Method for preparing a selectively permeable protective structure

1. A method for preparing a selectively permeable multilayer structure or article comprising:

(1) preparing a first composition comprising

(i) one or more ethylene acid copolymers; and

(ii) one or more organic acids; wherein at least 50% of the combined acidic groups in the acid copolymer and the organic acid are nominally neutralized to salts with metal ions and at least 50% of the metal ions are alkali metal ions;

(2) melt blending the first composition with one or more ethylene-containing polymers selected from the group consisting of polyethylene (PE) homopolymers, copolymers of ethylene and an α-olefin, copolymers of ethylene and a diolefin, and ethylene copolymers obtained from copolymerization of ethylene with at least one polar monomer selected from the group consisting of vinyl acetate, acrylic ester, methacrylic ester and carbon monoxide, wherein ethylene-containing polymer does not comprise a dicarboxylic acid derivative, to provide a second composition;

(3) melt blending the second composition with a polymer comprising 0.1 to 15 weight % of a dicarboxylic acid derivative selected from the group consisting of maleic anhydride, citraconic anhydride, itaconic anhydride, tetrahydrophthalic anhydride, monoalkyl esters of maleic acid, fumeric acid, citraconic acid, itaconic acid or tetrahydrophthalic acid, and combinations thereof, to provide a third composition in a molten condition;

(4) contacting a substrate with the molten third composition to adhere, embed, or impregnate the melted composition to the substrate or adhere, embed, or impregnate the substrate to the molten third composition to provide a coated substrate with the third composition in a molten condition;

(5) cooling the coated substrate to allow the molten third composition to cool and solidify.

2. The method of claim 1 wherein the substrate comprises textile or porous sheet material.

3. The method of claim 2 wherein the substrate is one or more porous films, flash spun non-woven fabrics, woven fabrics of synthetic fibers, natural fibers or combinations thereof, scrims, or filter materials.

4. The method of claim 3 wherein the substrate is a woven fabric of synthetic fibers, natural fibers or combinations thereof.

5. The method of claim 1 wherein at least 50% of the metal ions are sodium ions.

6. The method of claim 1 wherein at least 50% of the metal ions are potassium ions.

7. The method of claim 1 wherein the ethylene-containing polymer is selected from the group consisting of ethylene copolymers obtained from copolymerization of ethylene with at least one polar monomer selected from the group consisting of vinyl acetate, acrylic ester, methacrylic ester and carbon monoxide.

8. The method of claim 7 wherein the ethylene-containing polymer is an ethylene/alkyl acrylate or ethylene/alkyl methacrylate copolymer.

9. The method of claim 1 wherein both the ethylene-containing polymer and the dicarboxylic acid derivative-containing copolymer are blended simultaneously with the first composition.

10. The method of claim 1 wherein the third composition comprises

(a) 30 to 50 weight %, based on the combination of (a), (b) and (c), of a blended combination of

(1) 70 to 96 weight %, based on the combination of (1) and (2), of one or more E/X/Y ethylene acid copolymers or ionomers of the acid copolymers wherein E represents copolymerized units of ethylene, X is present in about 2 to about 35 weight % of the copolymer and represents copolymerized units of at least one C 3 to C 8 α,β-ethylenically unsaturated carboxylic acid, and Y is present in 0 to about 35 weight % of the copolymer and represents copolymerized units of alkyl acrylate or alkyl methacrylate;

(2) 4 to 30 weight %, based on the combination of (1) and (2), of one or more organic acids having from 4 to 36 carbon atoms, or salts thereof; wherein at least 50% of the combined acidic groups in the E/X/Y copolymer and the organic acid are nominally neutralized to salts with metal ions; wherein at least 50% of the metal ions are alkali metal ions;

(b) 40 to 60 weight %, based on the combination of (a), (b) and (c), one or more ethylene-containing polymers selected from the group consisting of polyethylene homopolymers, copolymers of ethylene and an α-olefin, copolymers of ethylene and a diolefin, and ethylene copolymers obtained from copolymerization of ethylene with at least one polar monomer selected from the group consisting of vinyl acetate, acrylic ester, methacrylic ester and carbon monoxide, wherein the ethylene-containing polymer does not comprise a dicarboxylic acid derivative; and

(c) 1 to 15 weight %, based on the combination of (a), (b) and (c), of the polymer comprising 0.1 to 15 weight % of a dicarboxylic acid derivative; wherein (a), (b) and (c) total 100 weight %.

11. The method of claim 10 wherein the ethylene-containing polymer is selected from the group consisting of ethylene copolymers obtained from copolymerization of ethylene with at least one polar monomer selected from the group consisting of vinyl acetate, acrylic ester, methacrylic ester and carbon monoxide.

12. The method of claim 11 wherein the ethylene-containing polymer is an ethylene/alkyl acrylate or ethylene/alkyl methacrylate copolymer.

13. The method of claim 11 wherein both the ethylene-containing polymer and the dicarboxylic acid derivative-containing copolymer are blended simultaneously with the first composition.

14. The method of claim 10 wherein the third composition comprising (a), (b) and (c) has greater adhesion to the substrate than a corresponding composition comprising an equal amount of (a) and an amount of (b) equal to the amount of (b) and (c) in the third composition.

15. The method of claim 1 wherein the third composition has a moisture vapor permeation value of at least 200 g-mil/m 2 /24 h measured at 37.8° C. and 100% relative humidity according to ASTM D-6701-01 and high water-entry pressure.

16. The method of claim 1 wherein the selectively permeable structure has a moisture vapor transmission rate of at least 30 g/m 2 /24 h measured at 37.8° C. and 100% relative humidity according to ASTM D-6701-01.