthetic fibers. Exemplary materials for forming thermoplastic fibers include polyolefins (e.g., polyethylene, polypropylene, polybutylene, ethylene copolymers, propylene copolymers, butylene copolymers, and copolymers and blends of these polymers), polyesters, and polyamides. The fibers may also be multi-component fibers, for example, having a core of one thermoplastic material and a sheath of another thermoplastic material.
Useful carriers may have any suitable basis weight or thickness that is desired for a particular application. For a fibrous carrier, the basis weight may range, e.g., from at least about 5, 8, 10, 20, 30, or 40 grams per square meter, up to about 400, 200, or 100 grams per square meter. The carrier may be up to about 5 mm, about 2 mm, or about 1 mm in thickness and/or at least about 0.1, about 0.2, or about 0.5 mm in thickness. In some embodiments in which both major surfaces of the film are bonded to a fibrous carrier, it is sometimes advantageous if one fibrous carrier has a higher basis weight than the other.
Lamination of a film disclosed herein to one or more carriers may be carried out while the film is being stretched in its width “x” direction, while the film is being stretched in its longitudinal “y” direction, or while not being stretched. Stretching the film may be carried out according to any of the methods described above. In some embodiments, machine direction stretching is carried out with differential speed rolls operating at increasingly greater speeds the further downweb they are located. Any number of two or more rolls may be useful. The speed may increase linearly or nonlinearly from one roll to the next. In other embodiments, differential speed rolls may deliver pulsed stretching. For example, a center roll may operate at a slower speed than rolls upweb and downweb, causing the film to go through sequences of stretch and recovery. The distance between adjacent rolls can be the same or different although the horizontal gap between rolls must be greater than the thickness of the film. The diameters of differential speed rolls can be the same or different. Upon stretching, lamination can be used to join one or two fibrous layers. Stretching films with side-by-side elastic and relatively inelastic segments beyond a point of plastic deformation just before lamination several advantages. It is only when such films are stretched beyond the plastic deformation limit of the inelastic segments that the film can become elastic. As long as the tension on the films disclosed herein on a manufacturing line is below that required to exceed the deformation limit, the film is not likely to prematurely stretch on the manufacturing line. Also, the process of stretching the relatively inelastic first segments in the machine direction can orient or tensilize those segments, offering strength and robustness during manufacturing line processing and in the end-use applications of the laminates.
In some embodiments, including those embodiments described above that include stretching before lamination, laminates according to the present disclosure are prepared by ultrasonic bonding. Ultrasonic bonding generally refers to a process performed, for example, by passing layers between a sonic horn and a patterned roll (e.g., anvil roll). Such bonding methods are well-known in the art. For instance, ultrasonic bonding through the use of a stationary horn and a rotating patterned anvil roll is described in U.S. Pat. No. 3,844,869 (Rust Jr.) and U.S. Pat. No. 4,259,399 (Hill). Ultrasonic bonding through the use of a rotary horn with a rotating patterned anvil roll is described, for example, in U.S. Pat. No. 5,096,532 (Neuwirth, et al.); U.S. Pat. No. 5,110,403 (Ehlert); and U.S. Pat. No. 5,817,199 (Brennecke, et al.). Other ultrasonic bonding techniques may also be useful. In embodiments in which the film is stretched using differential speed rolls as described above, the patterned roll and furthest downweb differential speed roll may operate at the same speed. Or, in other embodiments, the patterned roll acts as an extension of the differential speed rolls, for example, and operate at an increased speed than the differential speed rolls.
In some embodiments, ultrasonic bonding is used to join two fibrous carriers through a film according to the present disclosure, creating an extensible laminate in which the film is apertured but the nonwoven layers are not. This configuration may be useful in applications requiring breathability. In other embodiments, ultrasonic bonding can be useful to provide laminates in which apertures are created at the bond sites that extend through the film and both fibrous carriers. In some embodiments, a single fibrous carrier is laminated to the film. In embodiments in which the film has side-by-side elastic and relatively inelastic segments and has been stretched in the machine direction beyond the point of plastic deformation, an extensible laminate having a fibrous carrier on one side and the shirred texture of the relaxed film on the other can be provided. The non-laminated surface can be non-tacky and soft to the touch if soft-feeling resins are used to make the film. In yet another embodiment, a single fibrous carrier is laminated to the films disclosed herein by any of the above-mentioned lamination processes where the films are colored, multi-colored and/or contain a print pattern. The films disclosed herein can be colored by the addition of pigments and/or dyes to one or more segments and layers. A print pattern can be added to the films disclosed herein using a variety of known printing processes.
In some embodiments of laminates disclosed herein, the film according to the present disclosure is joined to a fibrous web carrier using surface bonding or loft-retaining bonding techniques. The term “surface-bonded” when referring to the bonding of fibrous materials means that parts of fiber surfaces of at least portions of fibers are melt-bonded to a surface of the film in such a manner as to substantially preserve the original (pre-bonded) shape of the film surface, and to substantially preserve at least some portions of the film surface in an exposed condition, in the surface-bonded area. Quantitatively, surface-bonded fibers may be distinguished from embedded fibers in that at least about 65% of the surface area of the surface-bonded fiber is visible above the film surface in the bonded portion of the fiber. Inspection from more than one angle may be necessary to visualize the entirety of the surface area of the fiber. The term “loft-retaining bond” when referring to the bonding of fibrous materials means a bonded fibrous material comprises a loft that is at least 80% of the loft exhibited by the material prior to, or in the absence of, the bonding process. The loft of a fibrous material as used herein is the ratio of the total volume occupied by the web (including fibers as well as interstitial spaces of the material that are not occupied by fibers) to the volume occupied by the material of the fibers alone. If only a portion of a fibrous web has the film surface bonded thereto, the retained loft can be easily ascertained by comparing the loft of the fibrous web in the bonded area to that of the web in an unbonded area. It may be convenient in some circumstances to compare the loft of the bonded web to that of a sample of the same web before being bonded, for example, if the entirety of fibrous web has the film surface bonded thereto. In some of these embodiments, the joining comprises impinging heated gaseous fluid (e.g., ambient air, dehumidified air, nitrogen, an inert gas, or other gas mixture) onto a first surface of the fibrous web carrier while it is moving; impinging heated fluid onto the film surface while the continuous web is moving; and contacting the first surface of the fibrous web with the film surface so that the first surface of the fibrous web is melt-bonded (e.g., surface-bonded or bonded with a loft-retaining bond) to the film surface. Impinging heated gaseous fluid onto the first surface of the fibrous web and impinging heated gaseous fluid on the film surface may be carried out sequentially or simultaneously. Further methods and apparatus for joining a continuous web to a fibrous carrier web using heated gaseous fluid may be found in U.S. Pat. Appl. Pub. Nos. 2011/0151171 (Biegler et al.) and 2011/0147475 (Biegler et al.).
