CA1243174A - Polymer blend films - Google Patents

Polymer blend films

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Publication number
CA1243174A
CA1243174A CA000465666A CA465666A CA1243174A CA 1243174 A CA1243174 A CA 1243174A CA 000465666 A CA000465666 A CA 000465666A CA 465666 A CA465666 A CA 465666A CA 1243174 A CA1243174 A CA 1243174A
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CA
Canada
Prior art keywords
film
blend
vinyl acetate
ethylene vinyl
acetate copolymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000465666A
Other languages
French (fr)
Inventor
Peter J. Metcalfe
Andrew J. Carter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Smith and Nephew PLC
Original Assignee
Smith and Nephew Associated Companies PLC
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Filing date
Publication date
Application filed by Smith and Nephew Associated Companies PLC filed Critical Smith and Nephew Associated Companies PLC
Application granted granted Critical
Publication of CA1243174A publication Critical patent/CA1243174A/en
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18Manufacture of films or sheets
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/22Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons containing macromolecular materials
    • A61L15/225Mixtures of macromolecular compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • C08L23/08Copolymers of ethene
    • C08L23/0846Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
    • C08L23/0853Vinylacetate
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2331/00Characterised by the use of copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, or carbonic acid, or of a haloformic acid
    • C08J2331/02Characterised by the use of omopolymers or copolymers of esters of monocarboxylic acids
    • C08J2331/04Homopolymers or copolymers of vinyl acetate
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02Homopolymers or copolymers of hydrocarbons
    • C08L25/04Homopolymers or copolymers of styrene
    • C08L25/06Polystyrene
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S602/00Surgery: splint, brace, or bandage
    • Y10S602/90Method of making bandage structure
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249953Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249955Void-containing component partially impregnated with adjacent component
    • Y10T428/249958Void-containing component is synthetic resin or natural rubbers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249953Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249978Voids specified as micro
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249953Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249987With nonvoid component of specified composition
    • Y10T428/249991Synthetic resin or natural rubbers

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Epidemiology (AREA)
  • Hematology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Shaping By String And By Release Of Stress In Plastics And The Like (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Materials For Medical Uses (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)

Abstract

ABSTRACT

POLYMER BLEND FILMS

A moisture vapour transmitting elastomeric film which comprises a blend of incompatible polymers and contains voids characterised in that the blend comprises a continuous matrix of ethylene vinyl acetate within which the incompatible polymer forms a discrete particulate phase matrix, processes for the preparation thereof and articles comprising these films are described.

Description

POLYMER BLEND FILMS

The present invention relates to moisture vapour transmitting elastomeric films, processes for their preparation and articles comprising these films.
' Elastomeric films possess good conformability and are therefore suitable for use in bodily contact ar~icles such as`dressi'ngs for example wound dressings, to provide such articles with good conformability to the skin. Desirably the elastomeric film should be moisture vapour transmitting to prevent for example maceration of the skin under the dressing.
Moisture vapour transmitting elastomeric films which contain voids and comprise a blend of polyurethane and an incompatible polymer are disclosed in British Patent Application No. 2,0'81,721A pu~lished Feb. 24, 1982 and Europeàn Patent ~pplication No. 096458 published Dec. 21, 1983, both publis~ed in the'name'of'Smith and N~phew Associated Companies p.l.c. Polyurethane films however, are relatively expensive to manufacture. It would therefore be desirable ~o to hàve'suitable el'astomeric films of a polymer which is less expensive than polyurethane. Unfortunately, films of such elastomers tend to have poor moisture vapour transmission properties. Published sritish Patent Application No. 2,103,537A
d3~scloses a moisture'vapour transmitting elastomeric film, suitable for use in adhesive medical ~ 2~ 7~

dressings, which contain voids and comprises a blend of 1,2 polybutadiene and an incompatible polymer. Such a film although more economical to manufacture than a polyurethane film has relatively poor moisture transmission properties without the provision of apertures in the film. Ethylene vinyl acetate copolymers are known to have elastomeric properties. Conventional ethylene vinyl acetate copolymer films, however, have moisture vapour transmission rates which are less than desirable for dressings. United States Patent No. 4,381,326 discloses an elastic reticulated sheet which comprises a blend of ethylene vinyl acetate copolymer and a block copolymer of styrene and butadiene or isoprene. The blends disclosed in this patent, however, do not contain more than 10~ by `, weight of ethylene vinyl acetate copolymer.

