WO2000023255A9 - Process for producing polyolefin microporous breathable film - Google Patents

Process for producing polyolefin microporous breathable film

Info

Publication number
WO2000023255A9
WO2000023255A9 PCT/US1999/023879 US9923879W WO0023255A9 WO 2000023255 A9 WO2000023255 A9 WO 2000023255A9 US 9923879 W US9923879 W US 9923879W WO 0023255 A9 WO0023255 A9 WO 0023255A9
Authority
WO
WIPO (PCT)
Prior art keywords
film
rollers
wvtr
polyolefin
films
Prior art date
Application number
PCT/US1999/023879
Other languages
French (fr)
Other versions
WO2000023255A1 (en
Inventor
John H Mackay
Original Assignee
Exxon Chemical Patents Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Exxon Chemical Patents Inc filed Critical Exxon Chemical Patents Inc
Priority to AT99951980T priority Critical patent/ATE249913T1/en
Priority to EP99951980A priority patent/EP1121239B1/en
Priority to HU0104016A priority patent/HU223746B1/en
Priority to DE69911446T priority patent/DE69911446T2/en
Priority to CA002346455A priority patent/CA2346455A1/en
Priority to BRPI9914600-2A priority patent/BR9914600B1/en
Priority to AU64298/99A priority patent/AU6429899A/en
Publication of WO2000023255A1 publication Critical patent/WO2000023255A1/en
Publication of WO2000023255A9 publication Critical patent/WO2000023255A9/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/18—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets by squeezing between surfaces, e.g. rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0068—Permeability to liquids; Adsorption

Definitions

  • This invention relates generally to an improved polyolefin microporous breathable film
  • this invention is directed toward a process by
  • WVTR Water Vapor Transmission Rate
  • polyolefins is well known in the art.
  • polyethylene with a filler, usually CaCO 3 , is widely used as a film with good WVTR, often, but
  • breathable film such as disposable diapers
  • roller temperature may be adjusted. As can be seen from the following examples, with all other
  • Figure 1 shows the geometry of interdigitating rollers
  • Figure 2 shows a machine direction orientation roller
  • Figure 3 shows a transverse direction orientation roller
  • Figure 4 shows a cross-section of a WVTR test cell.
  • This invention concerns polyolefin/filler based breathable films. While initial work was
  • This invention further includes certain polyolefins, their conversion into fabricated
  • articles such as films, articles made from such films, and applications in which such articles
  • Such consumer articles include, but are not limited
  • present invention may also be used in metallized films with a high WVTR, according to the
  • the preferred process is a cast melt embossed film process.
  • the films of the present invention can be formed into a single layer film, or may be one layer or
  • disclosure can be formed or utilized in the form of a resin blend where the blend components can
  • the breathable films of the present invention may be any suitable material known to those of ordinary skill in the art.
  • the breathable films of the present invention may be any suitable material known to those of ordinary skill in the art.
  • structure includes one or more polYolefin/filler film layers having the WVTR, or draw-down, and
  • the polyolefin precursor component can be any film forming polyolefin including
  • polyethylenes both linear low density and very low density (0.88 to 0.935 g/cm3), high density
  • polyethylene (0.935 - 0.970 g/cm3), Ziegler-Natta catalyzed linear low density polyethylene,
  • LDPE high pressure low density polyethylene
  • elastomers or other soft polymers may be blended with the majority polyolefin component, these
  • styrene-isoprene-styrene styrenic block co-polymer
  • styrene-butadiene-styrene styrenic
  • Ethylene-methacrylate Ethylene-ethyl-acrylate, Ethylene-butyl-acrylate.
  • Fillers useful in this invention may be any inorganic or organic material having a low
  • a filler should be a rigid material having a non-smooth hydrophobic surface, or a
  • the preferred mean average particle size of the filler is between about 0.5-5.0 microns for films generally having a thickness of
  • inorganic fillers examples include calcium carbonate, talc, clay, kaolin, silica,
  • diatomaceous earth magnesium carbonate, barium carbonate, magnesium, sulfate, barium
  • magnesium oxide magnesium oxide, titanium oxide, alumina, mica, glass powder, zeolite, silica clay, etc.
  • Carbonate (CaCO 3 ) is particularly preferred for its low cost, its whiteness, its inertness, and its
  • the selected inorganic filler such as calcium carbonate is preferably surface treated
  • treatment of the filler should improve binding of the filler to the polyolefin precursor while
  • Organic fillers such as wood powder, and other cellulose type powders may be used.
  • Polymer powders such as Teflon® powder and Kevlar ® powder can also be used.
  • the amount of filler added to the polyolefin precursor depends on the desired properties
  • an amount of filler less than about twenty percent (20%) by weight of the polyolefin/filler blend.
  • the minimum amount of filler (about twenty percent by weight) is needed to assure the
  • Preferred ranges include about 30% to about 70% by weight, more preferably from about 40%
  • fillers with much higher or much lower specific gravity may be included with the
  • polyolefin precursor at amounts outside the weight ranges disclosed. Such combinations will be
  • polyolefin/filler blend allowed film extrusion at higher throughput levels with some majority
  • Films can be incrementally oriented by a number of mechanical techniques, however,
  • the preferred technique is to stretch the film through pairs of interdigitating rollers, as shown in
  • Machine direction orientation is accomplished by stretching the film through a gear like
  • the tooth depth (d), is preferably 0.100"
  • the depth may be up to about 1.000" as mechanical interference is less of an issue with the transverse direction rollers.
  • interdigitating rollers that can be temperature controlled from about 50°F to about
  • 210°F More preferred is a temperature range of from about 70°F to about 190°F. Even more
  • a temperature range from about 85°F to about 180°F. And most preferred is a
  • Roll temperature range from about 95°F to about 160°F. Roll temperature may be maintained through
  • the depth of interengagement of the roller teeth determines the amount of orientation
  • the WVTR of such films should be above about 100 g/m 2 /24 hi @ 37.8°C, 100% RH, preferably above about 1000 g/m 2 /24 hr @ 37.8°C,
  • the amount of water vapor in the air stream is precisely measured by a pulse
  • PMIR modulated infra red
  • testing protocols are based
  • the Mocon Wl has a single test cell
  • Air is pumped through a desiccant dryer, then through the test cell, and
  • the Mocon W600 has six measurement cells with PMIR data fed into a computer.
  • Nitrogen is fed through a desiccant dryer, then through the active test cell, then past the PMIR
  • Total testing time is fifty-six minutes. Two of the six
  • measurement cells always measure reference films with a known WVTR.
  • the temperature of the interdigitating rolls was 140 °F.
  • the temperature of the interdigitating rolls was 110 °F.
  • the temperature of the interdigitating rolls was 70 °F.
  • activation water vapor transmission rate is predicted by the following equation:

