U.S. patent application number 14/524159 was filed with the patent office on 2017-01-12 for segmented films with high strength seams.
The applicant listed for this patent is Kimberly-Clark Worldwide, Inc.. Invention is credited to Wing-Chak Ng, Jose Augusto Vidal de Siqueira.
Application Number | 20170008212 14/524159 |
Document ID | / |
Family ID | 55791266 |
Filed Date | 2017-01-12 |
United States Patent
Application |
20170008212 |
Kind Code |
A9 |
Ng; Wing-Chak ; et
al. |
January 12, 2017 |
SEGMENTED FILMS WITH HIGH STRENGTH SEAMS
Abstract
Unitary films and laminates thereof are provided having at least
first and second film segments which extend adjacent one another
and are permanently joined together. The first and second film
segments are joined at an interface, wherein at the interface a tip
of the second segment overlaps the first segment in the
cross-direction of the film. The film has a thickness "T" at the
tip of the second segment, and the second segment has a thickness
"t" at a distance T in the cross direction from the tip of the
second segment. The ratio T/t is suitably greater than about 3. The
unitary films and laminates thereof are well suited, for example,
for use as outer covers in personal care articles.
Inventors: |
Ng; Wing-Chak; (Roswell,
GA) ; Vidal de Siqueira; Jose Augusto; (Roswell,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kimberly-Clark Worldwide, Inc. |
Neenah |
WI |
US |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20160114517 A1 |
April 28, 2016 |
|
|
Family ID: |
55791266 |
Appl. No.: |
14/524159 |
Filed: |
October 27, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12982979 |
Dec 31, 2010 |
8895126 |
|
|
14524159 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2307/724 20130101;
C08J 5/18 20130101; C08J 2323/16 20130101; B29C 48/19 20190201;
B32B 5/026 20130101; B32B 2555/00 20130101; C08J 2323/12 20130101;
B29C 48/40 20190201; B32B 27/308 20130101; B32B 3/263 20130101;
B32B 5/022 20130101; B32B 2437/00 20130101; C08J 2353/00 20130101;
B32B 2262/02 20130101; B32B 27/306 20130101; B32B 27/32 20130101;
B32B 5/145 20130101; B32B 25/042 20130101; B32B 2307/50 20130101;
B29L 2007/008 20130101; B32B 2535/00 20130101; B32B 27/40 20130101;
B32B 25/14 20130101; B32B 27/08 20130101; B32B 27/12 20130101; B32B
27/36 20130101; C08J 2323/06 20130101; B32B 25/08 20130101; B32B
3/04 20130101; B32B 27/302 20130101; B32B 2270/00 20130101; B32B
5/024 20130101; B29C 48/08 20190201; B32B 25/10 20130101; B32B
2307/51 20130101; B29C 48/10 20190201; B32B 5/142 20130101; B32B
2307/554 20130101; B29K 2301/12 20130101; B29C 55/12 20130101; B32B
27/34 20130101; B29C 48/21 20190201; B32B 27/20 20130101; B32B 5/04
20130101 |
International
Class: |
B29C 47/06 20060101
B29C047/06; C08J 5/18 20060101 C08J005/18 |
Claims
1. A method of forming a segmented film, the method comprising:
providing first and second polymer compositions to a segmented
feedblock; transferring the first and second polymer compositions
to a film die; co-extruding a segmented film comprising a first
film segment of the first polymer composition and a second film
segment of the second polymer composition, the first and second
film segments being joined at an interface, wherein at the
interface a tip of the second film segment overlaps the first film
segment in the cross-direction of the film, and wherein the film
has a thickness "T" at the tip of the second film segment, and the
second film segment has a thickness "t" at a distance T in the
cross direction from the tip of the second film segment, and
wherein the ratio T/t is greater than about 3.
2. The method of claim 1, wherein the interface is between the
first and second film segments and extends substantially in the
machine direction of the segmented film.
3. The method of claim 1, wherein the ratio T/t ranges from about 3
to about 100.
4. The method of claim 1, wherein the first and second polymer
compositions flow together in the film die substantially in a cross
direction prior to exiting the film die in a machine direction.
5. The method of claim 1, wherein the first and second film
segments extend adjacent one another continuously in the
machine-direction.
Description
RELATED APPLICATION
[0001] The present application is a divisional application of U.S.
patent application Ser. No. 12/982,979, by Wing-Chak Ng, filed on
Dec. 31, 2010, the contents of which are incorporated herein.
BACKGROUND OF THE INVENTION
[0002] Thin films have a wide variety of applications including use
as outer covers for personal care products (e.g. diapers or
incontinence garments), medical garments, industrial workwear and
so forth. In addition, laminates of such films have found use in
various bodily articles as well as numerous other applications. The
films can provide the desired barrier properties to the article
while other materials laminated thereto can provide additional
desired characteristics such as strength, abrasion resistance
and/or good hand.
[0003] Segmented films can be used to provide different properties
to different areas of a product. For example, it may not be
necessary to have high breathability and good stretch and recovery
properties in the same area of the film. In that case, a segmented
film having elastic segments on the outer edges and a breathable
barrier segment in the center can be used as an outercover film for
a personal care absorbent product.
[0004] However, segmented films may be weak at the interface
between the segments. The weak interface can be prone to tearing.
The weakness can be due to lack of cohesiveness between the
different materials used in the different segments of the film.
[0005] Thus, there exists a need for an improved segmented film
having improved strength at an interface between the segments of
the film.
SUMMARY OF THE INVENTION
[0006] The aforesaid needs are fulfilled and the problems
experienced by those skilled in the art overcome by the segmented
film of the present invention which includes a first film segment
having a first composition and a second film segment having a
second composition, the first and second film segments being joined
at an interface extending in the machine direction of the segmented
film. At the interface a tip of the second segment overlaps the
first segment in the cross-direction of the film. The film has a
thickness "T" at the tip of the second segment, and the second
segment has a thickness "t" at a distance T in the cross direction
from the tip of the second segment. The ratio T/t is suitably
greater than about 3. Desirably, the segmented film has a
substantially uniform thickness and the first and second segments
extend adjacent one another continuously in the machine-direction
of the film.
[0007] In another aspect, the first or second film segment may
include a microporous film. In one embodiment, the composition of
the first or second film segment includes thermoplastic polymer and
filler. The thermoplastic polymer may be an inelastic polyolefin
polymer. Desirably, the filler is distributed throughout the first
film segment. More desirably, the first or second film segment has
micropores adjacent the filler.
[0008] In a further aspect, the first or second film segment may
include an elastic polymer selected from the group consisting of
polyolefin elastomers, styrenic block copolymers, polyurethanes,
polyesters, polyamides, vinyl acetates, acrylates and blends
thereof.
[0009] In a further aspect, the segmented films of the present
invention can be laminated or fixedly attached to a sheet such as,
for example, a nonwoven web, woven fabric, and so forth. As used
herein, the term "sheet" refers to a layer of material which can be
a woven material, knitted material, scrim, nonwoven web or other
like material. In addition, the films and film laminates of the
present invention are well suited for use in personal care
articles, protective apparel, protective covers and infection
control products. As an example, personal care articles of the
present invention can include (i) a liquid pervious topsheet; (ii)
an outer cover comprising a segmented film or film laminate as
described herein; and (iii) an absorbent core positioned between
the outer cover and topsheet. The first and second film segments
can be selectively positioned within the article to provide the
desired attributes such as body conformance, regional water vapor
transmission rates and/or aesthetics.
