Granted Patent B2

US 11,123,965 · App. 16/449,762 · Granted Sep 21, 2021

Inventor: Mehdi Afshari (Midlothian, VA)

Assignee: Fiberweb Inc.

B32B27/12B32B5/022B32B5/24B32B27/285B32B27/308B32B27/32B32B27/40B32B37/153B32B2262/0253B32B2305/20B32B2307/7246B32B2307/7265B32B2419/00B32B2419/06Y10T442/676Y10T442/678

Abstract

Claims (20)

1. A method of forming a multilayer article, comprising: applying a first film layer onto a nonwoven substrate; wherein the first film layer is a monolithic film and comprises (i) a first polymer comprising a polyolefin grafted with an anhydride, an acid, or an acrylate; (ii) a second polymer that is different from the first polymer and comprising from 30% by weight to 35% by weight of the first film layer, the second polymer being selected from the group consisting of maleic anhydride block copolymers, glycidyl methacrylate block copolymers, polyether block copolymers, polyurethanes, polyethylene-containing ionomers, and mixtures thereof and (iii) from at least about 1% by weight to at most about 10% by weight of a polar compound comprising a polyetheramine.

2. The method of claim 1 , wherein applying the first film comprises extrusion coating the first film onto the nonwoven substrate.

3. The method of claim 1 , wherein the polyolefin comprises a homopolymer or copolymer.

4. The method of claim 1 , wherein the polyolefin comprises a polyethylene, a polypropylene, a poly(ethylene-co-vinyl acetate), or a poly(ethylene-co-acrylate).

5. The method of claim 1 , wherein the first polymer comprises a low-density polyethylene grafted with an anhydride, a linear low-density polyethylene grafted with an anhydride, a high-density polyethylene grafted with an anhydride, a polypropylene grafted with an anhydride, a poly(ethylene-co-acrylate) grated with an anhydride or an acid, and a poly(ethylene-co-vinyl acetate) grafted with an anhydride, an acid, or an acrylate.

6. The method of claim 1 , wherein the first film comprises from about 1% by weight to about 20% by weight of the first polymer.

7. The method of claim 1 , wherein the second polymer is selected from the group consisting of poly(olefin-co-acrylate-co-maleic anhydride), poly(olefin-co-acrylate-co-glycidyl methacrylate), polyether ester block copolymers, polyether amide block copolymers, poly(ether ester amide) block copolymers, and polyurethanes.

8. The method of claim 1 , wherein the second polymer is selected from the group consisting of polyether ester block copolymers, poly(ethylene-co-acrylate-co-maleic anhydride), and poly(ethylene-co-acrylate-co-glycidyl methacrylate).

9. The method of claim 1 , wherein the first film further comprises a vinyl polymer.

10. The method of claim 9 , wherein the first film comprises from about 20% by weight to about 50% by weight of the vinyl polymer.

11. The method of claim 1 , further comprising embossing the multilayer article.

12. The method of claim 1 , further comprising positioning an intermediate film layer between the first film layer and the nonwoven substrate.

13. The method of claim 12 , wherein the intermediate film layer comprises a third polymer comprising a polyolefin grafted with an anhydride, an acid, or an acrylate selected to improve adhesion to the nonwoven substrate; wherein the third polymer is the same or different than the first polymer.

14. The method of claim 1 , wherein the nonwoven substrate comprises randomly disposed continuous polymeric fibers, at least some of the fibers being bonded to one another.

15. The method of claim 1 , wherein the first film comprises a first weight ratio between the first polymer to the polar compound comprising from about 5.6:1 to about 4:1, and wherein a sum of the first polymer, the second polymer, and the polar compound comprises from about 50 to 55% by weight of the film layer.

16. The method of claim 1 , wherein the multilayer article has a moisture vapor transmission rate of at least about 8.5 perms, an adhesion strength between the nonwoven substrate and the first film is at least about 200 gram-force/in, or both.

17. A method of forming a multilayer article, comprising: extrusion coating a monolithic film onto a spunbond nonwoven; wherein the monolithic film comprises

(i) a first polymer comprising from about 5% by weight to 12% by weight of the monolithic film, the first polymer comprises a polyolefin grafted with an anhydride, an acid, or an acrylate;

(ii) a second polymer comprising from 30% by weight to 35% by weight of the monolithic film, the second polymer comprising a polyether amide block copolymer that is capable of absorbing and desorbing moisture and providing a barrier to aqueous fluids, and

(iii) from at least about 1% by weight to at most about 3% by weight of a polyetheramine.

Assignments (35)