Abstract

Polyolefin/filler breathable films may be produced by machine or transverse direction orientation using interdigitating grooved rollers (16, 26). Biaxial orientation to similarly produce breathable films may be accomplished by the same method. By heating the rollers (16, 26), the breathablity of the film is increased without increasing the depth of engagement of the interdigitating rollers.

Description

PROCESS FOR PRODUCING POLYOLEFIN MICROPOROUS BREATHABLE FILM
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application serial number
60/104,452 filed October 16, 1998 and U.S. Provisional Patent Application serial number
60/104,985 filed October 20, 1998.
BACKGROUND OF THE INVENTION
Field
This invention relates generally to an improved polyolefin microporous breathable film
and method of making same. More specifically, this invention is directed toward a process by
which increased Water Vapor Transmission Rate (WVTR) and enhanced film appearance can
be realized with substantially the same film formulation and orientation.
Background
Preparation of films having good WVTR from highly filled polymers, usually
polyolefins, is well known in the art. In the past, a combination of polyolefin, usually a
polyethylene, with a filler, usually CaCO3, is widely used as a film with good WVTR, often, but
not necessarily, in combination with non- woven polymers for use in diapers, adult incontinence
devices, feminine hygiene articles, surgical garments, housewrap composites, protective apparel,
roofing materials and the like.
The use of interdigitating rolls to orient films or non-wovens is also well known in the
art. In some cases this process is referred to as cold stretching. To increase the WVTR of films,
while employing interdigitating technology, it has been necessary to increase the level of filler
in the polyolefin/filler blend, or to increase the depth of interengagement of the orienting rollers - both of which have technical limits, and which may have a serious negative impact on
important physical properties of the resulting film. The technical limits of depth of engagement
of the interdigitating rolls and CaCO3 loading restrict film breathability level.
Also, it is desirable for many applications of breathable film, such as disposable diapers,
adult incontinence products, and feminine hygiene devices, that some visual evidence of a
difference between breathable and non-breathable films exist. It is thought that this product
differentiation could be of benefit to the consumer, as well as the manufacturer of the disposable
products.
SUMMARY
We have discovered that applying heat to interdigitating rollers results in a substantial
improvement in orientation effectiveness (WVTR increases), and imparts a third dimensionality
to the film which differentiates it from other breathable films. In addition, a new control is
provided for the adjustment of film breathability, i.e., rather than require a formulation change,
or adjustment to the depth of activation of the interdigitating rollers, to control WVTR levels,
roller temperature may be adjusted. As can be seen from the following examples, with all other
factors constant, an increase in the temperature of the interdigitating rolls from 70°F to 140°F,
increases WVTR from 1900 gm/sqm/day to 4100 gm/sqm/day.
Brief Description of the Drawings
A better understanding of the Process for Producing Polyolefin Microporous Breathable
Film may be obtained by reference to the following drawing figures together with the detailed
description.
Figure 1 shows the geometry of interdigitating rollers;
Figure 2 shows a machine direction orientation roller; Figure 3 shows a transverse direction orientation roller; and
Figure 4 shows a cross-section of a WVTR test cell.
DETAILED DESCRIPTION
Introduction
This invention concerns polyolefin/filler based breathable films. While initial work was
executed on a polypropylene based product, it will be shown that the disclosed process is
effective for all polyolefin materials.
This invention further includes certain polyolefins, their conversion into fabricated
articles such as films, articles made from such films, and applications in which such articles
having high WVTR combined with good physical properties are desirable. The resulting films,
and film composites, (including coextruded and laminated films) have combinations of properties
rendering them superior and unique to films or film composites previously available. The films
disclosed herein are particularly well suited for use in producing certain classes of high WVTR
films, consumer and industrial articles using the films in combination with, for instance,