Elastomeric films of ethylene vinyl acetate copolymer have now been found which have improved moisture vapour transmission rates and which are suitable for use in bodily contact articles such as wound dressings.

Accordingly the present invention provides a moisture vapour transmitting elastomeric film which comprises a blend of incompatible polymers and contains voids within the film, said voids not providing a continuous pathway through the film and wherein the blend comprises a continuous :~z~

matrix of ethylene vinyl ~cetate copolymex within which the incompa~ible polymer forms a discrete particulate phase.

The films of the invention are especially suitable for wound dressings.

The term ~voids" when used herein means small holes within the film. These small holes may interrupt the surface of the film or coalesce but do not provide a continuous pathway through the film.

Continuous films of the invention therefore will be impermeable to liquid water.

Accordingly in a favoured aspect the film of the invention is a liquid wa~er impermeable film.

The liquid water impermeable film of the invention can be used advantageously in wound dressings, for example as a backing layer in adhesive dressings. Such a film can provide a dressing when used over a wound with a barrier to bacteria and liquid water penetrating from the outside of the dressing to the wound surface. Liquid water impermeable films of the invention for use in wound dressings suitably have a moisture vapour transmision rate of at least 200g/m2, more suitably a rate of at least 350g/m2, desirably a rate of at least 500g/m2 and ~2~31~

preferably at least lOOOg/m2/2~hrs at 37C at 100% to 10% relative humidity difference.

The liquid water impermeable films of the invention suitably have a thickness of 0.05 to 0.25mm, desirably 0.05 to 0.20mm and preferably have a thickness of 0.075 to 0.1~5mm.

The voided films of the invention can have apertures.
Thus in a further preferred aspect the film of the invention is an apertured film.

The apertured films of the invention will allow the passage of water in liquid or vapour form and therefore can be used in wound dressings to provide a high moisture vapour transmission rate and to allow the passage of wound exudate and in sanitary absorbent pads to allow the 15` transmission of body exudate fluids.

In a favoured aspect the elastomeric apertured film of this invention is in the form of a net. When used herein the term "net" means a structure having a set of ribs. Suitably the ribs of the net are parallel. Also suitably the ribs of the net may be serpentine and touch or join each other intermittently. More suitably the nets of this invention will have at least two sets of parallel ~L243::~L7~

ribs which sets intersect or are skew to each other. Most suitably the nets of this invention will have two sets of parallel ribs which sets are perpendicular to each other.

The nets of this invention will frequently contain membranes extending outwardly from the ribs to define the aperture. Whether the aperture is defined by such membranes or by the ribs per se, it is believed that the area of aperture to the total area of the film is suitably 5 to 75%, more suitably 10 to 50% and is preferably 20 to 40~.

Nets of this invention will suitably contain at least one set of ribs which are from 0.03 to 2.5mm thick, more suitably ~.05 to lmm and preferably from 0.05 to 0.5mm thick in the direction of thickness of the film.

The nets ~f this invention maybe used as backings for dressings, as wound facing layers and as cover layers on sanitary absorbent pads such as sanitary towels, diapers, incontinence pads and the like.

The holes or apertures in the apertured films of the invention may suitably have an aproximately elliptical shape (for a uniaxially stretched film) or an approximately circular shape (for a biaxially stretched ~Z43~79L

film).

It is desirable that the films of this invention have a recoverable elastic strain of at least 25%, more suitably at least 50~ and preferably at least 100%.

The films of the invention are normally opague due to the voids in the body of the film.

The films of the invention have a desirable soft surface feel when they are used in the manufacture of articles for bodily contact.

Suitable ethylene vinyl acetate copolymers for use in the films of the invention comprise 3~ to 40~ by weight and preferably 5~ to 30% by weight of vinyl acetate residues. Favoured ethylene vinyl acetate copolymers of this type are known as EVATANE (trade mark) Nos~ 555, 539, 24-03 and 28-05 available from Imperial Chemical Industries Limited. EVATANE 555, 539, 24~03 and 28-05 contain respectively 12.S%, 18~, 24% and 28% by weight of vinyl acetate residues.

