Multilayer polymeric film

• US 5,006,394 A
• Filed: 06/23/1988
• Issued: 04/09/1991
• Est. Priority Date: 06/23/1988
• Status: Expired due to Term

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Baird, James C.
• Primary Examiner(s): Buffalow, Edith
• Application Number:
  US07/211,518
• Time in Patent Office: 1,020 Days
• Field of Search: 428/516, 428/520, 428/131, 428/913, 428/138, 428/284
• US Class Current: 428/138
• CPC Class Codes: A61F 13/15577 Apparatus or processes for manufacturing
• CPC Class Codes: A61F 13/51 characterised by the outer layers wicking or transfer layers A61F13/537
• CPC Class Codes: A61F 13/51113 comprising an additive, e.g. lotion or odour control A61F13/51108 takes precedence
• CPC Class Codes: A61F 13/5116 being formed of multiple layers A61F13/5123 takes precedence
• CPC Class Codes: A61F 13/5123 the apertures being formed on a multilayer top sheet
• CPC Class Codes: A61F 13/51394 creating a visual effect, e.g. having a printed or coloured topsheet, printed or coloured sub-layer but being visible from the topsheet, other than embossing for purposes of bonding, wicking, acquisition, leakage-prevention
• CPC Class Codes: A61F 2013/51061 for rendering the surface hydrophobic
• CPC Class Codes: A61F 2013/51147 being polymeric films
• CPC Class Codes: A61F 2013/51409 being a film
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/307 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2309/10 linear, e.g. length, distance, width
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 37/08 : characterised by the cooling method
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/153 : at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 37/203 : One or more of the layers being plastic
• CPC Class Codes: B32B 38/10 : Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: Y10S 428/913 : Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/31913 : Monoolefin polymer
• CPC Class Codes: Y10T 428/31928 : Ester, halide or nitrile of addition polymer

Abstract

A polymeric multilayer film structure having a high percentage of fillers is disclosed. The fillers are concentrated in a separate filler containing layer having about 5 to about 20 percent of the thickness of the total multilayer film. The filler containing layer is coextruded with a base layer comprising the balance of the thickness of the multilayer film. By keeping the filler containing layer thin, relative to the total film thickness, a multilayer film having a filler concentration up to about 60 weight percent is achievable without significantly adversely affecting the material properties of the multilayer film structure.

Claims

1. A substantially void-free polymeric multilayer film which exhibits an opaque appearance without being stretched, said polymeric multilayer film comprising:

(a) at least one relatively thick base layer comprised substantially of a polymer, said base layer having a thickness comprising at least about 80 percent of the total thickness of said multilayer film; and

(b) at least one relatively thin filler containing polymeric layer substantially continuously joined to said base layer, said filler containing polymeric layer having about 15 to about 60 weight percent fillers substantially uniformly dispersed therein, said filler containing layer having a thickness not exceeding about 20 percent of the total thickness of said multilayer film, whereby said fillers in said relatively thin filler containing polymeric layer scatter the light rays incident upon said multilayer film to produce said opaque appearance in said multilayer polymeric film without significantly detracting from the material properties of said base layer.

4. A multilayer film according to claim 1, 2 or 3 wherein said filler containing layer comprises fillers selected from the group consisting of titanium dioxide, calcium carbonate, silica, colored pigments, filaments and combinations thereof.

5. A multilayer film according to claim 4 wherein said fillers impart opacity to said multilayer film.

6. A multilayer film according to claim 1, 2 or 3 wherein said filler containing layer comprises polymers selected from the group consisting of polyolefins, copolymers having at least one olefinic constituent, polyesters, nylons, copolymers of polyesters and nylons, and combinations thereof.

7. A multilayer film according to claim 6 wherein said filler containing layer comprises polymers selected from the group consisting of polyethylenes, polypropylenes, ethylene vinyl acetate copolymer and combinations thereof.

8. A multilayer film according to claim 1, 2 or 3 wherein said base layer comprises polymers selected from the group consisting of polyolefins, copolymers having at least one olefinic constituent, polyesters, nylons, copolymers of polyesters and nylons and combinations thereof.

9. A multilayer film according to claim 8 wherein said base layer comprises polymers selected from the group consisting of polyethylenes, polypropylenes and combinations thereof.

10. A multilayer film according to claim 8 further comprising from about 1 to about 15 weight percent fillers dispersed in said base layer.

11. A multilayer film according to claim 1 or 2 wherein said filler containing layer comprises from about 5 to about 20 percent of the thickness of the multilayer film.

13. A multilayer film according to claim 1, 2 or 3 further comprising apertures.

14. A multilayer film according to claims 11 or 12 wherein at least one of the sides of said multilayer film is white.

15. A multilayer film according to claim 11 or 12 wherein the opposite sides of said multilayer film are of different colors.

16. A multilayer film according to claim 11 or 12 wherein said outer layers comprise substantially different compositions.

17. A multilayer film according to claim 1, 2 or 3 wherein said multilayer film is placed in register with and associated with one face of an absorbant core having two opposed faces.

18. A multilayer film according to claim 17 further comprising apertures.

19. A multilayer film according to claim 17 further comprising a second multilayer film according to claim 17 placed in register with and associated with the opposed face of said absorbant core, one of said multilayer films associated with one face of said absorbant core further comprising apertures, whereby said multilayer films and said absorbant core are adapted for use as a panty liner, catamenial pad, diaper or adult incontinent product.

2. A substantially void-free polymeric multilayer film which exhibits an opaque appearance without being stretched, said polymeric multilayer film comprising:

(a) a first relatively thick outer base layer comprised substantially of a polymer;

(b) a central relatively thin filler containing polymeric layer having a first side and a second side opposed thereto, said first side being substantially continuously joined to one side of said first outer base layer, said filler containing polymeric layer having about 15 to about 60 weight percent fillers substantially uniformly dispersed therein, and a thickness not exceeding about 20 percent of the total thickness of said multilayer film; and

(c) a second relatively thick outer base layer comprised substantially of a polymer and having one side substantially continuously joined to said second side of said central filler containing layer, said first outer base layer and said second outer base layer together comprising at least about 80 percent of the total thickness of said multilayer film, whereby said fillers in said relatively thin filler containing polymeric layer scatter the light rays incident upon said multilayer film to produce said opaque appearance in said multilayer polymeric film without significantly detracting from the material properties of said base layers.

3. A substantially void-free polymeric multilayer film which exhibits an opaque appearance without being stretched, said polymeric multilayer film comprising:

(a) two relatively thin outer filler containing polymeric layers, each of said outer filler containing polymeric layers having about 15 to about 60 weight percent fillers substantially uniformly dispersed therein, said filler containing layers together having a combined thickness not exceeding about 20 percent of the total thickness of said multilayer film; and

(b) a relatively thick central base layer having a first side and a second side opposed thereto and comprised substantially of a polymer, said base layer being interposed between said outer filler containing polymeric layers and having one of said outer filler containing polymeric layers substantially continuously joined to said first side of said base layer and the other of said outer filler containing layers substantially continuously joined to said second side of said base layer, said central base layer having a thickness comprising at least about 80 percent of the total thickness of said multilayer film, whereby said fillers in said relatively thin filler containing polymeric layers scatter the light rays incident upon said multilayer film to produce said opaque appearance in said multilayer polymeric film without significantly detracting from the material properties of said base layer.

12. A multilayer film according to claim 3 wherein said filler containing layers comprise from about 5 to about 20 percent of the thickness of the multilayer film.