Coextruded multilayer film with propylene-based polymer barrier layer

• US 10,583,637 B2
• Filed: 06/25/2014
• Issued: 03/10/2020
• Est. Priority Date: 06/28/2013
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Jenkins, Steven R., Lee, Patrick Chang Dong, Dooley, Joseph, Kirkpatrick, Donald E., Obi, Bernard E.
• Primary Examiner(s): Figg, Travis M
• Application Number:
  US14/900,481
• Publication Number:
  US 20160152009A1
• Time in Patent Office: 2,085 Days
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2250/42 Alternating layers, e.g. ABAB(C), AABBAABB(C)
• CPC Class Codes: B32B 2307/704 Crystalline
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/325 comprising polycycloolefins
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 7/027 Thermal properties

Abstract

The present disclosure provides a coextruded multi layer film. The coextruded multilayer film includes a core component having from 15 to 1000 alternating layers of layer A and layer B. Layer A has a thickness from 30 nm to 1000 nm and includes a propylene-based polymer having a crystallization temperature (T_1c). Layer B includes a second polymer having a glass transition temperature (T_2g), wherein T_1c<T_2g. Layer A has an effective moisture permeability less than 0.40 g-mil/100 in²/day.

Claims

1. A coextruded multilayer film comprising:

a core component comprising from 15 to 1000 alternating layers of layer A and layer B;

layer A having a thickness from 100 nm to 500 nm and comprising a propylene homopolymer having a melt flow rate from 1.5 g/10 min to 2.5 g/10 min and a crystallinity from 30% to 45%, and having a crystallization temperature (T₁c) from 115°

C. to less than 125°

C.;

layer B comprising a second polymer selected from the group consisting of (i) a polycarbonate having a glass transition temperature (T₂g) greater than 150°

C. and (ii) a pentablock hydrogenated styrene having a T₂g greater than 125°

C.; and

layer A comprises truncated spherulites and has an effective moisture permeability from 1.55 g-mil/m²/24 hr to less than or equal to 4.65 g-mil/m²/24 hr.

2. The multilayer film of claim 1 wherein layer A has a thickness from 200 nm to 400 nm.

3. The multilayer film of claim 1 wherein T₂g−

T₁c is greater than 20°

C.

4. The multilayer film of claim 1 wherein layer A has a thickness from 200 nm to 400 nm and layer A has an effective moisture permeability from 3.1 g-mil/m²/24 hr to less than or equal to 4.65 g-mil/m²/24 hr.

5. The multilayer film of claim 1 wherein the pentablock hydrogenated styrene has a T₂g greater than 135°

C.

6. The multilayer film of claim 5 wherein T₂g−

T₁c is greater than 20°

C.

7. The multilayer film of claim 5 wherein layer A has a thickness from 200 nm to 400 nm and layer A has an effective moisture permeability from 3.1 g-mil/m²/24 hr to less than or equal to 4.65 g-mil/m²/24 hr.

8. The multilayer film of claim 1 wherein the core component has a thickness from 0.1 mil to 10.0 mil.

9. The multilayer film of claim 1 comprising at least one skin layer.

10. The multilayer film of claim 9 wherein the skin layers comprise a propylene-based polymer.

11. The multilayer film of claim 1 wherein the propylene homopolymer has a crystallinity from 35% to 45%.

14. The multilayer film of claim 1 wherein the core component comprises from 30 to 300 alternating layers of layer A and layer B;

layer A has a thickness from 200 nm to 400 nm;

layer B has a thickness from 50 nm to 500 nm; and

the core component has a thickness from 0.1 mil to 10.0 mil.

15. The multilayer film of claim 1 wherein the core component has a thickness from 2.0 mil to 10.0 mil.

12. A coextruded multilayer film comprising:

a core component comprising from 15 to 1000 alternating layers of layer A and layer B;

layer A having a thickness from 100 nm to 500 nm and comprising a propylene homopolymer having a crystallinity from 35% to 50% and having a crystallization temperature (T₁c) from 115°

C. to less than 125°

C.;

layer B comprising a second polymer selected from the group consisting of (i) a polycarbonate having a glass transition temperature (T₂g) greater than 150°

C. and (ii) a pentablock hydrogenated styrene having a T₂g greater than 125°

C.; and

layer A comprises truncated spherulites and has an effective moisture permeability from 1.55 g-mil/m²/24 hr to less than or equal to 4.65 g-mil/m²/24 hr.

13. The multilayer film of claim 12 wherein the propylene homopolymer has a melt flow rate from 1.5 g/10 min to 2.5 g/10 min.

16. The multilayer film of claim 12 wherein the core component comprises from 30 to 300 alternating layers of layer A and layer B;

layer A has a thickness from 200 nm to 400 nm;

layer B has a thickness from 50 nm to 500 nm; and

the core component has a thickness from 0.1 mil to 10.0 mil.

17. The multilayer film of claim 12 wherein the core component has a thickness from 2.0 mil to 10.0 mil.

18. A coextruded multilayer film comprising:

a core component comprising from 15 to 1000 alternating layers of layer A and layer B;

layer A having a thickness from 100 nm to 500 nm and comprising a propylene homopolymer having a melt flow rate from 1.5 g/10 min to 2.5 g/10 min and a crystallinity from 30% to 45%, and having a crystallization temperature (T₁c) from 115°

C. to less than 125°

C.;

layer B comprising a second polymer comprising a polycarbonate having a glass transition temperature (T₂g) greater than 170°

C.;

layer A has an effective moisture permeability from 1.55 g-mil/m²/24 hr to less than or equal to 4.65 g-mil/m²/24 hr.

19. The multilayer film of claim 18 wherein the core component comprises from 30 to 300 alternating layers of layer A and layer B;

layer A has a thickness from 200 nm to 400 nm;

layer B has a thickness from 50 nm to 500 nm; and

the core component has a thickness from 0.1 mil to 10.0 mil.

20. The multilayer film of claim 18 wherein the core component has a thickness from 2.0 mil to 10.0 mil.