[0010] In another embodiment, a method of forming a segmented film
includes the steps of providing first and second polymer
compositions to a segmented feedblock; transferring the first and
second polymer compositions to a film die; and co-extruding from
the film die a segmented film comprising a first film segment of
the first polymer composition and a second film segment of the
second polymer composition, the first and second film segments
being joined at an interface, wherein at the interface a tip of the
second film segment overlaps the first film segment in the
cross-direction of the film, and wherein the film has a thickness
"T" at the tip of the second film segment, and the second film
segment has a thickness "t" at a distance T in the cross direction
from the tip of the second film segment, and wherein the ratio T/t
is greater than about 3.
[0011] In a further embodiment, a method of forming a segmented
film includes the steps of providing first and second polymer
compositions to a segmented feedblock that feeds the first and
second polymer compositions to a film die; and co-extruding from
the film die a segmented film comprising a first film segment of
the first polymer composition and a second film segment of the
second polymer composition, wherein the first and second polymer
compositions flow together in the film die substantially in a cross
direction prior to exiting the film die in a machine direction, and
further wherein the first and second film segments extend adjacent
one another continuously in the machine-direction.
[0012] Other features and aspects of the present invention are
described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth more particularly in the remainder of the
specification, which makes reference to the appended figures in
which:
[0014] FIG. 1 is a top, plan view of a multi-segmented film of the
present invention;
[0015] FIG. 1A is a cross-sectional view of the multi-segmented
film of FIG. 1 taken at 1A-1A;
[0016] FIG. 2 is an SEM photograph of a cross-section of an
exemplary segmented film.
[0017] FIG. 3 is an SEM photograph of a cross-section of another
exemplary segmented film.
[0018] Repeat use of reference characters in the present
specification and drawings is intended to represent same or
analogous features or elements of the invention.
DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS
[0019] Reference now will be made in detail to various embodiments
of the invention, one or more examples of which are set forth
below. Each example is provided by way of explanation, not
limitation of the invention. In fact, it will be apparent to those
skilled in the art that various modifications and variations may be
made in the present invention without departing from the scope or
spirit of the invention. For instance, features illustrated or
described as part of one embodiment, may be used on another
embodiment to yield a still further embodiment. Thus, it is
intended that the present invention cover such modifications and
variations.
[0020] In reference to FIGS. 1 and 1A, a unitary segmented film 32
having a machine direction (MD) and a cross direction (CD), further
having a first surface 18 and a second surface 20 parallel or
generally parallel to the first surface, is shown having at least a
first segment 12 attached to at least a second segment 14 with an
interface or seam 16 where the first segment is attached to the
second segment. The first segment 12, second segment 14, and the
seam 16 generally run continuously in the machine direction. At the
interface 16 the second segment 14 overlaps the first segment 12 in
the cross direction, that is, the first segment extends past the
second segment in the cross direction. The second segment 14
extends past or overlaps the first segment 12 to a tip 22 of the
second segment. The tip 22 of the second segment 14 is the part of
the second segment that extends the farthest in the cross direction
into the first segment 12.
[0021] The extent to which the second segment overlaps the first
segment may be assessed by comparing the thickness "T" of the film
32 at the tip 22 of the second segment 14 to the thickness "t" of
the second segment at a distance "T" in the cross-direction from
the tip. Desirably, the ratio T/t is large, indicating a greater
overlap of the first segment 12 and second segment 14 at the
interface 16. In some embodiments, the ratio T/t is suitably
greater than about 3, more suitably greater than about 5, and even
more suitably greater than about 7. In other embodiments, the ratio
T/t is suitably in a range from about 3 to about 50, more suitably
in a range from about 5 to about 50, even more suitably in a range
from about 7 to about 50. In another embodiment, the ratio T/t is
suitably in a range from about 3 to about 30, more suitably in a
range from about 6 to about 30, and even more suitably in a range
from about 10 to about 30.
[0022] Desirably, the first segment 12 comprises at least about 10%
of the area of the segmented film 32 and, even more desirably,
comprises between about 20% and about 80% of the area of the
segmented film 32. Although thicker segmented films are possible,
the unitary segmented film desirably has a maximum film thickness
less than about 50 microns and still more desirably has a maximum
film thickness between about 10 microns and about 35 microns. The
first and second segments 12 and 14 can be selected to comprise
distinct films having varied attributes such as, for example,
distinct breathability and/or elastic properties. As used herein,
the term "elastic" generally refers to material which, upon
application of a biasing force, is extensible or elongatable in at
least one direction and returns substantially to its original
dimensions immediately after the biasing force is removed.
[0023] Segmented films, as described herein, may have distinct film
segments which exhibit varied levels of breathability and/or
elasticity can be formed by various methods. Segmented films can be
formed by coextruding the respective adjacent segments such as, for
example, using the method and apparatus for forming films as
disclosed in U.S. Pat. No. 4,533,510 to Nissel et al., the entire
contents of which are incorporated herein by reference. Film dies
for forming side-by-side coextruded films are commercially
available from Extrusion Dies Industries, LLC of Chippewa Falls,
Wis. and Cloeren Inc. of Orange, Tex. The desired components of the
respective film segments can be separately mixed, heated and then
coextruded into the respective side-by-side segments of a unitary
segmented film. The film may be made by any one of a variety of
film forming processes known in the art such as, for example, by
using either cast or blown film equipment. Desirably, the first and
second compositions are introduced to a segmented feed block prior
to entering the film die. The segmented feed block allows contact
between the first and second compositions prior to the compositions
entering the film die. This early contact between the first and
second compositions is believed to result in the extended overlap
of the first and second segments at the interface between the
segments. In one embodiment, a feed block suitable for making
layered films from one or more polymer compositions is rotated 90
degrees with respect to the die body to provide segmented films
rather than layered films. Suitable feed blocks, such as micro feed
blocks or modular feed blocks, may be obtained from Randcastle
Extrusion Systems, Inc., of Cedar Grove, N.J. The extruded
segmented film is then processed as desired.
[0024] In one aspect, the unitary segmented film can be stretched
in at least one direction, thereby reducing the film gauge or
thickness. As discussed in more detail herein below, a particularly
desirable film or film segment is a microporous stretched
filled-film. Such microporous filled-film segments may include at
least a thermoplastic polymer and filler. With regard to
microporous stretched filled-films, in addition to reducing the
film thickness, stretching may also impart porosity to the film and
may form a micropore network therein which renders the films
breathable. As used herein the term "polymer" generally includes
but is not limited to, homopolymers, copolymers, such as for
example, block, graft, random and alternating copolymers,
terpolymers, etc. and blends and modifications thereof.
Furthermore, unless otherwise specifically limited, the term
"polymer" includes all possible spatial configurations of the
molecule. These configurations include, but are not limited to
isotactic, syndiotactic and random symmetries. As used herein the
term "blend" means a mixture of two or more polymers while the term
"alloy" means a sub-class of blends wherein the components are
immiscible but have been compatibilized. As used herein "filler" is
meant to include particulates and other forms of materials which
can be added to the polymer and which will not chemically interfere
with or adversely affect the extruded film but is able to be
dispersed throughout the film. The filler particles may optionally
be coated with a fatty acid, such as stearic acid or behenic acid,
and/or other material in order to facilitate the free flow of the
particles (in bulk) and their ease of dispersion into the polymer.