polymeric woven or non- woven materials. Such consumer articles include, but are not limited
to diapers, adult incontinence devices, feminine hygiene articles, medial and surgical gowns,
medical drapes, industrial apparel, building products such as "house-wrap", roofing components,
and the like made using one or more of the films disclosed herein. Additionally, the films of the
present invention may also be used in metallized films with a high WVTR, according to the
disclosure of U.S. Patent 5,055,338, which is to be incorporated herein by reference in its
entirety. Production of the Films
Films contemplated by certain embodiments of the present invention may be made
utilizing a polyolefin, by film processes including blown molding, casting, and cast melt
embossing. The preferred process is a cast melt embossed film process. In extrusion processes,
the films of the present invention can be formed into a single layer film, or may be one layer or
more of a multi-layer film or film composite. Alternatively, the polyolefin films described in this
disclosure can be formed or utilized in the form of a resin blend where the blend components can
function to modify the WVTR, the physical properties, the draw-down, the sealing, the cost, or
other parameters. Both blend components and the parameters provided thereby will be well
known to those of ordinary skill in the art. The breathable films of the present invention may
also be included in laminated structures. As long as a film, multi-layer film, or laminated
structure includes one or more polYolefin/filler film layers having the WVTR, or draw-down, and
the like of the film, such film, multi-layer film, or laminated structure will be understood to be
contemplated as an embodiment of the present invention.
Polyolefin Precursor Film Component
The polyolefin precursor component can be any film forming polyolefin including
polyethylene and polypropylene, ethylene polar comonomer polymers, ethylene α-olefin
copolymers and combinations hereof.
Figure imgf000007_0001
It will be understood that, in general, we contemplate that a large number of polyolefins
will be useful in the techniques and applications described herein. Also included in the group
of polyolefins that are contemplated as embodiments of this invention are metallocene catalyzed
polyethylenes, both linear low density and very low density (0.88 to 0.935 g/cm3), high density
polyethylene (0.935 - 0.970 g/cm3), Ziegler-Natta catalyzed linear low density polyethylene,
conventional high pressure low density polyethylene (LDPE), and combinations thereof. Various
elastomers or other soft polymers may be blended with the majority polyolefin component, these
include styrene-isoprene-styrene (styrenic block co-polymer), styrene-butadiene-styrene (styrenic
block co-polymer), styrene-ethylene/butylene-styrene (styrenic block co-ploymer), ethylene-
propylene (rubber), Ethylene-propylene-diene-modified (rubber), Ethylene-vinly-acetate,
Ethylene-methacrylate, Ethylene-ethyl-acrylate, Ethylene-butyl-acrylate.
FILLER
Fillers useful in this invention may be any inorganic or organic material having a low
affinity for and a significantly lower elasticity than the film forming polyolefin component.
Preferably a filler should be a rigid material having a non-smooth hydrophobic surface, or a
material which is treated to render its surface hydrophobic. The preferred mean average particle size of the filler is between about 0.5-5.0 microns for films generally having a thickness of
between about 1 to about 6 mils prior to stretching.
Examples of the inorganic fillers include calcium carbonate, talc, clay, kaolin, silica,
diatomaceous earth, magnesium carbonate, barium carbonate, magnesium, sulfate, barium
sulfate, calcium sulfate, aluminum hydroxide, zinc oxide, magnesium hydroxide, calcium oxide,
magnesium oxide, titanium oxide, alumina, mica, glass powder, zeolite, silica clay, etc. Calcium
carbonate (CaCO3) is particularly preferred for its low cost, its whiteness, its inertness, and its
availability. The selected inorganic filler such as calcium carbonate is preferably surface treated
to be hydrophobic so that the filler can repel water to reduce agglomeration. Also, the surface
treatment of the filler should improve binding of the filler to the polyolefin precursor while
allowing the filler to be pulled away from the precursor film under stress. A preferred coating
for the filler is calcium stearate which is FDA compliant and readily available.
Organic fillers such as wood powder, and other cellulose type powders may be used.
Polymer powders such as Teflon® powder and Kevlar ® powder can also be used.
