Vapor-permeable, substantially water-impermeable multilayer article

• US 9,827,755 B2
• Filed: 06/22/2012
• Issued: 11/28/2017
• Est. Priority Date: 06/23/2011
• Status: Active Grant

• Current Assignee: Fiberweb, Llc (Berry Global Group Inc.)
• Original Assignee: Fiberweb, Llc (Berry Global Group Inc.)
• Inventors: Afshari, Mehdi
• Primary Examiner(s): VAN SELL, NATHAN L
• Application Number:
  US13/530,425
• Publication Number:
  US 20120328841A1
• Time in Patent Office: 1,985 Days
• Field of Search: 442394, 442395, 442396, 442398, 428172, 156219, 156220, 156229
• CPC Class Codes: B29C 48/0011 combined with compression moulding
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/30 Extrusion nozzles or dies extrusion characterised by the shape or cross-section of the extruded article B29C48/03
• CPC Class Codes: B29C 48/305 having a wide opening, e.g. for forming sheets
• CPC Class Codes: B29C 48/395 using screws surrounded by a cooperating barrel, e.g. single screw extruders
• CPC Class Codes: B29C 48/49 using two or more extruders to feed one die or nozzle
• CPC Class Codes: B29C 48/914 cooling drums
• CPC Class Codes: B29C 55/005 characterised by the choice of materials
• CPC Class Codes: B29C 55/023 using multilayered plates or sheets
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B32B 2038/0028 Stretching, elongating
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/10 linear, e.g. length, distance, width
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/205 : the fillers creating voids or cavities, e.g. by stretching
• CPC Class Codes: B32B 27/28 : comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 37/153 : at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: E04D 12/002 : Sheets of flexible material, e.g. roofing tile underlay
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1041 : Subsequent to lamination
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/675 : Ester condensation polymer sheet or film [e.g., polyethylene terephthalate, etc.]
• CPC Class Codes: Y10T 442/676 : Vinyl polymer or copolymer sheet or film [e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, etc.]
• CPC Class Codes: Y10T 442/678 : Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]

Abstract

This disclosure relates to an article that includes a nonwoven substrate, a first film supported by the nonwoven substrate, and a second film such that the first film is between the nonwoven substrate and the second film. The first film includes a first polymer and a pore-forming filler. The difference between a surface energy of the first film and a surface energy of the nonwoven substrate is at most about 10 mN/m. The second film includes a second polymer capable of absorbing and desorbing moisture and providing a barrier to aqueous fluids.

Claims

1. An article, comprising:

a nonwoven substrate;

a microporous breathable film supported by the nonwoven substrate, the microporous breathable film comprising a first polymer and a pore-forming filler, the difference between a surface energy of the microporous breathable film and a surface energy of the nonwoven substrate being at most about 10 mN/m; and

a monolithic breathable film comprising a second polymer capable of absorbing and desorbing moisture and providing a barrier to aqueous fluids, the microporous breathable film being between the nonwoven substrate and the monolithic breathable film;

wherein the article has a moisture vapor transmission rate of at least 35 g/m²/day and at most 140 g/m²/day when measured at 23°

C. and 50 RH %.

2. The article of claim 1, wherein the second polymer is selected from the group consisting of maleic anhydride block copolymers, glycidyl methacrylate block copolymers, polyether block copolymers, polyurethanes, polyethylene-containing ionomers, and mixtures thereof.

3. The article of claim 1, wherein the second polymer is selected from the group consisting of poly(olefin-co-acrylate-co-maleic anhydride), poly(olefin-coacrylate-coglycidyl methacrylate), polyether ester block copolymers, polyether amide block copolymers, poly(ether ester amide) block copolymers, and polyurethanes.

4. The article of claim 1, wherein the second polymer is selected from the group consisting of poly(ethyl-co-acrylate-co-maleic anhydride) and poly(ethlyeneco-acrylate-co-glycidyl methacrylate).

5. The article of claim 2, wherein the monolithic breathable film further comprises a polyolefin.

6. The article of claim 5, wherein the polyolefin comprises a polyethylene or a polypropylene.

7. The article of claim 6, wherein the polyolefin comprises a polyethylene selected from the group consisting of low-density polyethylene, linear low-density polyethylene, high-density polyethylene, and copolymers thereof.

8. The article of claim 2, wherein the monolithic breathable film further comprises a vinyl polymer.

9. The article of claim 8, wherein the vinyl polymer comprises a copolymer formed between a first comonomer and a second comonomer, the first comonomer comprises ethylene, and the second comonomer comprises alkyl methacrylate, alkyl acrylate, or vinyl acetate.

10. The article of claim 8, wherein the vinyl polymer comprises a poly(ethylene-co-methyl acrylate), a poly (ethylene-co-vinyl acetate), a poly (ethylene-coethyl acrylate), or a poly(ethylene-co-butyl acrylate).