The ethylene vinyl acetate copolymer can contain additives such as fillers and antioxidants.

The incompatible polymer -~sed in the film of the ~IZ~317~

invention forms a discrete particulate phase within a continuous matrix of the ethylene vinyl ~cetate copolymer.

It is preferred that the particles of the discrete particulate phase of incompatible polymer should be spherical or ellipsoidal in shape and have a diameter of at least 0.25 micro metres, for example 0.5 micro metres to 5 micro metres.

It is desirable that mechanical and physical properties o~ the incompatible polymer are significantly 1~ different from that of the ethylene vinyl acetate copolymer at temperatures at which the film will cold draw. It is particularly desirable that the incompatible polymer should have a higher modulus than that of the ethylene vinyl acetate copolymer at cold draw temperatures.

Suitable incompatible polymers include those derived ' from the polymerisation of vinyl aromatic hydrocarbons.
An especially suitable incompatible polymer is polystyrene. --The polystyrene may be an unmodified ~homopolymer) or rubber modified grade that is a high impact polystyrene. High impact polystyrene is a preferred incompatible polymer.

A preferred high impact polys~yrene i~ known as Styron 485 supplied by Dow Chemicals.

The proportions o~ ethylene vinyl acetate copolymer and the incompatible polymer in ~he blend depend to some S extent on the individual polymers. However in general suitable blends contain 40~ to 95% by weight, desirably 45~ to 90% by weight and preferably 50% to 85~ by weight of ethylene vinyl acetate copolymer~

A preferred blend for water impermeable films of the invention contains 60% by weight of ethylene vinyl acetate copolymer (for example Evatane 555 or 28-05) and 40% by weight of incompatible polymer ~for example high impact grade polystyrene such as Styron 485).

A preferred blend for apertured films of tbe invention contains 80% by weight of ethylene vinyl acetate copolymer (for example Evatane 539 or 24-03) and 20% by weight of incompatible polymer (for example high impact polystyrene such as Styron 485).

The films of this invention are suitable for use in articles for bodily contact~ Thus in a further aspect the invention provides an article for bodily contact which comprises a film of the invention.

* Trade Mark 3~

Bodily contact articles of the invention include dressings such as wound dressings and hygienic absorbent pads, such as sanitary towels, diapers, incontinence pads and alike pads. It is preferred however that the bodily ` 5 contact article is a wound dressing.

Most aptly the films of this invention are used as the backing in an adhesive wound dressing such as a first aid dressing. Such wound dressings form part of this invention.

- 10 - - It is preerre~-that adhesive dressing of the invention have a moisture vapour transmission rate of at least 150g/m2, suitably at least 250g/m2 and preferably at least 500g/m2/24hrs at 37C at 100% to 10% relative humidity difference.

The moisture vapour transmission rate may be measured by the Payne Cup method. The method uses a cup 1.5cm deep with a flanged top. The inner diameter of the flange is such to provide an area for moisture vapour transmission of lOcm2. In this method lOml of distilled water is added to the cup and a sample of the material under test, large enough to completely cover the flange, is clamped over the cup. The complete assembly is then weighed and - ~2~3~

placed in a cabinet where the tempera~ure and relative humidity are maintained at 37C and 10~ respectively.
After 17 hours the cup is removed from the cabinet and allowed to cool a~ room temperature. After re-weighing, the mass of water lost by vapour transmission is calculated and the result expressed as in g/m2/24hrs at 37C at 100% to 10% relative humidity difference.
The adhesive layer can be discontinuous for example in t.he form of porous tincluding microporous) or patterned coated layers. However it is preferred that the adhesive layer is continuous.
Suitable continuous adhesive layers can comprise an acrylate ester copolymer or a poiyvinyl ether. Preferred acrylate ester copolymer adhesives are disclosed in Smith and Nephew United Kingdom AppIication No. 2070631 published September 9, lg81. A favoured acrylate ester copolymer adhesive is a copolymer of 47 parts by weight of 2-ethylhexyl acrylate, 47 parts by weight of n-butyl acrylate and 6 parts by weight of acrylic acid with a K
~0 value of 95 polymerised in acetone according to the method given in the above application.
Suitably the thickness of the adhesive layer of adhesive dressing Qf the invention can be from 12.5 micro metres to 75 micro metres. Suitable thicknesses of the 3~'7~

film backings of adhesive dressings of the invention are described hereinbefore in relation to films of the invention.