In some embodiments of the laminates according to the present disclosure, the carrier is a fibrous web activated by mechanical activation. Mechanical activation processes include stretching with diverging disks or incremental stretching methods such as ring-rolling, structural elastic film processing (SELFing), which may be differential or profiled, in which not all material is strained in the direction of stretching, and other means of incrementally stretching webs as known in the art. An example of a suitable mechanical activation process is the ring-rolling process, described in U.S. Pat. No. 5,366,782 (Curro). Specifically, a ring-rolling apparatus includes opposing rolls having intermeshing teeth that incrementally stretch and thereby plastically deform the fibrous web or a portion thereof forming the outer cover, thereby rendering the outer cover stretchable in the ring-rolled regions. Activation performed in a single direction (for example the cross direction) yields an outer cover that is uniaxially stretchable. Activation performed in two directions (for example the machine and cross directions or any two other directions maintaining symmetry around the outer cover centerline) yields an outer cover that is biaxially stretchable.
In some embodiments of the laminates according to the present disclosure, where the laminate includes a film disclosed herein in any of the aforementioned embodiments and an incrementally activated fibrous web, the distance between the midpoints between two first segments separated by one second segment is smaller than the pitch of the activation of the fibrous web. Activation pitch of the incrementally activated fibrous web is defined as the distance between the midpoints of two adjacent areas of higher deformation the fibrous web. Areas of higher deformation may be observed as areas of higher breakage, thinning, or higher elongation in the fibrous web. In some embodiments, areas of higher deformation may be observed as areas of a greater degree of shirring of the fibrous web. The activation pitch is typically equivalent to the pitch of the intermeshing surfaces in the apparatus used for incremental stretching. The pitch of the intermeshing surfaces is defined as the distance between two peaks of one of the intermeshing surfaces separated by one valley. The peaks can be defined as the apexes of outward pointing ridges of corrugated rolls (e.g., as described in U.S. Pat. No. 5,366,782 (Curro)) when such apparatuses are used. The peaks can also be defined as the peripheral surfaces (or center portion thereof) of discs used for incremental stretching such as those shown, for example, in U.S. Pat. No. 4,087,226 (Mercer). In other incremental stretching apparatuses, the peaks of one of the intermeshing surfaces would be readily identifiable to a person skilled in the art. In some embodiments of incrementally activated laminates according to the present disclosure, advantageously the first segments of the film, which include a first polymeric composition that is relatively less elastic than the second polymeric composition, are not plastically deformed in the laminate. Plastic deformation of the first segments can occur when the distance between the midpoints of two first segments separated by one second segment is larger than the activation pitch since the first segments can bridge between two peaks on one of the intermeshing surfaces. The plastically deformed regions can appear non-uniform resulting in a less aesthetically pleasing laminate, or the plastic deformation can result in breakage. In contrast, in embodiments of the laminate disclosed herein in which the distance between the midpoints between two first segments separated by one second segment is smaller than the pitch of the activation, the position and size of the first and second segments allow the second segments to stretch during incremental stretching of the laminate to take up the activation displacement without plastically deforming the first segments.
In some embodiments of the laminates according to the present disclosure, one or more zones of the carrier or the entire carrier may comprise one or more elastically extensible materials extending in at least one direction when a force is applied and returning to approximately their original dimension after the force is removed. In some embodiments, the extensible carrier is a nonwoven web that can be made by any of the nonwoven processes described above. The fibers for the nonwoven web may be made from elastic polymers, for example, any of those described above in connection core regions of the film disclosed herein. In some embodiments, the carrier may be extensible but inelastic. In other words, the carrier may have an elongation of at least 5, 10, 15, 20, 25, 30, 40, or 50 percent but may not recover to a large extent from the elongation (e.g., up to 40, 25, 20, 10 or 5 percent recovery). Suitable extensible carriers may include nonwovens (e.g., spunbond, spunbond meltblown spunbond, spunlace, or carded nonwovens). In some embodiments, the nonwoven may be a high elongation carded nonwoven (e.g., HEC). In some embodiments, the carrier may form pleats after it is extended. In some embodiments, the carrier is not pleated.
In some embodiments in which the laminate includes a fibrous web (e.g., a nonwoven web) that is extensible, a film or film article disclosed herein can be selected such that it has a relative low force to initially stretch the film. As described above, such a film can have, for example, second and optionally third layers in the second segments that are made from a softer, lower modulus material than the first segments and can have a geometry in which the thicknesses of the first and second segments are similar (e.g., within about 20%, 10%, or 5%). In these embodiments, the laminates may be considered not to require “activation”, and the ease of initially stretching the laminate would be apparent to the user.
Laminates of an extensible fibrous web and a film according to the present disclosure can advantageously be made by bonding under pressure discontinuously at discrete bond locations. The bonding can be carried out by a patterned embossing roll in which the pattern (that is, raised area) of the embossing roll provides up to about 30%, 25%, or 20% of the surface of the embossing roll. It is possible, but not required, that the pattern may be aligned with at least some of the first segments of the film. We have unexpectedly found that patterned bonding can be carried out in a nip at a temperature of up to 60° C., 55° C., 50° C., 40° C., 30° C., or even 25° C. using a pressure of at least one megapascal (MPa) (in some embodiments, 1.1, 1.2, 1.3, or 1.35 MPa).
If desired, lamination of the film according to the present disclosure to one or two fibrous carriers can be carried out such that certain zones are subjected to high heat and high pressure sufficient to create a non-stretchable zone in the laminate.
After laminates according to the present disclosure are prepared according to any of the methods described above, the laminate can be stored in roll form for incorporation into an article (e.g., those described below) in a separate process. In embodiments in which the film is stretched in at least one direction during lamination, the laminate can be stored in roll form in the stretched state and recovered at a later time. It is also possible to combine the method of making a laminate with a downline process of manufacturing an article. In embodiments in which the film is stretched in at least one direction during lamination, the laminate may be maintained in a stretched state and incorporated into an article in a downline process before allowing the web laminate to recover.