The amount of filler added to the polyolefin precursor depends on the desired properties
of the film including dart impact strength, tear strength, WVTR, and stretchability. However,
it is believed that a film with good WVTR generally cannot be produced as is taught herein with
an amount of filler less than about twenty percent (20%) by weight of the polyolefin/filler blend.
The minimum amount of filler (about twenty percent by weight) is needed to assure the
interconnection within the polyolefin precursor film of voids created at the situs of the filler -
particularly by the stretching operation to be subsequently performed. Further, it is believed that
useful films could not be made with an amount of the filler in excess of about seventy percent
(70%) by weight of the polyolefin/filler composition. Higher amounts of filler may cause difficulty in compounding and significant losses in strength of the final breathable film.
Preferred ranges include about 30% to about 70% by weight, more preferably from about 40%
to about 60%) by weight.
While a broad range of fillers has been described at a broad range of inclusion parameters
based on weight percentages, still other embodiments of the present invention are contemplated.
For instance, fillers with much higher or much lower specific gravity may be included with the
polyolefin precursor at amounts outside the weight ranges disclosed. Such combinations will be
understood to be contemplated as embodiments of our invention as long as the final film, after
orientation, has WVTR, or draw down similar to that described herein.
Film Physical Property Modification
It was found that the addition of small amounts of low density polyethylene to the
polyolefin/filler blend allowed film extrusion at higher throughput levels with some majority
polymers. Low density polyethylene with a melt flow index of about 0.9 to 25.0 grams per ten
minutes (12.0 grams per ten minutes being preferred), and a density of about 0.900 to 0.930 may
be used.
Further improvements in film impact and tear strength are possible by the addition of
plastomers, elastomers, styrenic block co-polymers (SIS, SBS, SEBS), or rubbers. Material
grades included are:
Figure imgf000009_0001
Figure imgf000010_0001
Stretching or Orienting
Final preparation of a breathable film is achieved by stretching the filled polyolefin
precursor film to form interconnected voids. Stretching or "orientation" is achieved by
incrementally orienting the polyolefin precursor in the machine direction, transverse direction,
or both. Films can be incrementally oriented by a number of mechanical techniques, however,
the preferred technique is to stretch the film through pairs of interdigitating rollers, as shown in
Figure 1. Therein it may be seen that the film is contracted by the apex 18 of a plurality of teeth
spaced a distance or pitch (W) apart. The apex 18 of each tooth extends into the open space 20
between the teeth on an opposing roller. The amount of interengagement depends both on the
tooth depth (d) and the relative position of the rollers.
Machine direction orientation is accomplished by stretching the film through a gear like
pair of rollers 16 as shown in Figure 2. Transverse direction orientation is accomplished by
stretching the film through a pair of disk-like rollers as shown in Figure 3.
The preferred embodiment employs rollers with a tooth pitch, W = 0.080", however a
pitch of about 0.040" to 0.500" is also acceptable. The tooth depth (d), is preferably 0.100",
however, a tooth depth of about 0.030" to 0.500" is also acceptable. For the transverse direction
orientation rollers, as shown in Figure 3, the depth may be up to about 1.000" as mechanical interference is less of an issue with the transverse direction rollers. The preferred embodiment
employs interdigitating rollers that can be temperature controlled from about 50°F to about
210°F. More preferred is a temperature range of from about 70°F to about 190°F. Even more
preferred is a temperature range from about 85°F to about 180°F. And most preferred is a
temperature range from about 95°F to about 160°F. Roll temperature may be maintained through
the internal flow of a heated or cooled liquid, an electrical system, an external source of
cooling/heating, combinations thereof, and other temperature control and maintenance methods
which will be apparent to those of ordinary skill in the art. The preferred embodiment is internal
flow of a heated or cooled liquid through the rollers.
The depth of interengagement of the roller teeth determines the amount of orientation