A wound dressing of this invention can have an absorbent pad covered with a non-adherent wound facing layer as is conventional in dressings of this type.

In a further aspect the invention provides a process for making a film of this invention which comprises ~orming a film from a blend of ethylene vinyl acetate copolyme. and an incompatible polymer, cold drawing (that is stretching at 10 to 60C) the film until voiding occurs and allowing the drawn film to contract~

The apertured fi~lms, including the nets of this invention maybe prepared by forming an ethylene vinyl acetate copolymer/ incompatible polymer blend film having ' thicker and thinner areas and stretching that film until apertures are formed. During stretching voiding of the film occurs which is then followed by rupture of the thinner areas to form apertures. -- -The thicker and thinner areas in the film can be conveniently formed by embossing.

Generally overall thickness of the embossed film will L'7~

be from 0.09 to 7.5mm thick, more sui~ably from 0.15 to 3.5mm thick and preferably from 0.15 tol.5mm thick. More suitably the thinner parts o~ the film employed will be from 0.02mm to 0.5mm thick, more suitably from O.OlOmm to O.Olmm thick and preferably from 0.005mm to 0.075mm thick.

The pattern of thicker and thinner areas provided on the film to be stretched will be chosen to ensure that undue propagation of the rupture will be prevented.
Suitable patterns thus include those set forth in British Patent Nos. 914489,1055963, 1075487 and 1110051.

lt is preferred that the film is formed by a hot melt process in particular by hot melt extrusion. It is also preferred that the blending of ethylene vinyl acetate copolymer and the incompatible polymer is carried out under hot melt conditions, for example, using a heated blade mixer or a compounding extruder although pre-mixing of the granules can be carried out by tumbling at room temperature.

The materials used in the process of the invention can be the materials described hereinbefore in relation to the film of the invention.

The liquid impermeahle and apertured films of the '7~-~

invention can be prepared by the general processes given in the aforementioned British Patent Application No.
2,081,721A and European Patent Application No. 096458.

. .

In a process for preparing a water impermeable film of the invention it is preferred that casting rollers have a plain surface.

In a process for preparing an apertured film of the invention one or both of the casting rollers can have a surface pattern of raised or depressed areas to provide a corresponding pattern of thicker and thinner areas on one or both sides of the blend film~

The extruded ethylene vinyl acetate copolymer and incompatible blend film is stretched to form the elastomeric film containing voids. The stretching should be càrried out at cold draw temperatures for example 10C
to 60C, preferably at 15C to 30C. The stretching can take place longitudinally or transversely to the extrusion direction or in both such directions either simultaneously or sequentially. It is preferred that the film is stretched in both the longitudinal and transverse direction to provide the film with a better balance of physical properties and also to increase tbe ~Z~3 area of the apertures in the apertured film~ It is preferred that the film should be given a stretch of between 100% to 500%. The degree of stretching should be greater than the yield elongation but less than the elongation at break of the film at cold draw temperatures.

After stretching the film is also allowed to contract. These stretching and relaxation stages convert the ethylene vinyl acetate copolymer-incompatible polymer blend films into an elastomeric film containing voids.
These voids are normally very small with diameters of between 2 and 12 micro metres and more usually between 3 and 6 micro metres.

Films of the invention can be provided with an adhesive layer by conventional coating methods which lS includè coating from a solution, an emulsion, by hot melt or by extrusion. The films may be coated directly OI`
indirectly, for example by transfer from a release surface.

The wound dressings of this invention may be prepared from a film of this invention in conventional manner, for example, on conventional dressing machines.

The apertured films of this invention may be made by
3~

using methods known in the art to be suitable when employing non-elastomeric materials such as polyolefines, for example polyethylene. It is therefore surprising that the polymer blends disclosed herein can be processed by such methods since it has herebefore been generally believed that elastomeric materials could not be processed in su~h manner.