In some embodiments of the laminates disclosed herein, wherein the carrier is an elastic or extensible fibrous web, a tensile elongation at maximum load of the film is up to 250 percent of the tensile elongation at maximum load of the extensible fibrous web. In embodiments in which the film undergoes plastic deformation before breaking, the tensile elongation at maximum load of the film is the elongation at the point where the film begins to undergo plastic deformation. This extension is readily recognizable as a shoulder in a stress strain curve measured as described in the Examples, below. In embodiments in which the film does not undergo plastic deformation before breaking, the tensile elongation at maximum load is the tensile elongation at break. The tensile elongation at maximum load of the fibrous web is generally the tensile elongation at break. In some embodiments, a tensile elongation at maximum load of the film is in a range from 25 percent to 250 percent, 50 percent to 225 percent, 75 percent to 200 percent, or 75 percent to 150 percent of the tensile elongation at maximum load of the extensible fibrous web. It is useful in laminates disclosed herein for the tensile elongation at maximum load of the film and the fibrous web to be comparable. In these laminates, there is not a large amount of unused elasticity in the film. For example, if an elastic film made completely of elastic polymers as described above has tensile elongation at maximum load of 800%, but an extensible fibrous web to which it is bonded only has a tensile elongation of about 200%, there is a large amount of elasticity in the film that is unused. Since more elastic polymers are typically more expensive than less elastic polymers, the unused elasticity translates to unnecessary expense. In the laminates according to the present disclosure, the first and second segments in the film allow for a lower amount of elastic polymers to be used while maintaining elongations that are comparable to extensible fibrous webs. On the other hand, the distribution of first and second segments across the film allow for more uniform extension than, for example, if only one region of elasticity was used in the film. This distribution of first and second segments better utilizes the extensible potential of the extensible fibrous web. Furthermore, when the tensile elongation of the extensible fibrous web and the film are this similar, delamination of the extensible fibrous web and the film is less likely to occur than when, for example, the elastic film is much more extensible than the fibrous web.
In some embodiments of the laminates disclosed herein, a recoverable elongation of the laminate is at least 50% of the recoverable elongation of a comparative film after elongation of 100%. The laminate may be made from an extensible fibrous web, or the laminate by be incrementally activated as described above. The recoverable elongation can be understood to be the maximum elongation that provides the film or laminate with a permanent set of up to 20%, in some embodiments, up to 15% or 10%. As used herein, recoverable elongation is determined using the test method described in the Examples, below. The comparative film is the same as the film comprising first and second segments except that it is not laminated to a carrier. The comparative film may be a film that is removed from the laminate, for example, by submerging the laminate in liquid nitrogen and peeling apart the carrier and the film. Or the comparative film may be a sample made identically to the film comprising first and second segments but never laminated to a carrier. In some embodiments, a recoverable elongation of the laminate is at least 75%, 80%, 85%, 90% or 95% of the recoverable elongation of a comparative film at after elongation of 100%. Again, in any of these embodiments, there is not a large amount of unused elasticity in the elastic film. Also, in embodiments in which the carrier is an extensible fibrous web, the distribution of first and second regions better utilizes the recoverable elongation of the extensible fibrous web as described above. Also, where the comparative film is a sample made identically to the film comprising first and second segments but never laminated to an extensible fibrous web and subsequently incrementally stretched, when the recoverable elongation of the laminate is at least 50% (in some embodiments, 75%, 80%, 85%, 90%, or 95%) of the recoverable elongation of a comparative film after elongation of 100%, it is an indication that the incremental stretching did not plastically deform the first segments of the film.
Films disclosed herein have a variety of uses, including wound care and other medical applications (e.g., elastic bandage-like material, surface layer for surgical drapes and gowns, and cast padding), booties, tapes (including for medical applications), and absorbent articles (e.g., diapers, training pants, adult incontinence devices, and feminine hygiene products).
In absorbent articles, the film according to the present disclosure may be useful as a layer(s) within the articles and/or as part of an attachment system for the articles or elastic components. In some embodiments, a non-extensible region attached to the extensible region of the film can be used to attach the film article to the absorbent article or provide a fingerlift. In some embodiments, the non-extensible region can be formed with molded hooks to provide attachment to a loop. However, in some embodiments, the first segments or segments made from a relatively less elastic polymeric composition are not formed with male fastening elements (e.g., hooks) or may not be formed with surface structure in general. Examples of disposable absorbent articles comprising films according to and/or made according to the present disclosure include disposable absorbent garments such as infant diapers or training pants, products for adult incontinence, and feminine hygiene products (e.g., sanitary napkins and panty liners). A typical disposable absorbent garment of this type is formed as a composite structure including an absorbent assembly (including, e.g., cellulosic fluff pulp, tissue layers, highly absorbent polymers (so called superabsorbents), absorbent foam materials, or absorbent nonwoven materials) disposed between a liquid permeable bodyside liner (e.g., nonwoven layers, porous foams, apertured plastic films) and a liquid impermeable outer cover (e.g., a thin plastic film, a nonwoven coated with a liquid impervious material, a hydrophobic nonwoven material which resists liquid penetration, or laminates of plastic films and nonwoven materials). These components can be combined with films disclosed herein and other materials and features such as further elastic components or containment structures to form the absorbent article.
In some embodiments, the film according to the present disclosure may be laminated to a fibrous (e.g., nonwoven) web. In some of these embodiments, the resulting laminate may be a fastening tab, for example, for an absorbent article. In some embodiments, the resulting laminate may be an extensible ear, for example, for an absorbent article. In some of these embodiments, the laminate may be in the shape of a trapezium, for example, as shown in
In a first embodiment, the present disclosure provides a film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition, wherein the first segments and second segments each have first major surfaces that collectively form the first major surface of the film, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, wherein at least two of the layered second segments have the second polymeric composition and the third polymeric composition in an identical arrangement, wherein the film has a moisture vapor transmission rate of less than 800 g/m2/day, wherein when the first segments are layered in the film's thickness direction, the first major surfaces of the first segments and the first major surfaces of the second segments do not share a common polymeric composition, and wherein when the layered second segments consist of the first and second layers and the third polymeric composition is the same as the first polymeric composition, the first polymeric composition extends through the entire thickness of the first segments.
In a second embodiment, the present disclosure provides a film according to the first embodiment, wherein the second polymeric composition is more elastic than the first polymeric composition.
In a third embodiment, the present disclosure provides a film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition that is more elastic than the first polymeric composition, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, and wherein the second segments each have a width in the film's width direction of less than one millimeter. Typically the first and second segments each have first major surfaces that collectively form the first major surface of the film, and wherein when the first segments are layered in the film's thickness direction, the first major surfaces of the first segments and the first major surfaces of the second segments do not share a common polymeric composition.
In a fourth embodiment, the present disclosure provides a film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition that is more elastic than the first polymeric composition, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, and wherein the time to failure in a hang shear evaluation is at least 100 minutes, wherein the hang shear evaluation is carried out at 38° C. by hanging a 200-gram weight on a sample 2.54 cm in length and such that the second segments in a 3.8 cm-wide portion of the film are stretched in the film's width direction.