imparted on the film. A balance must be drawn between the depth of engagement of the roller
teeth and the level of filler in the film, as many physical properties of the film are affected as
depicted in the following table.
Relationships between process and formulation factors
Figure imgf000011_0001
Properties of Films Produced
WVTR
In an embodiment of the present invention, certain films and articles made therefrom have
higher WVTR than previously thought possible. The WVTR of such films should be above about 100 g/m2/24 hi @ 37.8°C, 100% RH, preferably above about 1000 g/m2/24 hr @ 37.8°C,
100% RH, more preferably above about 2000 g/m2/24 hr @ 37.8°C, 100% RH. Some
applications benefit from film with a WVTR at or above about 10,000 g/m2/24 hr @ 37.8°C,
100% RH.
TEST METHODS
Water Vapor Transmission Rate (WVTR")
Both a Mocon Wl, and a Mocon W600 instrument are used to measure water evaporated
from a sealed wet cell at 37.8°C through the test film and into a stream of dry air or nitrogen. It
is assumed that the relative humidity on the wet side of the film is near 100%, and the dry side
is near 0%. The amount of water vapor in the air stream is precisely measured by a pulse
modulated infra red (PMIR) cell. Following appropriate purging of residual air, and after
reaching a steady state of water vapor transmission rate, a reading is taken. WVTR of the test
films are reported at Grams of Water/Meter2/Day @ 37°C. The output of the unit has been
calibrated to the results obtained with a film of known WVTR. The testing protocols are based
on ASTM 1249-90 and the use of a reference film, such as Celgard 2400, which has a WVTR
of 8700 g/m2/day @ 37.8°C. The diagram depicted in Figure 4 illustrates the basic operation of
the Mocon units.
Mocon Wl
As illustrated generally by reference to Figure 4, the Mocon Wl has a single test cell and
an analog chart recorder. Air is pumped through a desiccant dryer, then through the test cell, and
then past the PMIR sensor. A five-minute purge of residual air is followed by a six-minute test
cycle with controlled air flow. The result is a steady state value for WVTR. The purge and test
cycles are controlled manually. The unit is calibrated to a film with a known WVTR every twelve hours. Calibration results are control charted and adjustments are made to the instrument
calibration accordingly.
Mocon W600
The Mocon W600 has six measurement cells with PMIR data fed into a computer.
Nitrogen is fed through a desiccant dryer, then through the active test cell, then past the PMIR
sensor. In addition to data compilation, a computer controls test cycle sequencing. All cells are
purged simultaneously for an eight-minute period. This is followed by an eight-minute test cycle
for each of the six measurement cells. Total testing time is fifty-six minutes. Two of the six
measurement cells always measure reference films with a known WVTR.
EXAMPLES
Example 1. Experimental grade 400-6-1
A blend of 57% ECC FilmLink 400 CaCO3 was combined with 33% Exxon PD 7623
Impact Copolymer, 2% Exxon LD-200.48, and 8% Exxon Exact 3131 oriented in interdigitating
rolls of 0.80" pitch. The MD depth of engagement was 0.020", and the TD depth of engagement
was 0.040". The temperature of the interdigitating rolls was 140 °F.
Example 2. Experimental grade 400-6-2
A blend of 57% ECC FilmLink 400 CaCO3 was combined with 33% Exxon PD 7623
Impact Copolymer, 2% Exxon LD-200.48, and 8" Exxon Exact 3131 oriented in interdigitating
rolls of 0.080" pitch. The MD length of engagement was 0.020", and the TD depth of
engagement was 0.040". The temperature of the interdigitating rolls was 110 °F.
Example 3. Experimental grade 400-6-3
A blend of 57% ECC FilmLink 400 CaC03 was combined with 33% Exxon PD 7623
Impact Copolymer, 2% Exxon LD-200.48, and 8% Exxon Exact 3131 oriented in interdigitating rolls of 0.080" pitch. The MD depth of engagement was 0.020", and the TD depth of
engagement was 0.040". The temperature of the interdigitating rolls was 70 °F.
As can be seen from the following table, the WVTR rise from a roll temperature of 70°F
(considered ambient temperature) to 110°F, and then 140°F is dramatic, unexpected and
surprising.
Table of Example Film Properties
Example 1 Example 2 Example 3
Figure imgf000014_0001
A linear regression analysis reveals that with the above fixed formulation, depth of
activation water vapor transmission rate is predicted by the following equation:
WVTR = -329.73 + 31.216 * Roller Temperature (°F)
Changes and modifications in the specifically described embodiments can be carried out
without departing from the scope of the invention which is intended to be limited only by the
scope of the appended claims.