Stretching can be achieved by various means known to those skilled
in the art. Films can be stretched or oriented in either or both
the MD and CD. As used herein, the term "machine direction" or MD
means the direction in which a film or fabric is produced. The term
"cross machine direction" or CD means the direction associated with
the width of film or fabric, i.e. a direction generally
perpendicular to the MD. As examples, machine direction orientation
equipment is commercially available from vendors such as the
Marshall and Williams Company of Providence, R.I. and biaxial
orientation equipment is commercially available from Bruckner GMBH
of Siegsdorf, Germany. As a further example, the films can be
stretched utilizing grooved or patterned rollers such as, for
example, those described in U.S. Pat. No. 4,153,751 to Schwarz,
U.S. Pat. No. 5,028,289 to Rasmussen, and U.S. Pat. No. 6,368,444
to Jameson et al.; the entire contents of the aforesaid references
are incorporated herein by reference. When using one or more
elastic segments it may be advantageous to anneal or heat set the
stretched segmented film while in the stretched or tensioned state
in order to set the elastic segment and reduce the potential for
puckering of the film caused by the retractive force of the elastic
segments. In addition, when using films which have been
independently pre-formed and subsequently joined, it is possible to
process the films, for example to stretch-thin the films and so
forth, either prior to or after permanently joining the respective
segments together to form a unitary segmented film.
[0025] There exists a wide variety of polymers suitable for use
with the present invention. The segments of the segmented film can
be made from any thermoplastic polymer suitable for film formation
and desirably comprise thermoplastic polymers which can be readily
stretched to reduce the film gauge or thickness. Film forming
polymers suitable for use with the present invention, alone or in
combination with other polymers, include, by way of example only,
polyolefins, ethylene vinyl acetate (EVA), ethylene ethyl acrylate
(EEA), ethylene acrylic acid (EAA), ethylene methyl acrylate (EMA),
ethylene normal butyl acrylate (EnBA), polyester, polyethylene
terephthalate (PET), nylon, ethylene vinyl alcohol (EVOH),
polystyrene (PS), polyurethane (PU), polybutylene (PB), polyether
esters, polyether amides, and polybutylene terephthalate (PBT).
[0026] Suitable polymers for forming one or more of the film
segments, include, but are not limited to, polyolefins. A wide
variety of polyolefin polymers exist and the particular composition
of the polyolefin polymer and/or method of making the same is not
believed critical to the present invention and thus both
conventional and non-conventional polyolefins capable of forming
films are believed suitable for use in the present invention. As
used herein, "conventional" polyolefins refers to those made by
traditional catalysts such as, for example, Ziegler-Natta
catalysts. Suitable polyethylene and polypropylene polymers are
widely available and, as one example, linear low density
polyethylene is available from The Dow Chemical Company of Midland,
Mich. under the trade name AFFINITY and conventional polypropylene
is available from ExxonMobil Chemical Company of Houston, Tex. In
addition, elastic and inelastic polyolefins made by "metallocene",
"constrained geometry" or "single-site" catalysts are also suitable
for use in the present invention. Examples of such catalysts and
polymers are described in U.S. Pat. No. 5,472,775 to Obijeski et
al.; U.S. Pat. No. 5,451,450 to Erderly et al.; U.S. Pat. No.
5,278,272 to Lai et al.; U.S. Pat. No. 5,272,236 to Lai et al.;
U.S. Pat. No. 5,204,429 to Kaminsky et al.; U.S. Pat. No. 5,539,124
to Etherton et al.; and U.S. Pat. No. 5,554,775 to Krishnamurti et
al.; the entire contents of which are incorporated herein by
reference. The aforesaid patents to Obijeski and Lai teach
exemplary polyolefin elastomers and, in addition, exemplary low
density polyethylene elastomers are commercially available from The
Dow Chemical Company under the trade name AFFINITY, from ExxonMobil
Chemical Company, under the trade name EXACT, and from Dupont Dow
Elastomers, L.L.C. under the trade name ENGAGE. Moreover, exemplary
propylene-ethylene copolymer plastomers and elastomers are
commercially available from The Dow Chemical Company under the
trade name VERSIFY and ExxonMobil Chemical Company under the trade
name VISTAMAXX.
[0027] In addition, stereoblock polymers are also believed well
suited for practicing the present invention. The term "stereoblock
polymer" refers to polymeric materials with controlled regional
tacticity or stereosequencing to achieve desired polymer
crystallinity. By controlling the stereoregularity during
polymerization, it is possible to achieve atacticisotactic stereo
blocks. Methods of forming polyolefin stereoblock polymers are
known in the art and are described in the following articles: G.
Coates and R. Waymouth, "Oscillating Stereocontrol: A Strategy for
the Synthesis of Thermoplastic Elastomeric Polypropylene" 267
Science 217-219 (January 1995); K. Wagener, "Oscillating Catalysts:
A New Twist for Plastics" 267 Science 191 (January 1995).
Stereoblock polymers and methods of their production are also
described in U.S. Pat. No. 5,594,080 to Waymouth et al., U.S. Pat.
No. 5,208,304 to Waymouth and European Patent Application
Publication No. 0475306 A1. As indicated above, by controlling the
crystallinity of olefins it is possible to provide polymers
exhibiting unique tensile modulus and/or elongation properties. In
addition, polyolefin copolymers, and in particular
propylene-ethylene copolymers, are also suitable for use with the
present invention. As but one example, exemplary propylene-ethylene
copolymers can comprise multi-step reactor products wherein an
amorphous ethylene propylene random copolymer is molecularly
dispersed in a predominately semi-crystalline high propylene
monomer/low ethylene monomer continuous matrix. Examples of such
polymers are described in U.S. Pat. No. 5,300,365 to Ogale; U.S.
Pat. No. 5,212,246 to Ogale and U.S. Pat. No. 5,331,047 to
Giacobbe. Such polymers are commercially available from
LyondellBasell under the trade name CATALLOY polymers.
[0028] Other exemplary commercially available elastomeric materials
include, but are not limited to, the following polymers:
elastomeric polyurethanes such as, for example, those available
under the trade name ESTANE from Lubrizol Advanced Materials, Inc.;
elastomeric polyether esters such as, for example, those available
under the trade name HYTREL from E. I. DuPont De Nemours &
Company, and those available under the trade name ARNITEL available
from DSM of Sittard, Holland (formerly available from Akzo Plastics
of Arnhem, Holland); and elastomeric polyether amides commercially
available from Arkema, Inc. under the trade name PEBAX. As
additional examples, suitable thermoplastic elastomers also include
those made from block copolymers having the general formula A-B-A'
where A and A' are each a thermoplastic polymer endblock which
contains a styrenic moiety such as a poly(vinyl arene) and where B
is an elastomeric polymer midblock such as a conjugated diene or a
lower alkene polymer. Further, exemplary block copolymers include
A-B-A-B tetrablock polymers having an isoprene monomer unit
hydrogenated to a substantially poly(ethylene-propylene) monomer
unit such as a
styrene-poly(ethylene-propylene)-styrene-poly(ethylene-propylene)
elastomeric block copolymer. Examples of such styrene-olefin block
copolymers include styrene-(ethylene-butylene),
styrene-(ethylene-propylene), styrene-(ethylene-butylene)-styrene,
styrene-(ethylene-propylene)-styrene,
styrene-(ethylene-butylene)-styrene-(ethylene-butylene),
styrene-(ethylene-propylene)-styrene-(ethylene-propylene), and
styrene-ethylene-(ethylene-propylene)-styrene. These block
copolymers may have a linear, radial or star-shaped molecular
configuration. As specific examples, exemplary elastomers can
comprise (polystyrene/poly(ethylene-butylene)/polystyrene) block
copolymers available from the Kraton Polymers LLC under the trade
name KRATON as well as polyolefin/KRATON blends such as those
described in U.S. Pat. Nos. 4,663,220, 4,323,534, 4,834,738,
5,093,422, 5,304,599, and 5,332,613, the entire contents of the
aforesaid references are incorporated herein by reference. Still
other suitable copolymers include the S-I-S and S-B-S elastomeric
copolymers available from Dexco Polymers of Houston, Tex. under the
trade designation VECTOR.RTM..