In a fifth embodiment, the present disclosure provides the film of any one of the first to fourth embodiments, wherein the layered second segments further comprise a third layer in the film's thickness direction, wherein the first layer is a middle layer of the second polymeric composition disposed between the second layer and the third layer at opposite surfaces of the film, wherein the second layer comprises the third polymeric composition, wherein the third layer comprises a fourth polymeric composition, and wherein the third and fourth polymeric compositions can be identical or different.
In a sixth embodiment, the present disclosure provides the film of the fifth embodiment, wherein the third and fourth polymeric compositions are identical.
In a seventh embodiment, the present disclosure provides the film of any one of the first to sixth embodiments, wherein the third polymeric composition and the first polymeric composition are identical.
In an eighth embodiment, the present disclosure provides the film of any one of the first to seventh embodiments, wherein the first polymeric composition extends throughout the thickness of the first segments.
In a ninth embodiment, the present disclosure provides the film any one of the first to seventh embodiments, wherein at least some of the first segments are layered first segments comprising fourth and fifth layers in the film's thickness direction, wherein one of the fourth or fifth layers comprises a fifth polymeric composition different from the first polymeric composition, and wherein neither the first or fifth polymeric composition extends through the entire thickness of a given layered first segment.
In a tenth embodiment, the present disclosure provides the film of the ninth embodiment, wherein the layered first segments further comprise a sixth layer, wherein the fourth layer is a middle layer of the first polymeric composition disposed between the fifth layer and the sixth layer at opposite surfaces of the film, wherein the fifth layer comprises the fifth polymeric composition, wherein the sixth layer comprises a sixth polymeric composition, and wherein the fifth and sixth polymeric compositions can be identical or different.
In an eleventh embodiment, the present disclosure provides the film of the tenth embodiment, wherein the fifth and sixth polymeric compositions are identical.
In a twelfth embodiment, the present disclosure provides the film of the ninth of tenth embodiment, wherein at least one of the fifth or sixth polymeric compositions is a hot melt adhesive.
In a thirteenth embodiment, the present disclosure provides the film of any one of the ninth to twelfth embodiments, wherein at least one of the third or fourth or at least one of the fifth or sixth polymeric compositions is a hot melt adhesive.
In a fourteenth embodiment, the present disclosure provides the film of any one of the first to thirteenth embodiments, wherein the first segments have stretch-induced molecular orientation in a direction parallel to their lengths. In these embodiments, the present disclosure can provide a film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition that is more elastic than the first polymeric composition, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, and wherein the first segments have stretch-induced molecular orientation in a direction parallel to their lengths.
In a fifteenth embodiment, the present disclosure provides the film of any one of the first to fourteenth embodiments, wherein the first and second segments do not overlap in the film's width direction to form an interdigitated interface.
In a sixteenth embodiment, the present disclosure provides the film of any one of the first to fifteenth embodiments, wherein the first and second segments provide an extensible region of the film, wherein the film further comprises a non-extensible region. The non-extensible region can comprise the first polymeric composition.
In a seventeenth embodiment, the present disclosure provides a laminate comprising the film of any one of the first to fifteenth embodiments or the film article of the sixteenth embodiment joined to a fibrous carrier.
In an eighteenth embodiment, the present disclosure provides the laminate of the seventeenth embodiment, wherein the fibrous carrier is an extensible fibrous carrier with a tensile elongation at maximum load of at least 50 percent.
In a nineteenth embodiment, the present disclosure provides the laminate of the seventeenth embodiment, wherein the laminate is incrementally activated.
In a twentieth embodiment, the present disclosure provides the laminate of any one of the seventeenth to nineteenth embodiments, wherein the film is discontinuously bonded to the fibrous carrier, and wherein the fibrous carrier is bonded to the film predominantly at one of the first segments or the second segments.
In a twenty-first embodiment, the present disclosure provides an absorbent article comprising the laminate of any one of the seventeenth to twentieth embodiments.
In a twenty-second embodiment, the present disclosure provides a method of making the film of the eleventh embodiment or any one of the twelfth to fifteenth embodiments as dependent on the eleventh embodiment, the method comprising:
providing an extrusion die comprising at least a first cavity, a second cavity, a third cavity, and a fourth cavity, and a dispensing surface having a dispensing slot,
wherein a first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot;
wherein a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot;
wherein a third fluid passageway within the extrusion die extends on one side of the second fluid passageway from the third cavity, wherein upstream from the dispensing slot the third fluid passageway is diverted into branches that meet the second fluid passageway at areas above and below the second fluid passageways at the point where the second fluid passageway enters the dispensing slot;
and wherein a fourth fluid passageway within the extrusion die extends on one side of the first fluid passageway from the fourth cavity, wherein upstream from the dispensing slot the fourth fluid passageway is diverted into branches that meet the first fluid passageway at areas above and below the first fluid passageways at the point where the first fluid passageway enters the dispensing slot; and
extruding the first, second, third, and fifth polymeric compositions from the first, second, third, and fourth cavities, respectively, so as to form the film.
In a twenty-third embodiment, the present disclosure provides a method of making the film of the sixth embodiment or any one of the seventh to fifteenth embodiments as dependent on the fifth embodiment, the method comprising:
providing an extrusion die comprising at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot,
wherein a first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot;
wherein a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot; and
wherein a third fluid passageway within the extrusion die extends on one side of the second fluid passageway from a die cavity within the extrusion die, wherein upstream from the dispensing slot the third fluid passageway is diverted into branches that meet the second fluid passageway at areas above and below the second fluid passageways at the point where the second at the point where the second fluid passageway enters the dispensing slot; and
extruding the first, second, and third polymeric compositions from the first, second, and die cavities, respectively, so as to form the film.
In a twenty-fourth embodiment, the present disclosure provides the method of the twenty-third embodiment, wherein the die cavity is the same cavity as the first cavity.
In a twenty-fifth embodiment, the present disclosure provides the method of the twenty-third embodiment, wherein the die cavity is a third cavity, different from the first and second cavities.
In a twenty-sixth embodiment, the present disclosure provides a method of making the film of any of the first to fifteenth embodiments, the method comprising:
providing an extrusion die comprising at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot,
wherein a first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot,
wherein a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot, wherein the second slot segment and first slot segment are arranged side-by-side to provide a combined width; and
wherein a third fluid passageway within the extrusion die extends from a die cavity within the extrusion die to the second slot segment, wherein the third fluid passageway meets the second fluid passageway from an area above the second fluid passageway at a point where the second fluid passageway enters the dispensing slot, and wherein the third fluid passageway has a width at a point where it meets the second fluid passageway that is less than the combined width of the first and second slot segments; and
extruding the first, second, and third polymeric compositions from the first, second, and die cavities, respectively, so as to form the film.