The invention is illustrated by the following Exampies:

Example 1 This Example describes the pre~aration of a liquid water impermeable film of the invention.

Preparation of Polymer Blend 60 parts by weight of an ethylene vinyl acetate copolymer (Evatane 555) and 40 parts by weight of a high impact polystyrene (Styron 485) were weighed into a blade mixer chamber (Shearmix size 4 available from Baker Perkins Limited) heated to 165C and mixed for 4 minutes. The resultant mix was removed from the mixer and formed into sheet (approximately 1.5mm thick) on a heated two roll mill. The sheet was cut into strips of * Trade Mark approximately 50mm x 25mm, allowed to cool and then granulatPd in a Masson cutter.

Extrusion of Film A film was made by feeding the polymer blend mixture into a Brabender Extrusiograph extruder (length to diameter screw ratio of 25:1~ driven by a Brabender PLE
651 plasticorder and extruding the mixture through a l50mm film die into the nip of a two roller casting unit placed near the die. The extrusion conditions were as ollows:

Die temperature 190C
Screw speed 80 revs per minute Casting roller speed 2.2 metres/minute Back pressure 1 Kilo Newton Die gap 0.254 mm Stretching of ~ilm A voided film was made by stretching the cast film in a direction transverse to the machine direction on a laboratory Hounsfield tensometer. The film was stretched to a draw ratio of 4:1 (300% extension) at ambient room temperature 18C to 22C and the drawn film allowed to * Trade Mark ~\ ~

~Z~3~7~

contract to 2.5:1 (150%) to form a film of the invention.

The voided film had a thickness of 0.114mm and a moisture vapour transmission rate of 1450g/m2/24hrs at 37C at 100% to 10% relative humidity difference (Payne Cup). The film had a recoverable elastic strain of 100~.
The film was found to be impermeable to liquid water.

Example 2 This example describes the preparation of an apertured film (net) of the invention Preparation of Polymer Blend Granules of ethylene vinyl acetate copolymer (Evatane 24-03, 80 parts by weight) and high impact polystyrene lStyron 485, 20 parts by weight) were mixed by tumble blending. The mixed granules were then fed into a Brabender Extrusiograph l9mm extruder fitted with a 25:1 length to diameter screw of a polyolefine type having a compresion ratio of 3:1 and extruded through a tubular die. The extrusion was carried out using a die temperatue of 1&5C and a screw speed of 120rpm. The extruded tube was drawn through a water bath maintained at 20C at a speed to reduce the tube diameter to approximately 3mm.
After travelling a distance of approximately 1 metre :~Z'~ 74 through the bath, the tube was passed over a foam pad to remove excess moisture before being cut into 3 to 5 mm lengths using a laboratory model granluator (Accrapack).
The granules were collected from the granulator and dried for two hours at 70C in an air circulating oven in trays 2.5cm deep.

Extrusion of Film .

The polymer blend granules were fed into the hopper of a Brabender Extrusiograph instrumented extruder, which was driven by a 8rabender Plasticorder PLE 651 drive unit and which was equipped with a 150mm wide flat sheet die and a polyolefine-type screw with a length to diameter ratio of 3:1. The die was maintained at a temperature of 185C and, using a screw speed of 55rpm, which gave registered torque and axial back pressure measurements of 14Nm and 1.5KN respectively, the melt film was extruded longitudinally and fed into the nip of a two roller chill casting unit located 5cm from the die face.

One roller of this chill casting unit was provided with one conical projection per 0.725mm in both circumferential and axial directionsO The height of these projections above the roller surface was 0.21mm and their diameter at the roller surface was 0.42mm. The other roller in the chill casting unit was a flat surfaced roller. The casting nip speed was 2.1 metres/minute. The film produced was lOOmm wide, had a thickness of 0.102mm, had a weight per unit area of 72gsm and had a pattern of conical depressions (0.36mm diameter) on one surface which corresponded with the pattern of conical projections on the cast roller surface. The film however was not perforated.

