Granted Patent B2

US 11,866,863 · App. 17/121,929 · Granted Jan 9, 2024

Inventor: Mehdi Afshari (Midlothian, VA)

Assignee: BERRY GLOBAL, INC.

D04H1/4374B29C55/023B29C55/06B29C55/08B29C55/18B32B5/022B32B27/12B32B27/20B32B27/205B32B27/32B32B27/325C08L23/10D04H1/5412B32B2270/00B32B2307/724B32B2307/7265B32B2419/00C08L53/02C08L2203/16Y10T428/24612Y10T442/678

Abstract

Claims (23)

1. A method of making an article, comprising:

forming a laminate comprising a nonwoven substrate and a microporous breathable film consisting of a single-layer, wherein microporous breathable film is supported by the nonwoven substrate, wherein the single-layer microporous breathable film comprises a first polymer and a second polymer, the second polymer being immiscible with the first polymer, the first polymer comprises a polyolefin, and the second polymer comprises a polycycloolefin, a polymethylpentene, or a copolymer thereof; and

stretching the laminate to form the article;

wherein the article has a percent elongation at break of at least about 30% as determined according to ASTM D 5034, and a MVTR from 35 g/m 2 /day to 140 g/m 2 /day according to ASTM E96-A and measured at 23° C. and 50 RH %.

2. The method of claim 1 , wherein forming the laminate comprises extruding the film onto the nonwoven substrate.

3. The method of claim 1 , wherein the laminate is stretched and at an elevated temperature.

4. The method of claim 3 , wherein the elevated temperature is at least about 30° C.

5. The method of claim 1 , wherein the laminate is stretched in the machine direction.

6. The method of claim 1 , wherein the laminate is stretched in the cross-machine direction.

7. The method of claim 1 , wherein the laminate is stretched by a method selected from the group consisting of ring rolling, tentering, embossing, creping and button breaking.

8. The method of claim 1 , further comprising embossing the laminate prior to or after stretching the laminate.

9. The method of claim 1 , further comprising bonding randomly disposed polymeric fibers to produce the nonwoven substrate prior to forming the laminate.

10. The method of claim 1 , wherein the first polymer comprises at most about 99% of a total weight of the microporous breathable film and an amount of the second polymer comprises at least about 1% of the total weight of the microporous breathable film.

11. The method of claim 10 , wherein the second polymer has a polymer backbone similar to that of the first polymer such that at least about 5% by weight of the amount of the second polymer is blended with the first polymer.

12. The method of claim 10 , wherein at least about 30% by weight of the amount of the second polymer is blended with the first polymer.

13. The article of claim 10 , wherein 5-30% by weight of the amount of the second polymer is blended with the first polymer.

14. The method of claim 1 , wherein the second polymer comprises a poly(cycloolefin-co-olefin).

15. The method of claim 1 , wherein the second polymer comprises a poly(norbornene-co-ethylene) or a copolymer formed from ethylene and norbornene substituted with a substituent.

16. The method of claim 1 , wherein the first polymer comprises a polyethylene or a polypropylene.

17. The method of claim 1 , wherein the microporous breathable film is devoid of a pore-forming filler.

18. The method of claim 1 , wherein the microporous breathable film comprises a pore-forming filler.

19. The method of claim 18 , wherein the pore-forming filler comprises calcium carbonate.

20. The method of claim 1 , wherein the first polymer comprises a polyethylene or a polypropylene and accounts for at least 40% by weight of the microporous breathable film, and wherein the microporous breathable film is devoid of a pore-forming filler.

Assignments (25)

Continuity (5)