In a twenty-seventh embodiment, the present disclosure provides the method of any one of the twenty-second to twenty-sixth embodiments, wherein the extrusion die comprises multiple first passageways, multiple second passageways, and multiple third passageways within the die.
In a twenty-eighth embodiment, the present disclosure provides the method of any one of the twenty-second to twenty-seventh embodiments, wherein the extrusion die comprises a plurality of shims, wherein the plurality of shims comprises a plurality of sequences of shims, wherein each sequence comprises at least one first shim that provides the first fluid passageway, at least one second shim that provides the second fluid passageway, and at least one third shim that provides the third fluid passageway.
In a twenty-ninth embodiment, the present disclosure provides the method of the twenty-eighth embodiment, wherein each of the plurality of shims defines a portion of the dispensing slot.
In a thirtieth embodiment, the present disclosure provides an extrusion die comprising at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot,
wherein a first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot,
wherein a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot, wherein the second slot segment and first slot segment are arranged side-by-side to provide a combined width;
wherein a third fluid passageway within the extrusion die extends from a die cavity within the extrusion die to the second slot segment, wherein the third fluid passageway meets the second fluid passageway from an area above the second fluid passageway at a point where the second fluid passageway enters the dispensing slot, and wherein the third fluid passageway has a width at a point where it meets the second fluid passageway that is less than the combined width of the first and second slot segments.
In a thirty-first embodiment, the present disclosure provides a method of making a film, the method comprising:
providing the extrusion die of the thirtieth embodiment; and
extruding a first polymeric composition from the first cavity, a second polymeric composition from the second cavity, and a third polymeric composition from the die cavity, wherein at the point where the second fluid passageway enters the dispensing slot, the third polymeric composition flows on top of the second polymeric composition to form a layer to provide a film having first segments comprising the first polymeric composition and second segments comprising a layer of the third polymeric composition on top of the second polymeric composition.
In a thirty-second embodiment, the present disclosure provides the extrusion die of the thirtieth embodiment or the method of the thirty-first embodiment, wherein the die cavity is the same cavity as the first cavity.
In a thirty-third embodiment, the present disclosure provides the extrusion die of the thirtieth embodiment, wherein a fourth fluid passageway within the extrusion die extends from a cavity within the extrusion die to the first slot segment, wherein the fourth fluid passageway meets the first fluid passageway from an area above or below the first fluid passageway at a point where the first fluid passageway enters the dispensing slot, and wherein the fourth fluid passageway has a width at a point wherein it meets the first fluid passageway that is less than the combined width of the first and second slot segments.
In a thirty-fourth embodiment, the present disclosure provides the extrusion die of the thirty-third embodiment, wherein the cavity is the same cavity as the second cavity.
In a thirty-fifth embodiment, the present disclosure provides the extrusion die of the thirty-third or thirty-fourth embodiments, wherein the fourth fluid passageway extends on one side of the first fluid passageway from a cavity within the extrusion die, wherein upstream from the dispensing slot the fourth fluid passageway is diverted into branches that meet the first fluid passageway at areas above and below the first fluid passageways at the point where the first fluid passageway enters the dispensing slot.
In a thirty-sixth embodiment, the present disclosure provides the extrusion die of the thirty-fifth embodiment as dependent on the thirty-third embodiment, wherein the cavity is a fourth cavity, different from the first and second cavities.
In a thirty-seventh embodiment, the present disclosure provides the extrusion die of any one of the thirtieth or thirty-second to thirty-sixth embodiments, wherein the third fluid passageway extends on one side of the second fluid passageway, wherein upstream from the dispensing slot, the third fluid passageway is diverted into branches that meet the second fluid passageway at areas above and below the second fluid passageways at the point where the second fluid passageway enters the dispensing slot.
In a thirty-eighth embodiment, the present disclosure provides a method of making a film, the method comprising:
providing the extrusion die of the thirty-seventh embodiment; and
extruding a first polymeric composition from the first cavity, a second polymeric composition from the second cavity, and a third polymeric composition from the die cavity, wherein at the point where the second fluid passageway enters the dispensing slot, the third polymeric composition flows above and below the second polymeric composition to provide a film having first segments comprising the first polymeric composition and second segments comprising two layers of the third polymeric composition above and below the second polymeric composition.
In a thirty-ninth embodiment, the present disclosure provides a method of making a film, the method comprising:
providing the extrusion die of the thirty-seventh embodiment as dependent on the thirty-sixth embodiment, wherein the die cavity is a third cavity, different from the first, second, and fourth cavities; and
extruding a first polymeric composition from the first cavity, a second polymeric composition from the second cavity, a third polymeric composition from the third cavity, and a fifth polymeric composition from the fourth cavity, wherein at the point where the second fluid passageway enters the dispensing slot, the third polymeric composition flows above and below the second polymeric composition to provide a film having first segments comprising two layers of the fifth polymeric composition above and below the first polymeric composition and second segments comprising two layers of the third polymeric composition above and below the second polymeric composition.
In a fortieth embodiment, the present disclosure provides the extrusion die or method of any one of the thirtieth to thirty-ninth embodiments, wherein the extrusion die comprises multiple first passageways, multiple second passageways, and multiple third passageways within the die.
In a forty-first embodiment, the present disclosure provides the extrusion die or method of any one of the thirtieth to fortieth embodiments, wherein the extrusion die comprises a plurality of shims, wherein the plurality of shims comprises a plurality of sequences of shims, wherein each sequence comprises at least one first shim that provides the first fluid passageway, at least one second shim that provides the second fluid passageway, and at least one third shim that provides the third fluid passageway.
In a forty-second embodiment, the present disclosure provides the extrusion die or method of any one of the thirtieth to forty-first embodiments, wherein each of the plurality of shims defines a portion of the dispensing slot.
In a forty-third embodiment, the present disclosure provides the extrusion die or method of the forty-first or forty-second embodiment, wherein each sequence of shims further comprises at least one fourth shim between the at least one second shim and the at least one third shim that provides the branches in the third fluid passageway that lead to the second fluid passageway.
In a forty-forth embodiment, the present disclosure provides the extrusion die or method of any one of the forty-first or forty-third embodiments, wherein each sequence of shims further comprises at least one spacer shim between the at least one first shim and the at least one third shim, wherein the spacer shim has a dispensing opening but lacks a passageway between the dispensing opening and any of the cavities within the die.
In order that this disclosure can be more fully understood, the following examples are set forth. It should be understood that these examples are for illustrative purposes only, and are not to be construed as limiting this disclosure in any manner. All parts and percentages are by weight unless otherwise indicated.