[0029] Other additives may also be incorporated into the film, such
as melt stabilizers, crosslinking catalysts, pro-rad additives,
processing stabilizers, heat stabilizers, light stabilizers,
antioxidants, heat aging stabilizers, whitening agents,
antiblocking agents, bonding agents, tackifiers, viscosity
modifiers, etc. Examples of suitable tackifier resins may include,
for instance, hydrogenated hydrocarbon resins. REGALREZ.TM.
hydrocarbon resins are examples of such hydrogenated hydrocarbon
resins, and are available from Eastman Chemical. Other tackifiers
are available from ExxonMobil under the ESCOREZ.TM. designation.
Viscosity modifiers may also be employed, such as polyethylene wax
(e.g., EPOLENE.TM. C-10 from Eastman Chemical). Phosphite
stabilizers (e.g., IRGAFOS available from Ciba Specialty Chemicals
of Terrytown, N.Y. and DOVERPHOS available from Dover Chemical
Corp. of Dover, Ohio) are exemplary melt stabilizers. In addition,
hindered amine stabilizers (e.g., CHIMASSORB available from Ciba
Specialty Chemicals) are exemplary heat and light stabilizers.
Further, hindered phenols are commonly used as an antioxidant in
the production of films. Some suitable hindered phenols include
those available from Ciba Specialty Chemicals of under the trade
name "Irganox.RTM.", such as Irganox.RTM. 1076, 1010, or E 201.
Moreover, bonding agents may also be added to the film to
facilitate bonding of the film to additional materials (e.g.,
nonwoven web). Typically, such additives (e.g., tackifier,
antioxidant, stabilizer, etc.) are each present in an amount from
about 0.001 wt. % to about 25 wt. %, in some embodiments, from
about 0.005 wt. % to about 20 wt. %, and in some embodiments, from
0.01 wt. % to about 15 wt. % of the film.
[0030] As indicated above, the first segment of the segmented film
may include a breathable film. As used herein, the term
"breathable" or "breathability" refers to the water vapor
transmission rate (WVTR) of an area of fabric which is measured in
grams of water per square meter per day (g/m.sup.2/24 hours). WVTR
results are reported in grams/square meter/day. Further, as used
herein the term "breathable" refers to a fabric having a WVTR of at
least 800 g/m.sup.224 hours. Various breathable films are suitable
for use with the present invention, including both microporous and
monolithic (i.e. non-porous) films. Breathable films comprising the
first segment or segments can be elastic or inelastic and desirably
have a WVTR of at least about 800 g/m.sup.2/day, and more desirably
having a WVTR in excess of about 1500 g/m.sup.2/day, and still more
desirably a WVTR in excess of about 3500 g/m.sup.2/day, and even
more desirably a WVTR of about 5000 g/m.sup.2/day or more. In one
aspect, the first segments can be inelastic or less-elastic than
the second segment and may exhibit higher breathability levels
relative to the second segments before aperturing. Monolithic or
non-microporous breathable films can exhibit good breathability
when they comprise polymers which inherently have good water vapor
transmission rates (i.e., polymers which allow water vapor to
readily diffuse through the film) such as, for example,
polyurethanes, polyether esters, polyether amides, EMA, EEA, EVA
and the like. Examples of breathable microporous films suitable for
use as one or more segments of the segmented film include, but are
not limited to, those described in the following references: U.S.
Pat. No. 5,695,868 to McCormack; U.S. Pat. No. 6,075,179 to
McCormack et al.; U.S. patent application Ser. No. 08/722,726 filed
Oct. 1, 1996 to McCormack et al.; U.S. patent application Ser. No.
08/882,712 filed Jun. 25, 1997 to McCormack et al.; U.S. Pat. No.
6,111,163 to McCormack et al.; U.S. Pat. No. 6,045,900 to Haffner
et al.; U.S. patent application Ser. No. 08/843,147 filed Apr. 25,
1997 to Gwaltney et al; and U.S. patent application Ser. No.
09/122,326 filed Jul. 24, 1998 to Shawver et al; U.S. Pat. No.
4,777,073 to Sheth; and U.S. Pat. No. 4,867,881 to Kinzer; the
entire contents of the aforesaid references are incorporated herein
by reference.
[0031] The second segments can be non-breathable or breathable film
segments. In addition, the second segments can be elastic or
inelastic films. In one embodiment, the second segments are elastic
films and may comprise one or more elastic polymers. The second
segments can comprise films similar to those described above with
respect to the first segments. However, the composition and/or
structure of the first segment is distinct from that of the second
segment and the specific composition and/or structure of the first
and second segments will be selected with respect to one another to
achieve the desired functional and/or aesthetic attributes of the
unitary, segmented film. The particular film composition and/or
structure of the respective segments can be selected with respect
to various considerations such as end use, cost, durability,
strength, shelf and product life expectancy, etc.
[0032] In one aspect of the invention, a segmented film can
comprise a film having varied regional breathability. As an
example, the first segments can include breathable films separated
along a length of the film by the second segments. The second
segments can comprise either breathable or non-breathable films
prior to aperturing. In order to achieve a unitary film having
varied regional breathability first segments can be selected to
have a higher or lower WVTR relative to the second segments after
aperturing. WVTRs of adjacent segments can vary in accord with the
selected film composition and/or structure thereof, thereby
yielding a film having adjacent segments with distinct levels of
breathability. In this regard, first and second segments can have
distinct WVTRs by selecting different film compositions for the
respective segments. As an example, first segments can have a
higher weight percent of filler than second segments. Thus,
stretching of the filled film creates a segmented film having first
breathable segments and second breathable segments wherein the WVTR
of first segments are higher than the WVTR of second segments, at
least prior to aperturing. Additionally and/or alternatively, first
and second segments can comprise different types of filler
materials. The WVTRs of the respective segments can thus be varied
in accord with the desired application of the segmented film. High
and low breathability segments can be strategically located within
the unitary segmented film to achieve the desired breathability
levels in selected locations.
[0033] In a further aspect, it may be desirable to have each of the
segments comprise an opaque film. This may be aesthetically
desirably in certain articles, such as diapers, to mask a soiled
absorbent core. Opacifying fillers can be included within one or
more of the segments as needed in order to create a segmented film
which is uniformly opaque. However, the weight percent and/or type
of filler can be varied amongst respective segments in order to
selectively achieve disparate breathability levels while having
substantially uniform opacity. As a specific example, the first
segments may be a highly breathable microporous LLDPE film having
CaCO.sub.3 filler particles and second segments may be a less
breathable and less porous LLDPE film having TiO.sub.2 filler
particles.
[0034] As a further example, the first and second segments can
include different polymers in order to achieve distinct WVTR
levels. In this regard, the respective segments can be either
microporous or non-microporous films and/or filled or unfilled
films utilizing different polymeric compositions. In one aspect,
the first segments can comprise a filled polymeric film and second
segments a filled polymeric film comprising a polymer different
from that comprising first segments, wherein upon stretching of the
unitary segmented film a higher level of breathability is imparted
to first segments relative to the WVTR of the second segments. As
an example, first segments can comprise a linear low density
polyethylene (LLDPE) filled film and second segments can comprise
an elastomeric polyethylene filled film. The resulting breathable
stretched-thinned film will have first segments with a higher WVTR
than second segments. The amount and/or type of filler can likewise
be varied in combination with polymer composition in order to
achieve the desired WVTR, opacity and/or elasticity within the
respective segments.
