MULTI-LAYER, ELASTIC ARTICLES
The invention is an article comprising at least two layers, a low crystallinity layer and a high crystallinity layer. One or both layers is capable of being elongated so that a pre-stretched article is capable of being formed.
1 . An article having at least two layers, the article comprising (a) a low crystallinity layer and (b) a high crystallinity layer, wherein said article is capable of undergoing plastic deformation upon elongation and wherein said article comprises at least one ethylene/α-olefin interpolymer, wherein the ethylene/α-olefin interpolymer is a block copolymer comprising at least 50 mole percent ethylene and comprises one or more of the following criteria:
(a) has a Mw/Mn from 1.7 to 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm>− 2002.9+4538.5( d )−2422.2( d )2; or
(b) has a Mw/Mn from 1.7 to 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
Δ T>− 0.1299(Δ H )+62.81 for ΔH greater than zero and up to 130 J/g,
ΔT≧48° C. for ΔH greater than 130 J/g,
wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or
(c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re> 1481−1629( d ); or
(d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar, comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer;
(e) has a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is in the range of 1:1 to 9:1;
(f) an average block index greater than zero and up to 1.0 and a molecular weight distribution, Mw/Mn, greater than 1.3; or
(g) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to 1.
2 . The article of claim 1 , wherein the low crystallinity layer comprises a low crystallinity polymer and the high crystallinity layer comprises a high crystallinity polymer.
3 . The article of claim 1 , wherein the high crystallinity layer comprises a homopolymer or copolymer of propylene and one or more comonomers selected from ethylene and C4-C20 alpha-olefins.
4 . The article of claim 1 , wherein at least one layer of the article is capable of being elongated in at least one direction to an elongation of at least 50% of said article's original measurement at a temperature at or below the lowest melting point of the polymers comprising the article.
5 . The article of claim 1 , wherein at least one layer of the article has been elongated.
6 . The article of claim 1 in which the low crystallinity polymer and high crystallinity polymer have a difference in crystallinity of at least 3 weight percent.
7 . The article of claim 1 in which the low crystallinity polymer has a melting point as determined by Differential Scanning Calorimetry (DSC) that is greater than the melting point of the high crystallinity polymer.
8 . The article of claim 1 in which at least one high crystallinity layer comprises a nonwoven layer.
9 . The article of claim 1 in which at least one low crystallinity layer comprises a nonwoven layer.
10 . The article of claim 1 in which at least one high crystallinity layer comprises a film layer.
11 . The article of claim 1 in which at least one high crystallinity layer comprises a film layer and at least one low crystallinity layer comprises a film layer.
12 . The article of claim 1 in which at least one high crystallinity layer comprises a nonwoven layer and at least one low crystallinity layer comprises a film layer.
13 . An article comprising a multi-layer film comprising (a) a low crystallinity film non-skin layer comprising a low crystallinity polymer and (b) at least two high crystallinity film layers, wherein said article is capable of undergoing plastic deformation upon elongation and wherein said low crystallinity film layer comprises at least one ethylene/α-olefin interpolymer, wherein the ethylene/α-olefin interpolymer comprises one or more of the following criteria:
(a) has a Mw/Mn from 1.7 to 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm>− 2002.9+4538.5( d )−2422.2( d )2; or
(b) has a Mw/Mn from 1.7 to 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
Δ T>− 0.1299(Δ H )+62.81 for ΔH greater than zero and up to 130 J/g,
ΔT≧48° C. for ΔH greater than 130 J/g,
wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or
(c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re> 1481−1629( d ); or
(d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer;
(e) has a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is in the range of 1:1 to 9:1 and wherein at least one high crystallinity layer comprises a polymer selected from the group consisting of a propylene homopolymer, a copolymer of propylene and one or more comonomers selected from ethylene and C4-C20 alpha-olefins, an ethylene homopolymer, and a copolymer of ethylene and one or more comonomers selected from ethylene and C3-C20 alpha-olefins;
(f) an average block index greater than zero and up to 1.0 and a molecular weight distribution, Mw/Mn, greater than 1.3; or
(g) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to 1.