EXAMPLES
The partially hydrogenated styrene triblock copolymer obtained under the trade designation “KRATON MD6843” was analyzed by nuclear magnetic resonance (NMR) spectroscopy in solutions of unknown concentration in deuterated chloroform and deuterated 1,1,2,2-tetrachloroethane (TCE) using a 600 MHz NMR spectrometer obtained from Varian (Palo Alto, Calif.) under the trade designation “INOVA”. The spectrometer was equipped with a conventional room temperature inverse probe head. One-dimensional 1H-NMR and 13C-NMR spectra were collected followed by 1H/13C-NMR gradient heteronuclear single quantum coherence (gHSQC) and homo-nuclear two-dimensional NMR to confirm spectral assignments. The residual proto-solvent resonances were used as secondary chemical shift references in the proton dimension. All of the NMR data were collected with the samples held at 25° C. After analysis, it was concluded that hydrogenated butadiene moieties dominate the mid-block of the triblock copolymer, but minor amounts hydrogenated isoprene moieties were found in the mid-block as well. Integration of the 1H-NMR data suggested that polystyrene made up about 24 mole percent (36 weight percent) of the triblock copolymer.
The weight average and number average molecular weights of the partially hydrogenated styrene-butadiene-styrene copolymer obtained under the trade designation “KRATON MD6843” were determined by comparison to linear polystyrene polymer standards using gel permeation chromatography (GPC). The GPC measurements were carried out using a combined autosampler, controller and pump (Alliance Model 2695 Separations Module and Empower 3 data acquisition software obtained from Waters Corporation, Milford, Mass.) controlled to 40° C. and using three 250 millimeter (mm) by 10 mm linear columns of divinylbenzene polymer particles (obtained from Jordi Associates, Inc., Bellingham, Mass., under the trade designation “Jordi GEL”) with two columns of pore sizes Mixed Bed and one column of 500 angstroms. A differential refractive index (RI) detector (Waters Model 2414, obtained from Waters Corporation) was used at 40° C. A 20-milligram (mg) sample of the “MD6843” copolymer was diluted with 10 mL of tetrahydrofuran (inhibited with 250 ppm of BHT) into a 20-mL glass vial, capped with a polyethylene-lined cap and slowly rotated until dissolved. The sample solution was filtered through a 0.45-micrometer pore size 13-mm diameter polytetrafluoroethylene (PTFE) syringe filter into a 1.8-mL glass autosampler vial capped with a PTFE/silicone septum cap and placed in the autosampler along with two vials of polystyrene standards and a vial of control solution. At the beginning of the analysis, the tetrahydrofuran (inhibited with 250 ppm of BHT) mobile phase was incrementally brought to a flow rate of 1 mL/minute over six minutes, the reference side of the RI detector was flushed for 10 minutes and was filled with fresh tetrahydrofuran from the mobile phase. The sample was analyzed after 48 minutes of column equilibration, two 55-microliters injections of polystyrene standards and one 99-microliters injection of a control sample, each of 48 minutes duration. A sample volume of 99 microliters was injected onto the column bank and data collected by the Empower 3 software. Molecular weight calibration was performed using 15 narrow dispersity polystyrene standards (obtained from Polymer Standards Service-USA, Inc) with peak molecular weights ranging from 2.13×106 grams per mole to 266 grams per mole. The molecular weight distribution calculations were performed using Empower 3 GPC software using a third order polynomial fit and yielded an R value greater than 0.9995 for the molecular weight calibration curve. Duplicate injections were run and averaged. The weight average molecular weight of the triblock copolymer was found to be 181,600 grams per mole, and its number average molecular weight was found to be 159,000 grams per mole.
Test Methods Elongation to BreakAn “INSTRON” Tensile Tester model “1122”, “5500R”, “5564HS”, or “3345” (Instron, Inc., Norwood Mass.) was used to test all samples. Sample dimensions were 1 inch (2.54 cm) wide by 50 mm gauge length (GL). A crosshead speed of 20 inches (50.8 cm) per minute was used. Evaluations were carried out at 72° F. (22° C.) plus or minus 4° F. (2.2° C.) and 50% relative humidity plus or minus 5% relative humidity. The sample was stretched until it broke. Elongation to Break was measured as a percentage of the unstretched length.
Permanent SetThe “INSTRON” Tensile Tester was used to measure Permanent Set after a two-cycle hysteresis test. A sample as described in the Elongation to Break test was stretched to 100% (twice original length), then returned at a speed of 20 inches (50.8 cm) per minute. There was a one-second hold before the first load (stretch) was applied, a one-second hold before the first unload, a one-second hold before the second load to 100%, and a one-second hold before the second unload. Permanent Set was calculated from the elongation (%) at 0.1 N after the second unload minus the elongation (%) at 0.1 N after the first load.
LoadThe “INSTRON” Tensile Tester was used to measure the force required to stretch the sample 50% past the original length during the first load, second load, and at the second unload unless otherwise specified.
ShearShear (hang shear) was determined by hanging a 200-gram weight on a sample that was 2.54 cm long in the direction of the segments by 6 to 8 cm wide at 100° F. (38° C.). The weight was positioned such that the second segments were stretched in the film's width direction. Tape was used to cover a portion of the width of the sample so that clips and the weight could be applied. The exposed width of the film subjected to testing was 3.8 cm. Shear is reported as the time (minutes) for film to break.
Moisture Vapor Transmission Rate (MVTR)MVTR was measured using an upright cup method at 40° C.±1° C. and 20% relative humidity±2%. The upright cup method is considered a dry method since the sample is not contacted with liquid water. A 3.8-cm diameter sample was placed between adhesive-containing surfaces of two foil adhesive rings, each having a 5.1-cm2 elliptical opening. The holes of each ring were carefully aligned. Finger pressure was used to form a foil/sample/foil assembly that was flat, wrinkle free, and had no void areas in the exposed sample.
A 120-mL glass jar was filled with approximately 50 grams of tap water. The jar was fitted with a screw-on cap having a 3.8-cm diameter hole in the center thereof and with a 4.45 cm diameter rubber washer having an approximately 3.6-cm hole in its center. The rubber washer was placed on the lip of the jar and foil/sample/foil assembly was placed backing side down on the rubber washer. The lid was then screwed loosely on the jar.
The assembly was placed in a chamber at 40° C. and 20% relative humidity for four hours. At the end of four hours, the cap was tightened inside the chamber so that the sample was level with the cap (no bulging) and the rubber washer was in proper seating position.