[0035] In a further aspect, unitary films with improved body
conformance can also be achieved in accord with the present
invention. The segmented film can comprise first and second
segments wherein one of the first or second segments is elastic and
the other segments are breathable segments. As an example, first
segments can comprise inelastic breathable segments whereas second
segments can comprise an elastic segment. Desirably, first
breathable segments comprise at least about 25% of the area of
segmented film and, even more desirably, comprise between about 50%
and about 95% of the area of segmented film. The elastic, second
segments can comprise a breathable or a non-breathable film. As a
particular example, first segments can comprise a microporous LLDPE
filled film and second segments a non-porous film comprising an
elastomeric polyolefin such as elastomeric polyethylene.
Alternatively, second segments can comprise an elastic breathable
non-porous film such as, for example, a polyurethane, polyether
ester, or polyether amide film. Still further, the first segment
can comprise a microporous polyolefin filled-film and the second
segment can comprise a KRATON/polyolefin polymer blend.
[0036] Elastic film segments can comprise an elastomer and
desirably have a hysteresis of less than 60% and more desirably a
hysteresis of less than about 50% and still more desirably a
hysteresis of less than about 40%. Inelastic segments can include
those segments comprising a non-elastomeric polymer having a
hysteresis of greater than about 60%. In a further aspect the
elastic film segments can comprise a film of a thermoplastic
elastomer having a retraction/extension percent greater than 25 and
desirably has a retraction/extension percent greater than about 35
and still more desirably a retraction/extension percent of at least
about 50. In this regard, inelastic film segments can comprise a
film of a thermoplastic polymer having retraction/extension ratio
less than about 25. In a further aspect, the elastic segments
desirably comprise a thermoplastic elastomer film which, upon
application of a biasing force, is elongatable, to a stretched or
biased length which is at least about 160 percent of its relaxed
unbiased length, and which, will immediately recover at least 55
percent of its elongation upon release of the elongating force. A
hypothetical example would be a one (1) centimeter sample of a
material which is elongatable to at least 1.60 centimeters and
which, upon release of the elongating force, will recover to a
length of not more than 1.27 centimeters. Many thermoplastic
elastomer films exhibit greater stretch and recovery properties and
many highly elastic materials can be stretched to 160 percent of
their relaxed unbiased length, and immediately recover in excess of
about 75% percent of its elongation upon release of the elongating
force.
[0037] In a further aspect of the present invention, the individual
film segments may themselves comprise either mono-layer or
multi-layered films. For example, the segmented film may include
first segments including a multi-layered film and second segments
including a mono-layer film. The first segments may include one or
more outer layers and one or more central or intermediate layers.
In other embodiments multi-layered film segments can include films
such as, for example, those described in U.S. Pat. No. 6,075,179 to
McCormack et al.; U.S. Pat. No. 6,045,900 to Haffner et al. and
U.S. patent application No. 08/882,712 filed Jun. 25, 1997 to
McCormack et al., the contents of the aforesaid references are
incorporated herein by reference. Additionally, the first and
second segments may both include multi-layered films. For example,
the first segments can comprise outer layers and a core layer and
the second segments may include outer layers and a core layer. The
outer layers of the first and second segments may include
identical, similar or different compositions. Where one or more of
the segments are elastic it is desirable that outer layers
extending over the elastic segments include an extensible layer. In
this regard, when comprising a small percent of the overall film
thickness, layers which by themselves are inelastic can still be
utilized as they will not impede the stretch and recovery provided
by the elastic core layer. Desirably, however, outer layers
extending over elastic segments exhibit good extensibility. As an
example, the core layer of the first segment may include an
inelastic breathable microporous LLDPE filled film and the core
layer of the second segment may include an elastic polyolefin and
the outer layers of the first and second segments may include a
blend of LLDPE and EMA.
[0038] In a further aspect of the invention, the segmented film may
include one or more discrete elastic segments positioned between
breathable segments. In one embodiment, the breathable segments
include substantially inelastic segments having high levels of
breathability. For example, the segmented film may include first
segments and discrete second segments disposed there between. The
discrete elastic segments can either be breathable or
non-breathable. Desirably, the first breathable segments include at
least about 25% of the area of the segmented film and, even more
desirably, include between about 50% and about 95% of the area of
the segmented film. In addition, discrete elastic segments may have
a width (dimension in the CD of the film) of at least 0.1 cm and
desirably have a width of at least about 1 cm or more. The width of
the breathable segments separating the second elastic segments can
vary in accord with the desired attributes of the segmented film;
use of larger elastic segments and/or more closely grouped segments
will improve the overall stretch and recovery attributes of the
unitary segmented film. The first breathable segments and the
second elastic segments may include either mono-layer or
multi-layer films. For example, the first breathable segments may
include a multi-layered film including outer layers and a central
core layer and the second elastic segments may include a mono-layer
film. In a particular embodiment, the first breathable segments may
include an inelastic multilayered film such as those described in
U.S. Pat. No. 6,309,736 to McCormack et al. and the second elastic
segments may include an elastic polyethylene. As a further example,
the first breathable segments and the second elastic segments may
both include multi-layered films with the first segment comprising
outer layers and an intermediate layer and the second segment
comprising outer layers and an intermediate layer. Desirably, the
outer layers of the first breathable segments and the second
elastic segments may include a similar or identical polymer
composition such as, for example, EMA, EEA, EVA or polyolefin
blends thereof.
[0039] As indicated above, a wide variety of polymers are suitable
for use with the present invention. Polymers of adjacent segments
should be compatible in the sense that they exhibit sufficient
cohesion to form a continuous, cohesive film. In this regard,
utilization of polymer blends can improve cohesion of adjacent
segments. For example, polyethylene and polypropylene are not, by
themselves, compatible whereas polyethylene/polypropylene blends
can be compatible with polyethylene and/or polypropylene segments.
In a particular embodiment, a first segment can comprise LLDPE and
a polypropylene impact copolymer (such as taught in U.S. Pat. No.
6,072,005 Kobylivker et al., the entire contents of which are
incorporated herein by reference), and an adjacent second segment
can comprise an elastic polypropylene. Further, compatibilization
may likewise be achieved through addition of one or more bonding or
tackifying resins within a segment. Exemplary bonding or tackifying
resins are described in U.S. Pat. No. 5,695,868 to McCormack. In
addition, compatibilization segments or tie segments can be used in
order to utilize a wider range of polymers. Accordingly, the use of
a compatibilizing segment makes it possible to achieve a continuous
cohesive segmented film using discrete segments of incompatible
polymers. For example, the segmented film may include first
segments and second segments wherein compatibilizing segments are
disposed between the first and second segments. As a particular
example, the first segments may include a breathable inelastic
segment comprising a microporous LLDPE film and the second segments
may include elastic polypropylene. Compatibilizing segments may be
disposed between the first and second segments and may include, for
example, an ethylene-propylene copolymer. In a further aspect, a
compatibilizing segment can itself include a bonding or tackifying
resin such as an amorphous polyalphaolefins such as REXTAC from
Rextac LLC and VESTOPLAST from Huels AG of Marl, Germany.
Composition of the compatibilizing segment can vary in accord with
the desired film attributes and the particular polymers comprising
adjacent segments.
[0040] To concurrently form apertures and embossments in the
segmented film, the aperturing/embossing is may be generally
accomplished via feeding the segmented film through a nip defined
by at least one patterned roll such as described in U.S. patent
application Ser. No. 12/649,427 to Ng, et al.
[0041] The segmented film may be "pre-stretched" (prior to nipping)
by rolls rotating at different speeds of rotation so that the sheet
is stretched to the desired stretch ratio in the machine direction.
This uniaxially stretched film may also be oriented in the
cross-machine direction to form a "biaxially stretched" film. The
orientation temperature profile during the "pre-stretching"
operation is generally below the melting point of one or more
polymers in the film, but high enough to enable the composition to
be drawn or stretched. For example, the film may be stretched at a
temperature from about 15.degree. C. to about 50.degree. C., in
further embodiments from about 25.degree. C. to about 40.degree.