14 . An article comprising a multi-layer laminate comprising (a) a low crystallinity film or nonwoven non-skin layer comprising a low crystallinity polymer and (b) at least two high crystallinity film or nonwoven layers wherein said article is capable of undergoing plastic deformation upon elongation and wherein said low crystallinity film layer comprises at least one ethylene/α-olefin interpolymer, wherein the ethylene/α-olefin interpolymer comprises one or more of the following criteria:
(a) has a Mw/Mn from 1.7 to 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm>− 2002.9+4538.5( d )−2422.2( d )2; or
(b) has a Mw/Mn from 1.7 to 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
Δ T>− 0.1299(Δ H )+62.81 for ΔH greater than zero and up to 130 J/g.
ΔT≧48° C. for ΔH greater than 130 J/g,
wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or
(c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re> 1481−1629( d ); or
(d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer;
(e) has a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is in the range of 1:1 to 9′, 1 and wherein said high crystallinity layer(s) comprises a polymer selected from the group consisting of a propylene homopolymer, a copolymer of propylene and one or more comonomers selected from ethylene and C4-C20 alpha-olefins, an ethylene homopolymer, and a copolymer of ethylene and one or more comonomers selected from ethylene and C3-C20 alpha-olefins;
(f) an average block index greater than zero and up to 1.0 and a molecular weight distribution, Mw/Mn, greater than 1.3; or
(g) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to 1.
15 . The article of claim 14 , wherein the high crystallinity film or nonwoven layer(s) comprises a polymer selected from the group consisting of homogeneously branched polymers, LLDPE, LDPE, HDPE, SLEP, hPP, and PP plastomers and PP elastomers, and RCP.
16 . The article of claim 14 , wherein said low crystallinity film layer is a blown film and wherein said ethylene/α-olefin interpolymer has a melt index (ASTM D1238 condition 190 C/2.16 kg) of from 0.5 to 5 g/10 minutes.
17 . The article of claim 14 in which the multi-layer laminate comprises a third layer located between the low crystallinity layer and the high crystallinity layer.
18 . The article of claim 14 in which the multi-layer laminate comprises a third layer, wherein the low crystallinity layer is located between the third layer and the high crystallinity layer.
19 . The article of claim 18 , wherein the third layer comprises a second high crystallinity polymer.
20 . The article of claim 14 , wherein the multi-layer laminate has a haze value of greater than 70%.
21 . The article of claim 14 wherein the multi-layer laminate has a permanent set of less than 30% after a 50% hysteresis test.
22 . A garment portion comprising an article of claim 14 adhered to a garment substrate.
23 . An article of claim 14 , wherein the multi-layer film comprises at least one elongated film layer.
24 . The article of claim 14 in which at least one film layer is cross-linked.
25 . A fiber comprising (a) a low crystallinity polymer and (b) a high crystallinity polymer, wherein said fiber is capable of undergoing plastic deformation upon elongation and wherein said low crystallinity polymer comprises at least one ethylene/α-olefin interpolymer, wherein the ethylene/α-olefin interpolymer is a block copolymer comprising at least 50 mole percent ethylene and comprises at least one criteria selected from the group consisting of:
(a) has a Mw/Mn from 1.7 to 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm>− 2002.9+4538.5( d )−2422.2( d )2; or
(b) has a Mw/Mn from 1.7 to 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
Δ T>− 0.1299(Δ H )+62.81 for ΔH greater than zero and up to 130 J/g,
ΔT≧48° C. for ΔH greater than 130 J/g,
wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or
(c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re> 1481−1629( d ); or
(d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction elating between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer;
(e) has a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100 C), wherein the ratio of G′(25° C.) to G′(100° C.) is in the range of 1:1 to 9:1 and wherein said high crystallinity polymer comprises a polymer selected from the group consisting of a propylene homopolymer, a copolymer of propylene and one or more comonomers selected from ethylene and C4-C20 alpha-olefins, an ethylene homopolymer, and a copolymer of ethylene and one or more comonomers selected from ethylene and C3-C20 alpha-olefins;
(f) an average block index greater than zero and up to 1.0 and a molecular weight distribution, Mw/Mn, greater than 1.3; or
(g) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to 1.
