Enhanced barrier multifunctional coatings for nylon films
View Patent ↗High barrier multilayer films are disclosed that incorporate a selectively permeable outer layer and a moisture barrier nanocomposite membrane. More particularly, insulation facing materials and insulation articles can incorporate an insulation facing material having a variable vapor barrier. The facing materials can include a moisture barrier membrane that incorporates a nanoclay.
1. A multilayer film comprising, in order:
a) a selectively permeable outer layer comprising a polyamide;
b) optionally an intermediate adhesive primer layer;
c) a moisture barrier membrane comprising a polyvinylidene chloride nanocomposite, said polyvinylidene chloride nanocomposite comprising an unmodified, non-intercalated, layered nanoclay dispersed in a polyvinylidene chloride polymer;
d) a first adhesive tie layer; and
e) a fibrous substrate on the first adhesive tie layer.
2. The multilayer film of claim 1 , wherein the moisture barrier membrane consists essentially of an unmodified, non-intercalated, layered nanoclay dispersed in a polyvinylidene chloride polymer.
3. The multilayer film of claim 1 , wherein the nanoclay content of the moisture barrier membrane is from greater than zero to about 2% by weight of the moisture barrier polymer.
4. The multilayer film of claim 1 , wherein the moisture barrier membrane consists of an unmodified, non-intercalated, layered nanoclay dispersed in a polyvinylidene chloride polymer.
5. The multilayer film of claim 1 , wherein the moisture barrier membrane has a coating weight of from about 0.05 lb/ream to about 1.2 lb/ream.
6. The multilayer film of claim 1 , wherein the moisture barrier membrane has a moisture permeability rate of about 0.5 perm or less at 25% RH and 21° C. as determined by ASTM E96, Procedure A (50% dry cup), and from about 5 perm to about 40 perm at 95% RH and 21° C. as determined by ASTM E96, Procedure B (90% wet cup).
7. The multilayer film of claim 1 , wherein the selectively permeable outer layer consists essentially of a biaxially oriented polyamide layer having a thickness of about 15 μm or less.
8. The multilayer film of claim 1 , wherein the fibrous substrate comprises a non-woven fabric comprising biodegradable polymeric fibers.
9. The multilayer film of claim 8 , wherein the fibrous substrate comprises multiple plies of non-woven fibers that are consolidated with a polymeric matrix material.
10. The multilayer film of claim 1 , wherein the optional intermediate adhesive primer layer is present, and wherein the fibrous substrate comprises multiple plies of non-woven fibers that are consolidated with a polymeric matrix material.
11. The multilayer film of claim 1 , wherein the amount of nanoclay in the moisture barrier membrane is from greater than zero to about 10% by weight relative to the weight of the moisture barrier polymer, and wherein the selectively permeable outer layer consists of a polyamide.
12. A multilayer article comprising an insulation material attached to the fibrous substrate of claim 1 via a second adhesive tie layer.
13. A multilayer film consisting of, in order:
a) a nylon 6 layer;
b) optionally, an intermediate adhesive primer layer;
c) a polyvinylidene chloride nanocomposite layer, said polyvinylidene chloride nanocomposite consisting of an unmodified, non-intercalated, layered nanoclay dispersed in a polyvinylidene chloride polymer;
d) a first adhesive tie layer; and
e) a fibrous substrate on the first adhesive tie layer.
14. A method of producing a multilayer film, comprising:
a) providing a selectively permeable outer layer comprising a polyamide;
b) optionally applying an intermediate adhesive primer layer onto the selectively permeable outer layer;
c) applying a moisture barrier membrane onto the selectively permeable outer layer, the moisture barrier membrane comprising a polyvinylidene chloride nanocomposite, said polyvinylidene chloride nanocomposite comprising an unmodified, non-intercalated, layered nanoclay dispersed in a polyvinylidene chloride polymer;
d) applying a first adhesive tie layer onto the moisture barrier membrane; and
e) applying a fibrous substrate on the first adhesive tie layer.
15. The method of claim 14 , further comprising attaching an insulation material to the fibrous substrate via a second adhesive tie layer.
16. The method of claim 14 , wherein the nanoclay content of the moisture barrier membrane is from greater than zero to about 2% by weight of the moisture barrier polymer.
17. The method of claim 14 , wherein the selectively permeable outer layer comprises a biaxially oriented polyamide layer having a thickness of about 15 μm or less.
18. The method of claim 14 , wherein the fibrous substrate comprises a non-woven fabric.
19. The method of claim 14 , wherein the moisture barrier membrane has a coating weight of from about 0.05 lb/ream to about 1.2 lb/ream.
20. The method of claim 14 , wherein the moisture barrier membrane has a moisture permeability rate of about 0.5 perm or less at 25% RH and 21° C. as determined by ASTM E96, Procedure A (50% dry cup), and from about 5 perm to about 40 perm at 95% RH and 21° C. as determined by ASTM E96, Procedure B (90% wet cup).