The foil sample assembly was removed from the chamber and weighed immediately to the nearest 0.01 gram for an initial dry weight, W1. The assembly was then returned to the chamber for at least 18 hours, the exposure time T1 in hours, after which it was removed and weighed immediately to the nearest 0.01 g for a final dry weight, W2. The MVTR in grams of water vapor transmitted per square meter of sample area per 24 hours was then calculated using the following formula:
Upright (Dry) MVTR=(W1−W2)×(4.74×104)/T1.
Two 6-inch (150-mm) co-extrusion dies, Die 1 and Die 2, each with three cavities, as generally depicted in
The inlet fittings on the two end blocks were each connected to conventional single-screw extruders. Compositions of the polymer compositions feeding each extruder and flow rates for each of Examples 1 to 9 (Ex. 1 to 9) are shown in Table 3. Extruder 1 feeding the first cavity leading to the first fluid passageways described in Table 2, above, was loaded with the first polymeric composition. Extruder 2 fed the second cavity leading to the second fluid passageways, and Extruder 3 fed the third cavity leading to the third fluid passageways described in Table 2, above. Extruder 2 was loaded with the second polymeric composition, and Extruder 3 was loaded with the third polymeric composition. The first, second, and third polymeric compositions for each of Examples 1 to 9 are shown in Table 3, which refers to abbreviated names of the materials listed in Table 1. The third polymeric composition for Examples 1 to 3 and 7 also included less than 2% by weight of a red color concentrate in polypropylene, the third polymeric composition for Example 4 included less than 2% by weight of a green color concentrate in polypropylene, and the third polymeric composition for Examples 5 and 6 included less than 2% by weight of a blue color concentrate in polypropylene. The second polymeric composition for Examples 2 to 4 included less than 2% by weight of a pink color concentrate in polypropylene. The first polymeric composition for Examples 1 to 6 included 3% by weight of a white color concentrate in polypropylene. Unless noted in Table 3, all extruders were set to 218° C. The polymeric compositions were extruded from the die at a rate of 1.2 meters per minute (m/min) and then drawn at the rate shown in Table 3, below. A chill roll was positioned adjacent to the dispensing slot of the co-extrusion die to receive the extruded material.
Using an optical microscope, the widths and thickness of the first and second segments were measured for Examples 4 and 8. The thicknesses of the second and third layers of the second segments were also measured. For Example 4, at a magnification of 16×, the width of the second segments was 403 micrometers (average of 3 measurements), and the width of the first segments was 775 micrometers (average of 3 measurements). The thicknesses of the first and second segments were measured at a magnification of 50× and found to be 45.3 micrometers and 40.3 micrometers, respectively. Each of these thicknesses was an average of two measurements. The thicknesses of the second and third layers of the second segments were measured at a magnification of 500× and found to be 2.20 micrometers and 2.53 micrometers, respectively. Each of these thicknesses was an average of two measurements.
For Example 8, at a magnification of 16×, the width of the second segments was 290 micrometers (average of 4 measurements), and the width of the first segments was 709 micrometers (average of 4 measurements). The thicknesses of the first and second segments were measured at a magnification of 50× and found to be 31.0 micrometers and 49.7 micrometers, respectively. Each of these thicknesses was an average of two measurements. The thicknesses of the second and third layers of the second segments were measured at a magnification of 500× and found to be 1.54 micrometers and 1.58 micrometers, respectively. Each of these thicknesses was an average of three measurements.
Examples 1 to 9 (Ex. 1 to 9) were measured for basis weight and bulbosity, which is the ratio of the thickness of the second segments to the thickness of the first segments. Elongations to break, permanent set, load 1, load 2, unload 2, and hang shear were measured using the test methods described above with each sample being stretched in the cross-direction (direction transverse to the first and second segments). The results are shown in Table 4. Moisture vapor transmission rate (MVTR) was measured according to the test method described above for Examples 1 to 4, 8, and 9. The results are shown in Table 5. Each value reported in Table 5 is an average of 3 replicates.
The elongation properties of Examples 5, 8, and 9 were also evaluated in the machine direction (direction parallel to the first and second segments) for load and elongation at break using the methods described above. The first load at 5% elongation, first load at 10% elongation, elongation at break, and maximum load were measured. The results are shown in Table 6, below.
Example 8 was further analyzed for elongation in the machine direction (direction parallel to the first and second segments). A 2-inch (5.08-cm) wide sample was stretched to 400% using a 50 mm gauge length (GL) and a crosshead speed of 20 inches (50.8 cm) per minute. The sample was then allowed to relax for 10 minutes, during which time the sample relaxed to a width of a little greater than one inch (2.54 cm). A one-inch (2.54-cm) sample was then cut from the relaxed sample. A two-cycle hysteresis was carried out using the method described above, with the modification that Permanent Set was calculated from the elongation (%) at 0.05 N after the second unload minus the elongation (%) at 0.05 N after the first load. The following data are averages of three replicates. Load 1 at 10%, 50%, and 100% elongation was 0.17 N, 0.54 N, and 0.74, respectively. Load 2 at 50% and 100% elongation was 0.39 N and 0.70 N, respectively, and unload 2 at 75% and 50% was 0.34 N and 0.18 N, respectively. The permanent set was 25.4%.
Example 10A three layer laminate was made with a film of Example 9 position between outer layers of nonwoven (hydrophobic nonwovens obtained from Fitesa, Simpsonville, S.C., having item number “C1223” and style number “570D”). This structure was placed on a hotplate at 140° C. and pressed with a second plate preheated to 140° C. for 10 seconds at approximately 80 kilopascals. The nonwoven preferentially bonded to the surface of the second segments, as determined by visual inspection. The sample was able to stretch and recover in the CD without an activation step.
Prophetic Examples (PE)The resins shown in Table 7 may be used to make films according to the present disclosure using any of the methods described above. For each of the Prophetic Examples, the first polymeric composition of the first segments may the same or different from the third polymeric composition in the second layer of the second segments, providing it is capable of forming a bond with the second polymeric composition in the first layer of the second segments.
Foreseeable modifications and alterations of this disclosure will be apparent to those skilled in the art without departing from the scope and spirit of this invention. This invention should not be restricted to the embodiments that are set forth in this application for illustrative purposes.
Claims
1. A film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition, wherein the first segments and second segments each have first major surfaces that collectively form the first major surface of the film, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, wherein at least two of the layered second segments have the second polymeric composition and the third polymeric composition in an identical arrangement, wherein the film has a moisture vapor transmission rate of less than 800 g/m2/day, wherein when the first segments are layered in the film's thickness direction, the first major surfaces of the first segments and the first major surfaces of the second segments do not share a common polymeric composition, and wherein when the layered second segments consist of the first and second layers and the third polymeric composition is the same as the first polymeric composition, the first polymeric composition extends through the entire thickness of the first segments.