11. The article of claim 2, wherein the monolithic breathable film further comprises a compatibilizer.

12. The article of claim 11, wherein the compatibilizer comprises polypropylene grafted with maleic anhydride (PP-g-MAH) or a polymer formed by reacting PP-g-MAH with a polyetheramine.

13. The article of claim 1, wherein the monolithic breathable film comprises at least about 20% by weight of the second polymer;

at least about 10% by weight of a vinyl polymer;

at least about 5% by weight of a polyolefin; and

at least about 0.1% by weight of a compatibilizer, based on the weight of the monolithic breathable film.

14. The article of claim 2, wherein the monolithic breathable film further comprises a polyester.

15. The article of claim 14, wherein the polyester is selected from the group consisting of a polybutylene terephthalate, a polyethylene terephthalate, and a polytrimethylene terephthalate.

16. The article of claim 1, wherein the first polymer comprises a polyolefin or a polyester.

17. The article of claim 16, wherein the first polymer comprises a polyethylene or a polypropylene.

18. The article of claim 16, wherein the first polymer comprises a polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polyglycolide, polylactide, polycaprolactone, polyethylene adipate, polyhydroxyalkanoate, or a copolymer thereof.

19. The article of claim 1, wherein the pore-forming filler comprises calcium carbonate.

20. The article of claim 19, wherein the microporous breathable film comprises from about 30% by weight to about 70% by weight of the calcium carbonate.

21. The article of claim 1, wherein the microporous breathable film further comprises a nanoclay.

22. The article of claim 21, wherein the nanoclay is a montmorillonite clay.

23. The article of claim 1, wherein the microporous breathable film further comprises an elastomer.

24. The article of claim 23, wherein the elastomer is a propylene-ethylene copolymer.

25. The article of claim 1, wherein the microporous breathable film is from about 2% to about 98% of the total weight of the microporous breathable film and monolithic breathable film.

26. The article of claim 1, wherein the nonwoven substrate comprises randomly disposed polymeric fibers, at least some of the fibers being bonded to one another.

27. The article of claim 1, wherein the article has a tensile strength of at least about 40 pounds in the machine direction as measured according to ASTM D5034.

28. The article of claim 1, wherein the article has tensile strength of at least about 35 pounds in the cross-machine direction as measured according to ASTM D5034.

29. The article of claim 1, wherein the article has a hydrostatic head of at least about 55 cm.

30. The article of claim 1, wherein the article is embossed.

31. A construction material, comprising the article of claim 1.

32. The construction material of claim 31, wherein the construction material is a housewrap or a roofwrap.

33. The article of claim 1, wherein the article has a hydrostatic head of at least 55 cm and the adhesion between the substrate and the first film is at least 200 gram-force/in.

34. The article of claim 1, wherein the a weight ratio between the monolithic breathable film and the microporous breathable film is from 4:

1 to 49;

1.

35. The article of claim 34, wherein the monolithic breathable film a comprises from 80% to about 95% of the total weight of the monolithic breathable film and microporous breathable film.

36. The article of claim 1, wherein the microporous breathable film comprises a functionalized polyolefin;

wherein the functionalized polyolefin is a polypropylene grafted with maleic anhydride (PP-g-MAH) or a polymer formed by reacting PP-g-MAH with a polyetheramine.

37. An article, comprising:

a nonwoven substrate;

a microporous breathable film supported by the nonwoven substrate, the microporous breathable film comprising a first polymer and a pore-forming filler, the difference between a surface energy of the microporous breathable film and a surface energy of the nonwoven substrate being at most about 10 mN/m; and

a monolithic breathable film comprising a second polymer selected from the group consisting of maleic anhydride block copolymers, glycidyl methacrylate block copolymers, polyether block copolymers, polyurethanes, polyethylene-containing ionomers, and mixtures thereof, the microporous breathable film being between the nonwoven substrate and the monolithic breathable film;

wherein the article has a moisture vapor transmission rate of at least 35 g/m²/day and at most 140 g/m²/day when measured at 23°

C. and 50 RH %.

38. An article, comprising:

a nonwoven substrate;

a microporous breathable film supported by the nonwoven substrate, the microporous breathable film comprising a first polymer and a pore forming filler, the first polymer comprising a polyolefin or a polyester; and

a monolithic breathable film comprising a second polymer selected from the group consisting of maleic anhydride block copolymers, glycidyl methacrylate block copolymers, polyether block copolymers, polyurethanes, polyethylene-containing ionomers, and mixtures thereof, the microporous breathable film being between the nonwoven substrate and the monolithic breathable film;

wherein the article has a moisture vapor transmission rate of at least 35 g/m²/day and at most 140 g/m²/day when measured at 23°

C. and 50 RH %.