Stretching of Film The extruded film was stretched in a Laboratory Hounsfield tensometer. A sample of width 140mm and length 60mm was stretched at a ratio 2.5:1 in a direction transverse (perpendicular) to the extrusion direction (machine direction). The film was allowed to contract and a sample of width 75mm and length 80mm was stretched at a ratio of 2.2:1 in a direction parallel to the extrusion direction ~machine direction) and allowed to contract to a ratio of 1.4:1.

The resulting film had elliptical apertures with their major axis in the machine direction. The apertures in the film varied in size from 0.42 to 0.68mm in the major axis and from 0.28 to 0.39mm in the minor axis. The film had a weight per unit area of 41g/m2 and a thickness of 0.066mm.

Example 3 The example describes the preparation of another apertured film (net) of the invention.

Preparation of Polymer Blend The polymer blend was prepared in the same manner as Example 2 using Evatane 539 instead of Evatane 24-030 Extrusion of film The polymer blend film was prepared in the same manner as Example 2 using the following extrusion conditions:

Screw speed 70rpm Torque 14Nm Back Pressure 1.5KN
Casting Roller Speed 3 metres/minute The film produced had a width of 104mm, a thickness of 0.155mm and a weigbt per unit area of 68.7g/m2. The film had a pattern of conical depressions on one surface which corresponded with the conical projections on the :~Z'~3~7~

cast roller surface.

Stretching of the Film The film was stretched in a similar manner to the film of Example 2 except that the transverse direction was ommitted and the film was stretched at a ratio of 2:1 in the machine direction only.

The resulting film had elliptical apertures with major axis in the machine direction. The apertures in the film had a size of approximately 0.38mm in the major axis and approximately 0.19 in the minor axis direction. The area of the apertures was approximately 20% of the total area of the film.

Exam~les 4, 5 and 6 The liquid impermeable film of Example l and the apertured (net) films of Examples 2 and 3 were coated by means of transfer coating process with a polyacrylate adhesive (30 micro metres thick). The polyacrylate adhesive used was a copolymer of 47 parts by weight-of~
2-ethylhexyl acrylate, 47 parts by weight of n-butyl acrylate and 6 parts by weight of acrylic acid with a K
value of 95 polymerised in acetone according to the method given in United Kingdom Application No. ~Y~31.

3~7~1L

The adhesive coated films were made into adhesive first aid dressings.

Example 7 This example describes the preparation of another liquid water impermeable film of the inventionO

Preparation of Polymer blend .

A polymer blend of 60 parts by weight of Evatane 28-05 and 40 parts by weight of Styron 485 was prepared in the same-manner-as Example 2 except that the extrusion was carried out using a die temperature of 200C.

Extrusion of Film A film was prepared in the same manner às Example 1 using the following extrusion conditlons.
Die temperature 200C --15 Screw speed 31 revs per minute Back pressure 1.5KN
Casting roller speed 0.75m/min -^
Casting roller temperature 30C
Die gap 0.254mn Stretching of Film L2'~3~7~

A voided film was prepared by stretching the cast film in the extrusion machine direction on a laboratory Hounsfield tensometer. The film was stretched to a draw ratio of 4.5:1 and allowed to contract to 3:1 to form a film of the invention. ~he voided film had a thickness of 0.125mm and a moisture vapour transmission rate of 998g/m2/24 hr at 37C at 100% to 10% relative humidity difference. The ~ilm was found to be impermeable to liquid water.

Example 8 This example describes the preparations of a further apertured film (net3 of the invention.

Preparation of polymer blend A polymer blend of 80 parts by weight of Evatane ~15 28-05 and 20 parts by weight-of Styron 485 was prepared in the same manner as example 2 using an extrusion die temperature of 2000C and screw speed of 118 rpm.

Extrusion of Film The polymer blend granules were fed into the hopper of a Brabender Extrusiograph instrumented extruder, which was driven by a Brabender Plasticorder PLE 651 drive unit and which was equipped with a 150mm wide film flex lip die and a polyolefine-type screw with a length to diameter ratio of 3:1. The die was maintained at a temperature of 200C and using a screw speed of 115 rpm, which gave a registered torque and axial back pressure measurements of 14Nm and 1.5KN respectively, the melt film was extruded vertically downward~ and fed into the nip of a two roller chill casting unit located 4cm from the die face. The casting rollers were maintained at a temperature of 40C
and had a casting speed of 0.75m/min.