2. The film of claim 1, wherein the layered second segments further comprise a third layer in the film's thickness direction, wherein the first layer is a middle layer of the second polymeric composition disposed between the second layer and the third layer at opposite surfaces of the film, wherein the second layer comprises the third polymeric composition, wherein the third layer comprises a fourth polymeric composition, and wherein the third and fourth polymeric compositions can be identical or different.
3. The film of claim 2, wherein the first polymeric composition extends throughout the thickness of the first segments.
4. The film of claim 1, wherein at least some of the first segments are layered first segments comprising fourth and fifth layers in the film's thickness direction, wherein one of the fourth or fifth layers comprises a fifth polymeric composition different from the first polymeric composition, and wherein neither the first or fifth polymeric composition extends through the entire thickness of a given layered first segment.
5. The film of claim 4, wherein the layered first segments further comprise a sixth layer, wherein the fourth layer is a middle layer of the first polymeric composition disposed between the fifth layer and the sixth layer at opposite surfaces of the film, wherein the fifth layer comprises the fifth polymeric composition, wherein the sixth layer comprises a sixth polymeric composition, and wherein the fifth and sixth polymeric compositions can be identical or different.
6. The film of claim 5, wherein at least one of the fifth or sixth polymeric compositions is a hot melt adhesive.
7. The film of claim 1, wherein the second polymeric composition is more elastic than the first polymeric composition and the third polymeric composition.
8. The film of claim 7, wherein the time to failure in a hang shear evaluation is at least 100 minutes, wherein the hang shear evaluation is carried out at 38° C. by hanging a 200-gram weight on a sample 2.54 cm in length and such that the second segments in a 3.8 cm-wide portion of the film are stretched in the film's width direction.
9. The film of claim 1, wherein the first segments have stretch-induced molecular orientation in a direction parallel to their lengths.
10. A laminate comprising the film of claim 1 joined to a fibrous carrier.
11. A laminate comprising a film joined to a fibrous carrier, the film comprising first segments and second segments arranged across the film's width direction and separated from each other by polymer interfaces, the first segments comprising a first polymeric composition and the second segments comprising a second polymeric composition that is more elastic than the first polymeric composition, wherein at least some of the second segments are layered second segments comprising first and second layers in the film's thickness direction, wherein one of the first or second layers comprises a third polymeric composition different from the second polymeric composition, wherein neither the second or third polymeric composition extends through the entire thickness of a given layered second segment, and wherein the second segments each have a width in the film's width direction of less than one millimeter.
12. The laminate of claim 11, wherein the first polymeric composition extends throughout the thickness of the first segments.
13. The laminate of claim 11, wherein the fibrous carrier is an extensible fibrous carrier with a tensile elongation at maximum load of at least 50 percent, or wherein the laminate is incrementally activated.
14. The laminate of claim 11, wherein the film is discontinuously bonded to the fibrous carrier, and wherein the fibrous carrier is bonded to the film predominantly at one of the first segments or the second segments.
15. An absorbent article comprising the laminate of claim 11.
16. A method of making the film of claim 2, the method comprising: wherein a first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot; wherein a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot; and wherein a third fluid passageway within the extrusion die extends on one side of the second fluid passageway from a die cavity within the extrusion die, wherein upstream from the dispensing slot the third fluid passageway is diverted into branches that meet the second fluid passageway at areas above and below the second fluid passageways at the point where the second fluid passageway enters the dispensing slot; and
- providing an extrusion die comprising at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot,
- extruding the first, second, and third polymeric compositions from the first, second, and die cavities, respectively, so as to form the film, wherein the third and fourth polymeric compositions in the second and third layers of the layered second segments, respectively, are identical.
17. A method of making the film of claim 1, the method comprising: wherein a first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot, wherein a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot, wherein the second slot segment and first slot segment are arranged side-by-side to provide a combined width; and wherein a third fluid passageway within the extrusion die extends from a die cavity within the extrusion die to the second slot segment, wherein the third fluid passageway meets the second fluid passageway from an area above the second fluid passageway at a point where the second fluid passageway enters the dispensing slot, and wherein the third fluid passageway has a width at a point where it meets the second fluid passageway that is less than the combined width of the first and second slot segments; and
- providing an extrusion die comprising at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot,
- extruding the first, second, and third polymeric compositions from the first, second, and die cavities, respectively, so as to form the film.
18. An extrusion die comprising at least a first cavity, a second cavity, and a dispensing surface having a dispensing slot,
- wherein a first fluid passageway within the extrusion die extends from the first cavity to a first slot segment of the dispensing slot,
- wherein a second fluid passageway within the extrusion die extends from the second cavity to a second slot segment of the dispensing slot, wherein the second slot segment and first slot segment are arranged side-by-side to provide a combined width; and
- wherein a third fluid passageway within the extrusion die extends from a die cavity within the extrusion die to the second slot segment, wherein the third fluid passageway meets the second fluid passageway from an area above the second fluid passageway at a point where the second fluid passageway enters the dispensing slot, and wherein the third fluid passageway has a width at a point where it meets the second fluid passageway that is less than the combined width of the first and second slot segments.
19. The extrusion die of claim 18, wherein a fourth fluid passageway within the extrusion die extends from a cavity within the extrusion die to the first slot segment, wherein the fourth fluid passageway meets the first fluid passageway from an area above or below the first fluid passageway at a point where the first fluid passageway enters the dispensing slot, and wherein the fourth fluid passageway has a width at a point wherein it meets the first fluid passageway that is less than the combined width of the first and second slot segments.
20. The extrusion die of claim 19, wherein the third fluid passageway extends on one side of the second fluid passageway, wherein upstream from the dispensing slot the third fluid passageway is diverted into branches that meet the second fluid passageway at areas above and below the second fluid passageway at the point where the second at the point where the second fluid passageway enters the dispensing slot.
21. The extrusion die of claim 18, wherein the fluid passageways are provided by a plurality of sequences of shims, wherein each sequence comprises at least one first shim that provides the first fluid passageway, at least one second shim that provides the second fluid passageway, and at least one third shim that provides the at least one third fluid passageway.
Type: Application
Filed: Mar 1, 2013
Publication Date: Sep 4, 2014
Applicant: 3M INNOVATIVE PROPERTIES COMPANY (ST. PAUL, MN)
Inventors: Thomas P. Hanschen (Mendota Heights, MN), Ronald W. Ausen (St. Paul, MN), William J. Kopecky (Hudson, WI), Vathsala Rajagopal (Woodbury, MN)
Application Number: 13/782,376
International Classification: B32B 3/14 (20060101); B32B 3/16 (20060101); B32B 3/18 (20060101);