26 . The fiber of claim 25 , wherein the high crystallinity polymer comprises a polymer selected from the group consisting of LLDPE, LDPE, HDPE, SLEP, hPP, and RCP.
27 . The fiber of claim 25 in the form of a bicomponent fiber in which the high crystallinity polymer comprises at least a portion of the surface of the fiber.
28 . The fiber of claim 25 in the form of a bicomponent fiber in which the low crystallinity polymer comprises at least a portion of the surface of the fiber.
29 . A web comprising the fiber of claim 25 .
30 . The web of claim 29 in which at least a portion of the fibers are bonded to each other.
31 . The fiber of claim 25 in which the high crystallinity polymer, low Crystallinity polymer, or both, further comprises succinic acid or succinic anhydride functionality.
32 . The fiber of claim 25 in which the high crystallinity layer comprises at least one Ziegler-Natta, metallocene or single site catalyzed polyolefin and the low crystallinity layer comprises a propylene-based polymer.
33 . An article comprising (a) a fiber comprising a low crystallinity polymer and (b) a high crystallinity polymer, wherein said article is capable of undergoing plastic deformation upon elongation and wherein said low crystallinity polymer comprises at least one ethylene/α-olefin interpolymer, wherein the ethylene/α-olefin interpolymer comprises at least one criteria selected from the group consisting of:
(a) has a Mw/Mn from 1.7 to 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm>− 2002.9+4538.5( d )−2422.2( d )2; or
(b) has a Mw/Mn from 1.7 to 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
Δ T>− 0.1299(Δ H )+62.81 for ΔH greater than zero and up to 130 J/g,
ΔT≧48° C. for ΔH greater than 130 J/g,
wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or
(c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re> 1481−1629( d ); or
(d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer;
(e) has a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is in the range of 1:1 to 9:1 and wherein said high crystallinity polymer comprises a polymer selected from the group consisting of a propylene homopolymer, a copolymer of propylene and one or more comonomers selected from ethylene and C4-C20 alpha-olefins, an ethylene homopolymer, and a copolymer of ethylene and one or more comonomers selected from ethylene and C3-C20 alpha-olefins;
(f) an average block index greater than zero and up to 1.0 and a molecular weight distribution, Mw/Mn, greater than 1.3, or
(g) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to 1.
34 . The article of claim 33 further comprising at least one nonwoven layer, wherein said layer comprises high crystallinity polymer (b).
35 . An article comprising: A) a first layer of filaments comprising a low crystallinity polymer; B) a second layer of elastomeric meltblown fibers, said meltblown fibers bonded to at least a portion of the first layer filaments; C) a third layer of spunbond fibers; and, D) a fourth layer of spunbond fibers; wherein said first and second layers are disposed between said third and fourth layers; wherein the low crystallinity polymer comprises at least one criteria selected from the group consisting of:
(a) has a Mw/Mn from 0.7 to 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm>− 2002.9+4538.5( d )−2422.2( d )2; or
(b) has a Mw/Mn from 1.7 to 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
Δ T>− 0.1299(Δ H )+62.81 for ΔH greater than zero and up to 130 J/g,
ΔT≧48° C. for ΔH greater than 130 J/g,
wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or
(c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re> 1481−1629( d ); or
(d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer;
(e) has a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is in the range of 1:1 to 9:1;
(f) an average block index greater than zero and up to 1.0 and a molecular weight distribution, Mw/Mn, greater than 1.3; or
(g) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to 1.
36 . The article of claim 35 , wherein (C) and (D) are skin or surface layers.