C., and in even further embodiments, from about 30.degree. C. to
about 40.degree. C. When "pre-stretched" in the manner described
above, the degree of stretch during lamination may be increased,
maintained, or slightly reduced (retracted) to desired degree of
tension.
[0042] The raw materials for the first and second segments of the
film are prepared and added to a hoppers of an extrusion apparatus
for each segment. The materials are dispersively mixed in the melt
and compounded using any known technique, such as batch and/or
continuous compounding techniques that employ, for example, a
Banbury mixer, Farrel continuous mixer, single screw extruder, twin
screw extruder, etc.
[0043] Any known technique may be used to form a segmented film
from the compounded materials, including blowing, casting, flat die
extruding, etc. For example, the extruded film may be blown into
nip rolls to form a single-layered precursor segmented film. The
rolls may be kept at temperature sufficient to solidify and quench
the precursor segmented film as it is formed, such as from about 20
to 60.degree. C.
[0044] Various additional potential processing and/or finishing
steps known in the art, such as passing it through a
film-orientation unit or machine direction orienter ("MDO"),
aperturing, embossing, slitting, treating, printing graphics, etc.,
may be performed without departing from the spirit and scope of the
invention. For instance, the segmented film may optionally be
mechanically stretched in the cross-machine and/or machine
directions to enhance extensibility. In one embodiment, the
segmented film may be coursed through two or more rolls that have
grooves in the CD and/or MD directions. The grooved rolls may be
constructed of steel or other hard material (such as a hard
rubber). Such grooved satellite/anvil roll arrangements are
described in U.S. Patent Application Publication Nos. 2004/0110442
to Rhim, et al. and 2006/0151914 to Gerndt, et al., which are
incorporated herein in their entirety by reference thereto for all
purposes.
[0045] The segmented films may, optionally, be laminated to one or
more additional films and/or fabrics. For example, a segmented film
described herein may be bonded to a nonwoven web. As used herein
the term "nonwoven" fabric or web means a web having a structure of
individual fibers or threads which are interlaid, but not in an
identifiable manner as in a knitted or woven fabric. Nonwoven
fabrics or webs have been formed by many processes such as for
example, meltblowing processes, spunbonding processes,
hydroentangling, air-laid and bonded carded web processes. As used
herein the term "spunbond" refers to small diameter fibers of
molecularly oriented polymeric material. Spunbond fibers are
generally formed by extruding molten thermoplastic material as
filaments from a plurality of fine, usually circular capillaries of
a spinneret with the diameter of the extruded filaments then being
rapidly reduced as by, for example, in U.S. Pat. No. 4,340,563 to
Appel et al., and U.S. Pat. No. 3,692,618 to Dorschner et al., U.S.
Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and
3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, U.S. Pat.
No. 3,542,615 to Dobo et al, U.S. Pat. No. 5,382,400 to Pike et al.
and in commonly assigned U.S. patent applications Ser. No.
08/756,426 now allowed filed Nov. 26, 1996 to Marmon et al. and
U.S. application Ser. No. 08/565,261 now U.S. Pat. No. 5,759,926
filed Nov. 30, 1995 to Pike et al. As used herein the term
"meltblown" or "meltblowing" refers to fine fibers of polymeric
material which are generally formed by extruding a molten
thermoplastic material through a plurality of fine, usually
circular, die capillaries as molten threads or filaments into
converging high velocity, usually hot, gas (e.g. air) streams which
attenuate the filaments of molten thermoplastic material to reduce
their diameter. Thereafter, the meltblown fibers can be carried by
the high velocity gas stream and are deposited on a collecting
surface to form a web of randomly dispersed meltblown fibers. Such
a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to
Butin et al.; U.S. Pat. No. 4,526,733 to Lau; U.S. Pat. No.
5,652,048 to Haynes et al.; and U.S. Pat. No. 5,366,793 to Fitts et
al. Meltblown fibers may be continuous or discontinuous, are
generally less than 10 microns in average diameter, and are
commonly between about 0.5 and about 7 microns in average diameter.
Nonwovens may also be multilayer nonwoven laminates that include at
least one layer of a nonwoven web and/or multiple nonwoven layers
such as, for example, a spunbond/meltblown/spunbond (SMS) laminate.
Examples of multilayer nonwoven laminates are disclosed in U.S.
Pat. No. 4,041,203 to Brock et al., U.S. Pat. No. 5,178,931 to
Perkins et al. and U.S. Pat. No. 5,188,885 to Timmons et al.
[0046] The particular composition of any additional layers attached
to the segmented film may be selected to achieve desired attributes
such as, for example, aesthetics, strength, durability, hand, etc.
As examples, segmented films can be laminated to knitted fabrics,
nonwoven fabrics, foams, scrims, multilayered nonwoven laminates,
and so forth. As used herein, the term "scrim" means a lightweight
fabric used as a backing material. Scrims are often used as the
base fabric for coated or laminated products. The segmented film
and other fabric(s) can be laminated together by means known to
those skilled in the art such as, for example, by thermal bonding,
ultrasonic bonding, adhesive bonding and the like. Thermal point
bonding is an exemplary means of laminating the respective layers.
As used herein "point bonding" means bonding one or more layers of
fabric at a plurality of discrete bond points. For example, thermal
point bonding generally involves passing one or more layers to be
bonded between heated rolls such as, for example an engraved
pattern roll and a smooth calender roll. The engraved roll is
patterned in some way so that the entire fabric is not bonded over
its entire surface, and the anvil roll is usually flat. As a
result, various patterns for engraved rolls have been developed for
functional as well as aesthetic reasons. One example of thermal
point bonding is described in U.S. Pat. No. 3,855,046 to Hansen et
al. Numerous other bonding patterns are known such as, for example,
those described in U.S. Design Pat. No. 356,688 to Uitenbroek et
al. and U.S. Pat. No. 5,620,779 to Levy et al.
[0047] Where one or more of the segments within the segmented film
comprises an elastic segment, any additional layers laminated
thereto desirably comprise an extensible material or fabric. In
this regard, the additional layer or layers can comprise, as
examples, extensible nonwoven materials (e.g. creped nonwovens or
nonwovens comprising highly crimped fibers), meshed fabrics,
loosely woven fabrics, elastic composite materials and/or other
like materials. Desirably the fabric comprises one or more layers
of thermoplastic fibers which are elastic, inherently extensible or
which have been treated so as to be become extensible and/or
elastic and which also have a cloth-like hand and drape. Examples
of suitable extensible and/or elastic materials are described in
U.S. Pat. No. 4,965,122 to Morman et al.; U.S. Pat. No. U.S. Pat.
No. 5,114,781 to Morman et al.; U.S. Pat. No. 5,336,545 to Morman
et al.; U.S. Pat. No. 4,720,415 to Vander Wielen et al.; U.S. Pat.
No. 4,789,699 to Kieffer et al.; U.S. Pat. No. 5,332,613 to Taylor
et al. ; U.S. Pat. No. 5,288,791 to Collier et al.; U.S. Pat. No.
4,663,220 to Wisneski et al.; U.S. Pat. No. 5,540,976 to Shawver et
al.; European Application No. 0,712,892 A1 to Djiaw et al.; U.S.
Pat. No. 5,952,252 to Shawver et al.; U.S. Pat. No. 5,714,107 to
Levy et al.; and U.S. Pat. No. 6,054,002 to Griesbach et al.; the
contents of the aforesaid references are incorporated herein by
reference. The composition of the thermoplastic polymer may be
selected as desired to achieve a material having the desired
physical attributes such as, for example, elasticity, hand, tensile
strength, cost and so forth. Further, the outer nonwoven layer may
be treated such as, for example, by embossing, hydroentangling,
mechanically softening, printing, anti-static treatment or treated
in some other manner in order to achieve desired aesthetics and/or
functional characteristics.
