Vapor-permeable, substantially water-impermeable multilayer article
This disclosure relates to an article that includes a nonwoven substrate, a first film supported by the nonwoven substrate, and a second film such that the first film is between the nonwoven substrate and the second film. The first film includes a first polymer and a pore-forming filler. The difference between a surface energy of the first film and a surface energy of the nonwoven substrate is at most about 10 mN/m. The second film includes a second polymer capable of absorbing and desorbing moisture and providing a barrier to aqueous fluids.
1. An article, comprising:
a nonwoven substrate;
a microporous breathable film supported by the nonwoven substrate, the microporous breathable film comprising a first polymer and a pore-forming filler, the difference between a surface energy of the microporous breathable film and a surface energy of the nonwoven substrate being at most about 10 mN/m; and
a monolithic breathable film comprising a second polymer capable of absorbing and desorbing moisture and providing a barrier to aqueous fluids, the microporous breathable film being between the nonwoven substrate and the monolithic breathable film;
wherein the article has a moisture vapor transmission rate of at least 35 g/m 2 /day and at most 140 g/m 2 /day when measured at 23° C. and 50 RH %.
2. The article of claim 1 , wherein the second polymer is selected from the group consisting of maleic anhydride block copolymers, glycidyl methacrylate block copolymers, polyether block copolymers, polyurethanes, polyethylene-containing ionomers, and mixtures thereof.
3. The article of claim 1 , wherein the second polymer is selected from the group consisting of poly(olefin-co-acrylate-co-maleic anhydride), poly(olefin-coacrylate-coglycidyl methacrylate), polyether ester block copolymers, polyether amide block copolymers, poly(ether ester amide) block copolymers, and polyurethanes.
4. The article of claim 1 , wherein the second polymer is selected from the group consisting of poly(ethyl-co-acrylate-co-maleic anhydride) and poly(ethlyeneco-acrylate-co-glycidyl methacrylate).
5. The article of claim 2 , wherein the monolithic breathable film further comprises a polyolefin.
6. The article of claim 5 , wherein the polyolefin comprises a polyethylene or a polypropylene.
7. The article of claim 6 , wherein the polyolefin comprises a polyethylene selected from the group consisting of low-density polyethylene, linear low-density polyethylene, high-density polyethylene, and copolymers thereof.
8. The article of claim 2 , wherein the monolithic breathable film further comprises a vinyl polymer.
9. The article of claim 8 , wherein the vinyl polymer comprises a copolymer formed between a first comonomer and a second comonomer, the first comonomer comprises ethylene, and the second comonomer comprises alkyl methacrylate, alkyl acrylate, or vinyl acetate.
10. The article of claim 8 , wherein the vinyl polymer comprises a poly(ethylene-co-methyl acrylate), a poly (ethylene-co-vinyl acetate), a poly (ethylene-coethyl acrylate), or a poly(ethylene-co-butyl acrylate).
11. The article of claim 2 , wherein the monolithic breathable film further comprises a compatibilizer.
12. The article of claim 11 , wherein the compatibilizer comprises polypropylene grafted with maleic anhydride (PP-g-MAH) or a polymer formed by reacting PP-g-MAH with a polyetheramine.
13. The article of claim 1 , wherein the monolithic breathable film comprises at least about 20% by weight of the second polymer; at least about 10% by weight of a vinyl polymer; at least about 5% by weight of a polyolefin; and at least about 0.1% by weight of a compatibilizer, based on the weight of the monolithic breathable film.
14. The article of claim 2 , wherein the monolithic breathable film further comprises a polyester.
15. The article of claim 14 , wherein the polyester is selected from the group consisting of a polybutylene terephthalate, a polyethylene terephthalate, and a polytrimethylene terephthalate.
16. The article of claim 1 , wherein the first polymer comprises a polyolefin or a polyester.
17. The article of claim 16 , wherein the first polymer comprises a polyethylene or a polypropylene.
18. The article of claim 16 , wherein the first polymer comprises a polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polyglycolide, polylactide, polycaprolactone, polyethylene adipate, polyhydroxyalkanoate, or a copolymer thereof.
19. The article of claim 1 , wherein the pore-forming filler comprises calcium carbonate.
20. The article of claim 19 , wherein the microporous breathable film comprises from about 30% by weight to about 70% by weight of the calcium carbonate.
21. The article of claim 1 , wherein the microporous breathable film further comprises a nanoclay.
22. The article of claim 21 , wherein the nanoclay is a montmorillonite clay.
23. The article of claim 1 , wherein the microporous breathable film further comprises an elastomer.
24. The article of claim 23 , wherein the elastomer is a propylene-ethylene copolymer.
25. The article of claim 1 , wherein the microporous breathable film is from about 2% to about 98% of the total weight of the microporous breathable film and monolithic breathable film.
26. The article of claim 1 , wherein the nonwoven substrate comprises randomly disposed polymeric fibers, at least some of the fibers being bonded to one another.
27. The article of claim 1 , wherein the article has a tensile strength of at least about 40 pounds in the machine direction as measured according to ASTM D5034.
28. The article of claim 1 , wherein the article has tensile strength of at least about 35 pounds in the cross-machine direction as measured according to ASTM D5034.
29. The article of claim 1 , wherein the article has a hydrostatic head of at least about 55 cm.
30. The article of claim 1 , wherein the article is embossed.
31. A construction material, comprising the article of claim 1 .
32. The construction material of claim 31 , wherein the construction material is a housewrap or a roofwrap.
33. The article of claim 1 , wherein the article has a hydrostatic head of at least 55 cm and the adhesion between the substrate and the first film is at least 200 gram-force/in.
34. The article of claim 1 , wherein the a weight ratio between the monolithic breathable film and the microporous breathable film is from 4:1 to 49:1.
35. The article of claim 34 , wherein the monolithic breathable film a comprises from 80% to about 95% of the total weight of the monolithic breathable film and microporous breathable film.
36. The article of claim 1 , wherein the microporous breathable film comprises a functionalized polyolefin; wherein the functionalized polyolefin is a polypropylene grafted with maleic anhydride (PP-g-MAH) or a polymer formed by reacting PP-g-MAH with a polyetheramine.
37. An article, comprising:
a nonwoven substrate;
a microporous breathable film supported by the nonwoven substrate, the microporous breathable film comprising a first polymer and a pore-forming filler, the difference between a surface energy of the microporous breathable film and a surface energy of the nonwoven substrate being at most about 10 mN/m; and
a monolithic breathable film comprising a second polymer selected from the group consisting of maleic anhydride block copolymers, glycidyl methacrylate block copolymers, polyether block copolymers, polyurethanes, polyethylene-containing ionomers, and mixtures thereof, the microporous breathable film being between the nonwoven substrate and the monolithic breathable film;
wherein the article has a moisture vapor transmission rate of at least 35 g/m 2 /day and at most 140 g/m 2 /day when measured at 23° C. and 50 RH %.
38. An article, comprising:
a nonwoven substrate;
a microporous breathable film supported by the nonwoven substrate, the microporous breathable film comprising a first polymer and a pore forming filler, the first polymer comprising a polyolefin or a polyester; and
a monolithic breathable film comprising a second polymer selected from the group consisting of maleic anhydride block copolymers, glycidyl methacrylate block copolymers, polyether block copolymers, polyurethanes, polyethylene-containing ionomers, and mixtures thereof, the microporous breathable film being between the nonwoven substrate and the monolithic breathable film;
wherein the article has a moisture vapor transmission rate of at least 35 g/m 2 /day and at most 140 g/m 2 /day when measured at 23° C. and 50 RH %.