- One roller of this--chill casting unit had a surface pattern of parallel ribs and grooves (1 per mm) arranged in the axial dirèction of the roller.~The parallel ribs and grooves-had a-tEu~cated triangular shape and a height or depth of 0.6mm. The-other roller had a surface pattern ~ of parallel ribs and grooves (1 per mm) arranged in the circumferential direction of the roller. The parallel ribs and grooves of this roller had a truncated triangular shape and height or depth of 0.65 mm.

The extruded cast film had a weight per unit area of 441 g/m2 and a thickness of 0.75mm. The film had an e~bossed pattern of ribs and grooves (1 per mm) on one surface which intersected at right angles with a similar 3~'7~ -.

pattern of ribs and grooves on the other surface of the film. The areas of intersection between the embossed grooves on either side of the film provide the thin areas in the film.

Stretching of Film The extruded film was stretched in laboratory Hounsfield tensometer. A sample film of width 120mm and length lOOmm was stretched a draw ratio of 3:1 in the machine dlrection (extrusion direction). The film was allowed to contract and a sample of width 120mm and length 80mm was stretched at a draw ratio of 3:1 in the transverse direction (perpendicular to machine direction) to form a net of the invention.

The net had elliptical apertures with their major axis in the transverse direction. The aperture size was 1.04mm in major axis and 0.75mm in the minor axis. The area of the apertures in the net were 30~ of the total area of the net.

The net had a weight per unit area of 63g/m2. The net exhibited two sets of intersecting parallel ribs which were perpendicular to each other.

Claims (11)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A moisture vapour transmitting elastomeric film which comprises a blend of incompatible polymers and contains voids within the film, said voids not providing a continuous pathway through the film and wherein the blend comprises a continuous matrix of ethylene vinyl acetate copolymer within which the incompatible polymer forms a discrete particulate phase.
2. A film as claimed in claim 1 which is employed in a wound dressing.
3. A film as claimed in claim 1 which is liquid water impermeable and has a moisture vapour transmission rate of at least 500g/m224 hours at 37°C at 100% to 10%
relative humidity difference.
4. A film as claimed in claim 1 which is apertured.
5. A film as claimed in claim 4 which is in the form of a net and in which the area of apertures is 10% to 50%
of the total area of the film.
6. A film as claimed in any of claims 1 to 3 in which the polymer blend contains 45% to 90% by weight of ethylene vinyl acetate copolymer.
7. A film as claimed in any of claims 1 to 3 in which the incompatible polymer comprises polystyrene.
8. An article for bodily contact which comprises a film of claims 1 to 3.
9. An article as claimed in claim 8 which is a wound dressing.
10. A process for making a film as claimed in claim 1 which comprises forming a film from a blend of ethylene vinyl acetate copolymer and an incompatible polymer, cold drawing the film until voiding occurs and allowing the drawn film to contract.
11. A process as claimed in claim 10 for making an apertured film as claimed in claims 4 and 5 which comprises forming a film having thicker and thinner areas from a blend of ethylene vinyl acetate copolymer and an incompatible polymer and stretching the film until apertures form in the thinner areas.
CA000465666A 1983-10-22 1984-10-17 Polymer blend films Expired CA1243174A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8328279 1983-10-22
GB838328279A GB8328279D0 (en) 1983-10-22 1983-10-22 Polymer blend films

Publications (1)

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CA1243174A true CA1243174A (en) 1988-10-18

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EP (1) EP0141592B1 (en)
AU (1) AU574391B2 (en)
CA (1) CA1243174A (en)
DE (1) DE3482549D1 (en)
GB (1) GB8328279D0 (en)
ZA (1) ZA848181B (en)

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Also Published As

Publication number Publication date
GB8328279D0 (en) 1983-11-23
DE3482549D1 (en) 1990-07-26
AU574391B2 (en) 1988-07-07
ZA848181B (en) 1985-08-28
EP0141592B1 (en) 1990-06-20
US4596738A (en) 1986-06-24
AU3426884A (en) 1985-04-26
EP0141592A2 (en) 1985-05-15
EP0141592A3 (en) 1987-02-04

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