[0048] The segmented films of the present invention, and laminates
thereof, can be utilized in a wide variety of applications such as,
for example, in personal care articles, infection control products,
protective apparel, protective covers, garments and so forth. As
used herein, the term "personal care product" means personal
hygiene oriented items such as diapers, training pants, absorbent
underpants, adult incontinence products, feminine hygiene products,
and the like. As used herein, the term "infection control product"
means medically oriented items such as surgical gowns and drapes,
head coverings like bouffant caps, surgical caps and hoods,
industrial workwear, footwear like shoe coverings, boot covers and
slippers, wound dressings, bandages, sterilization wraps, lab
coats, coveralls, aprons and so forth. As used herein, the term
"protective apparel" means industrial related apparel or garments
such as coveralls, aprons, workwear, coveralls and so forth. As
used herein, the term "protective cover" means a cover for vehicles
such as cars, boats, airplanes, etc., covers for articles or
equipment often left outdoors (e.g. grills and lawn furniture),
yard and garden equipment, floor coverings, tents and the like. As
used herein, the term "garment" means any type of non-medically or
non-industrial oriented apparel which may be worn. This includes
coveralls, undergarments, pants, shirts, jackets, gloves, socks,
and the like.
[0049] Further, it will be appreciated by those skilled in the art
that the segmented films of the present invention can be
advantageously utilized in numerous other applications employing
breathable barrier fabrics. As used herein, the term "barrier"
means a film, laminate or other fabric which is relatively
impermeable to the transmission of liquids and which has a
hydrohead of at least about 50 mbar. Hydrohead as used herein
refers to a measure of the liquid barrier properties of a fabric
measured in millibars (mbar). However, it should be noted that in
many applications of barrier fabrics, it may be desirable that they
have a hydrohead value greater than about 80 mbar, 150 mbar or even
200 mbar. In one embodiment, the embossed segment of the segmented
film may have a higher hydrohead value than the apertured segment.
Advantageously, the embossed segment may be used in an area of the
product that requires good barrier properties, while the apertured
segment may be used in an area of the product that requires more
breathability.
[0050] As a particular example, segmented films of the present
invention can be readily converted and incorporated within a
breathable barrier of a diaper or incontinence garment. Although
the breathability provided by microporous films and/or laminates
thereof is advantageous in many articles, there exist some
situations where high breathability can be undesirable. For
example, in personal care articles such as diapers or incontinence
garments the breathable barrier and absorbent core generally work
together to retain bodily fluids discharged into the garment.
However, when fluid is retained within the absorbent core
significantly higher levels of water vapor begin to pass through
the breathable barrier. The increased levels of water vapor passing
through the outer cover can form condensate on the outer portion of
the garment. The condensate is simply water but can be perceived as
leakage. In addition, the condensate can create a damp
uncomfortable feel to the outer portion of the garment which is
unpleasant for those handling the article. Providing a breathable
barrier which has a lower WVTR in such regions, while providing
good breathability in the remaining regions, would provide a
garment with excellent wearer comfort yet which limits the
potential for outer cover dampness. In this regard, as discussed in
greater detail herein below, segments having relatively high and
low breathability can be strategically positioned within absorbent
articles to help reduce and/or eliminate outer cover dampness. In a
further aspect, the present invention provides films having stretch
and recovery in the CD direction thereby providing a film and/or
article incorporating the same, with excellent body conformance
attributes. Moreover, excellent body conformance can be achieved
without significant loss of breathability or loss of barrier
properties.
[0051] Personal care articles generally include a liquid permeable
topsheet, which faces the wearer, and a liquid-impermeable bottom
sheet or outer cover. Disposed between the topsheet and outer cover
is an absorbent core. Often the topsheet and outer cover are sealed
to encase the absorbent core. The segmented films and film
laminates of the present invention are particularly well suited for
use as an outer cover of a personal care article. Exemplary
personal care articles are described, by way of examples only, in
the following references: U.S. Pat. No. 5,415,644 to Enloe et al.;
U.S. Pat. No. 4,798,603 to Meyer et al.; U.S. Pat. No. 5,810,797 to
Menard et al.; U.S. Pat. No. 4,641,381 to Herren et al.; U.S. Pat.
No. 4,701,175 to Boland et al.; and U.S. Pat. No. 4,938,797 to Van
Gompel et al.; the entire content of the aforesaid references are
incorporated herein by reference. In addition, although the
following detailed description is made in the context of a
disposable diaper, one skilled in the art will appreciate that the
concepts of the present invention would also be suitable for use in
connection with other types of absorbent articles, particularly
other personal care products. In addition, although the present
invention is described in the context of several specific
configurations, it will be appreciated that further combinations or
alterations of the specific configurations discussed below may be
made by one skilled in the art without departing from the spirit
and scope of the present invention.
[0052] For example, a baffle for a diaper or incontinence garment
may include a continuous segmented film including a first segment
and second segments have an interface as described herein. The
baffle can be converted from the segmented film wherein the "ears"
of the diaper correspond with second regions and the central
portion of the article corresponds to one or more first segments.
The first segment desirably comprises a breathable film, such as
for example a monolithic film or a mono-layer or multi-layered
microporous film which can be elastic or inelastic. The second
segments desirably comprise an elastic segment with excellent
stretch and recovery properties, such as for example, film segments
comprising elastic polyurethane or KRATON/polyolefin blends. In a
further example, the segmented film may be converted such that the
segments run across the width of the article as opposed to the
length of the article. When the segments run across the width of
the article, the first region may include a breathable film
corresponding to the central portion of the article and the second
regions may include an elastic segment corresponding with the
"waist" of the article.
[0053] Segmented films and/or laminates thereof may likewise be
converted into surgical gowns, protective workwear and the like. In
this regard, medical apparel is often required to provide a higher
degree of protection to the wearer such as, for example, preventing
penetration of blood and/or blood-borne pathogens. By comprising a
segmented continuous film, good stretch and body conformance can be
achieved without loss of the desired barrier properties in the
desired areas. For example, surgical gowns or workwear may include
breathable barrier first segments having excellent WVTRs barrier
properties and the second segments may include elastic apertured
segments and provide the garment with additional improved stretch,
body conformance attributes, and breathability where barrier is not
required.
[0054] While various patents and other reference materials have
been incorporated herein by reference, to the extent there is any
inconsistency between incorporated material and that of the written
specification, the written specification shall control. In
addition, while the invention has been described in detail with
respect to specific embodiments thereof, it will be apparent to
those skilled in the art that various alterations, modifications
and other changes may be made to the invention without departing
from the spirit and scope of the present invention.
EXAMPLES
[0055] Example films having three segments were produced to
demonstrate the invention. The sample films were produced from a
Randcastle film die configured for making segmented films. The film
die had a main center feed port and a side edge port at the die end
plate was used. The side edge port was positioned 1.5 inches
upstream from the die lip where the segmented film exits the film
die. A feed block configured for making segmented films with entry
ports for two polymers was connected to the center feed port. The
feed block was positioned 10.5 inches upstream from the die lip
where the segmented film exits the film die. A first polymer
composition was used to create the center segment of the film. A
first extruder (twin screw Leistritz, 27 mm) was used to melt the
first polymer composition and feed it to one of the feed ports on
the feed block. A second polymer composition was used for the edge
segments. A second extruder (single screw 1.25'' Killion extruder)
was used to melt the second polymer composition. After exiting the
second extruder, the second polymer composition was split into two
flows using a "Y" block and two 8' heated polymer hoses set to the
same temperature. One flow stream was fed to one of the side edge
ports of the film die. The second flow stream was fed to the second
feed port on the feed block. The resultant film had a center
segment of the first polymer composition with two edge segments of
the second polymer composition.