Claims

What we claim is:
L A process for imparting higher water vapor transmission rate (WVTR) to a filled polyolefin film comprising the steps of: extruding a polyolefin filler combination into a film; and passing said film through at least one pair of interdigitating grooved rollers wherein said rollers are heated to at least 80°F.
2. The process as defined in Claim 1 wherein said interdigitating grooved rollers are positioned in a direction selected from the group including machine direction, transverse direction, and a combination thereof.
3. The process as defined in Claim 2 wherein said polyolefin is selected from the group consisting of polypropylene, polyethylene, ethylene polar comonomer polymers, α-olefin copolymers, and combinations thereof.
4. The process as defined in Claims 1, 2, or 3 wherein said rollers are heated to at least 120 °F.
5. The process as defined in Claims 1, 2, or 3 wherein said rollers are heated to at least 130 °F.
6. The process as defined in Claims 1, 2, or 3 wherein said rollers are heated to at least 140 °F.
7. The process as defined in Claims 1, 2, or 3 wherein said rollers are heated to at least 150 °F.
8 The process as defined in Claims 1 , 2, or 3 wherein said rollers are heated to at least 160 °F.
9. A process for imparting higher water vapor transmission rate (WVTR) in grams per square meter per day to a filled polyolefin film wherein the water vapor transmission rate is determined by the equation: WVTR = -329.73 * 31.2162 (Roller Temperature in °F)
PCT/US1999/023879 1998-10-16 1999-10-14 Process for producing polyolefin microporous breathable film WO2000023255A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
AT99951980T ATE249913T1 (en) 1998-10-16 1999-10-14 METHOD FOR PRODUCING MICROPOROUS BREATHABLE POLYETHYLENE FILM
EP99951980A EP1121239B1 (en) 1998-10-16 1999-10-14 Process for producing polyolefin microporous breathable film
HU0104016A HU223746B1 (en) 1998-10-16 1999-10-14 Process for producing polyolefin microporous breathable film
DE69911446T DE69911446T2 (en) 1998-10-16 1999-10-14 METHOD FOR PRODUCING MICROPOROUS, BREATHABLE POLYETHYLENE FILMS
CA002346455A CA2346455A1 (en) 1998-10-16 1999-10-14 Process for producing polyolefin microporous breathable film
BRPI9914600-2A BR9914600B1 (en) 1998-10-16 1999-10-14 process for adjusting the water vapor transmission rate of a breathable film.
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US6706228B2 (en) 2004-03-16
DE69911446D1 (en) 2003-10-23
DE69911446T2 (en) 2004-07-01
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US20010042938A1 (en) 2001-11-22
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WO2000023255A1 (en) 2000-04-27
BR9914600A (en) 2001-06-26
HU223746B1 (en) 2004-12-28
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US6264864B1 (en) 2001-07-24
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