[0056] Various first and second polymer compositions were used to
generate five films as shown in Table 1. In Table 1, "Kraton" is 68
wt. % styrene-ethylene-butylene-styrene block copolymer
(KRATON.RTM. MD6937, available from Kraton Polymers), 20 wt. %
tackifier (REGALREZ.TM. 1126, available from Eastman Chemical) and
12 wt. % polyethylene wax (EPOLENE.TM. C-10, available from Eastman
Chemical). "PE" is 70 wt. % polyethylene (DOWLEX.TM. 2047G,
available from The Dow Chemical Company) and 30 wt. % CaCO.sub.3
concentrate (25 wt. % polyethylene (DOWLEX.TM. 2047G) and 75 wt. %
CaCO.sub.3). "PP-PE" is 70 wt. % polypropylene (PP3155 available
from ExxonMobil Chemical Company) and 30 wt. % CaCO.sub.3
concentrate (25 wt. % polyethylene (DOWLEX.TM. 2047G) and 75 wt. %
CaCO.sub.3). "PP" is 100 wt. % polypropylene (PP3155).
[0057] Process conditions:
[0058] Twin screw extruder conditions: Zone1: 178 C, Zone2: 187 C,
Zone 3: 187 C, Zone 4: 180 C, Zone 5: 181 C, Zone 6:187 C, Zone 7:
197 C, Zone 8; 200 C, Flange: 200 C, Hose: 410 F, screw speed: 300
rpm, melt pressure: 800 psi.
[0059] Single screw Killion Extruder conditions: Zone1: 350 F, Zone
2: 390 F, Zone 3: 420 F, Flange and Melt Pump: 420 F, Melt Pump: 25
rpm, melt pressure: 500 psi, "Y" block 420 F, hoses from "Y" block
420 F.
[0060] Die, feedblock and end plate temperature settings: 420
F.
[0061] Winder speed: 20 fpm.
[0062] Tensile testing was done on the samples produced. Tensile
testing may be done on a Sintech Corp. constant rate of extension
tester 2/S with a computer-based data acquisition and frame control
system or equivalent with an appropriate load cell so that the peak
load falls between 10 and 90 percent of the full-scale load of the
load cell (Sintech Corp, of Cary, N.C.). The tests were conducted
under ambient conditions. For testing the strength of a single
seam, the sample size was 3 inches in the cross-machine direction
by 6 inches in the machine direction with the seam in generally in
the middle of the sample. The grip size was 3 inches in width. The
grip separation (gage length) was 4 inches at the start of the
test. For testing the strength of both edge seams in a single test,
the sample size and gage length were extended such that both edge
seams were between the jaws of the grips. Samples were pulled to
break at a speed of 12 inches per minute. Peak load, elongation
percent at peak load (as percentage of gage length), and energy at
break (area under the load-elongation curve from the origin to the
point of rupture) were recorded.
[0063] In general, the seams created by introducing the edge
polymer through the feedblock were found to be stronger (higher
peak load and energy) than the edge seams created by introducing
the edge polymer through the edge port. For the film in Ex. 1, the
center segment polymer composition was similar to the edge segment
polymer compositions, which is believed to have contributed to the
seams of that film having similar strengths. It is noted, though,
that when both seams were tested at the same time, the edge seam
created by feeding the edge polymer composition through the edge
port was the seam to fail.
TABLE-US-00001 TABLE 1 1st (center) polymer composition // 2.sup.nd
Feedblock Seam Edge Port Seam (edges) Peak Peak polymer Load Energy
Load Energy composition (gf) Elongation % (g-cm) (gf) Elongation %
(g-cm) Ex. 1 PP-PE // PP 17745 6.3 5002 18922 4.2 2792 Ex. 2 PP-PE
// 6613 305 57245 1799 128 13737 Kraton Ex. 3 PE // PP-PE NA NA NA
NA NA NA Ex. 4 PE // PE NA NA NA NA NA NA Ex. 5 Kraton // PE 6952
638 154406 4676 260 44078 Test done simultaneously Peak Load Energy
(gf) Elongation % (g-cm) Comment Ex. 1 PP-PE // PP 15136 56.4 4240
break at edge port side Ex. 2 PP-PE // 864 80.4 13763 break at edge
port Kraton side Ex. 5 Kraton // PE 3200 334 83720 no break, but
weakness appeared at the edge port side
[0064] Of note, for Examples 3 and 4 above, the film edge port seam
split during production of the film, so no tensile testing was
possible.
[0065] SEM photos of the seams for Example 5 are shown in FIGS. 2
and 3. FIG. 2 is an SEM photo of the edge port seam. FIG. 3 is an
SEM photo of the feedblock seam. In each photo, the second (edge)
segment 14 extends past or overlaps the first (center) segment 12
to a tip 22 of the second segment. It is evident from the SEM
photos that the feedblock seam extends much further than the edge
port seams, as further evidenced by calculations of T/t made for
the two photos. T/t for the edge port seam shown in FIG. 2 was 2.6
(50/19). T/t for the feedblock seam shown in FIG. 3 was 25
(75/3).
[0066] The thicknesses "T" and "t" are measured from SEM
photographs of cross sections of segmented films showing the tip of
the seam between two segments of the film. The SEM photographs, as
in FIGS. 2 and 3, are prepared as follows. A sample may be cut into
a lengthwise strip and marked at the cut ends. The strip is then
placed in liquid nitrogen and allowed to equilibrate for at least
two minutes. The sample is then bisectioned with a fresh single
edged razor against a stainless steel backplate while still
immersed in the liquid nitrogen. The blade is allowed to chill for
around 5 to 10 seconds prior to making the cut.
[0067] The sample is then mounted on a 25 mm SEM mount (specimen
stub) between small bars of aluminum such that the cut surface is
horizontal. The sample is then exposed to ruthenium tetraoxide
vapors for a period of 1 hour. The sample is allowed to outgas
overnight and then is evaluated in the scanning electron microscope
with no additional treatment or coating. The ruthenium stain reacts
with cyclic unsaturation causing compounds with styrenic
functionality to be aggressively stained. When an organic material
is stained with a heavy metal, the backscatter coefficient
increases causing the backscatter signal to increase, resulting in
brighter image details. Since the secondary electron image has a
backscatter component, this brightening effect from the stain is
often seen in these images as well.
[0068] A Hitachi S-4500 field emission scanning electron
microscope, or equivalent, may be used to evaluate the surface of
the cross-section at low voltage (800-1200 volts) using both a
microchannel plate (backscattered) and secondary electron detectors
at magnifications of 100 to 1,000 times. Digital images may be
acquired using a Quartz PCI image acquisition system, or
equivalent, that is interfaced to the microscope. The Quartz PCI
software, or equivalent, can also be used to make thickness and
other measurements.
[0069] While the invention has been described in detail with
respect to the specific embodiments thereof, it will be appreciated
that those skilled in the art, upon attaining an understanding of
the foregoing, may readily conceive of alterations to, variations
of, and equivalents to these embodiments. Accordingly, the scope of
the present invention should be assessed as that of the appended
claims and any equivalents thereto. As used herein, the term
"comprising" is inclusive or open-ended and does not exclude
additional unrecited elements, compositional components, or method
steps. In addition, it should be noted that any given range
presented herein is intended to include any and all lesser included
ranges. For example, a range of from 45-90 would also include
50-90; 45-80; 46-89 and the like.
* * * * *