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1. (WO2019005814) FILMS MULTICOUCHES RESPIRANTS ET STRATIFIÉS EN COMPRENANT
Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

THAT WHICH IS CLAIMED:

1. A breathable multilayer film comprising:

a monolithic core layer comprising a core-layer composition; wherein the core-layer composition comprises a core-layer highly breathable polymer and has a core-layer water absorption rate; and

at least a first skin layer comprising a first-skin-layer composition; wherein the first-skin-layer composition comprises a first-skin-layer highly breathable polymer and has a first-skin-layer water absorption rate;

wherein the core-layer water absorption rate is at least about 10 times larger than first-skin-layer water absorption rate.

2. The film of claim 1 , wherein the core-layer water absorption rate is from at least about 10 to about 50 times larger than first-skin-layer water absorption rate, such as from at least about 10 to about 45, 40, 35, 30, 25, 20, or 15 times larger than first-skin-layer water absorption rate.

3. The film of any of the preceding claims, wherein the breathable multilayer film comprises at least one of (i) an average density being less than about 1.0 g/cc, such as from about 0.4 to about 0.9 g/cc, or from about 0.4 to about 0.8 g/cc, or from about 0.4 to about 0.7 g/cc, or from about 0.4 to about 0.6 g/cc and/or (ii) a contact angle from about 60 to about 70 degrees as determined according to ASTM D5946, such as from about 62 to about 68 degrees, or from about 65 to about 68 degrees.

The film of any of the preceding claims, wherein the core-layer water absorption rate comprises at least about 15% as determined according to ISO 62, such as from about 15% to about 150%, or from about 15% to about 130%, or from about 15% to about 120%, or from about 15% to about 110%, or from about a 15% to about 100%, 90%, 80%, 70%, 60%, 50%, 40%, or 30% as determined according to ISO 62.

The film of any of the preceding claims, wherein the first-skin-layer water absorption rate comprises less than about 5% as determined according to ISO 62.

The film of claim 5, wherein the first-skin-layer water absorption rate comprises from about 5% to about 0.5% as determined according to ISO 62, such as from about 4% to about 0.5%, or from about 3% to about 0.5%, or from about 2% to about 0.5% as determined according to ISO 62.

The film of any of the preceding claims, wherein the first-skin layer is monolithic.

The film of any of the preceding claims, further comprising a second skin layer; wherein the monolithic core layer is directly or indirectly sandwiched between the first skin layer and the second skin layer.

The film of claim 8, wherein the second skin layer comprises a second-skin-layer composition, the second-skin-layer composition comprises a second-skin-layer highly breathable polymer and has a second-skin-layer water absorption rate, and wherein the core-layer water absorption rate is at least about 10 times larger than second-skin-layer water absorption rate.

10. The film of claim 9, wherein the core-layer water absorption rate is from at least about 10 to about 50 times larger than second-skin-layer water absorption rate, such as from at least about 10 to about 45, 40, 35, 30, 25, 20, or 15 times larger than second-skin-layer water absorption rate.

11. The film of any claim 10, wherein the second-skin-layer water absorption rate comprises less than about 5% as determined according to ISO 62.

12. The film of claim 11, wherein the second-skin-layer water absorption rate

comprises from about 5% to about 0.5% as determined according to ISO 62, such as from about 4% to about 0.5%, or from about 3% to about 0.5%, or from about 2% to about 0.5% as determined according to ISO 62.

13. The film of any of the preceding claims, wherein the second-skin layer is

monolithic.

14. The film of any of the preceding claims, wherein at least one of the first-skin-layer composition, the second-skin-layer composition, or the core-layer composition is devoid of a soft polymer having a T below 0°C.

15. The film of any of the preceding claims, wherein at least one of the first-skin-layer composition, the second-skin-layer composition, or the core-layer composition is devoid of a pore-forming filler.

16. The film of any of the preceding claims, wherein the multilayer film is co- extruded.

17. The film of any of the preceding claims, wherein the multilayer film comprises an MVTR of at least 700 g/m2/day as determined by ASTM Test Method E-96D, such as at least about 700 g/m2/day, or 1000 g/m2/day, or 1300 g/m2/day as determined by ASTM Test Method E-96D.

18. The film of any of the preceding claims, wherein the multilayer film has a basis weight comprising from about 5 to about 30 gsm, such as from about 10 to about 20 gsm or from about 10 to about 15 gsm.

19. The film of any of the preceding claims, wherein the multilayer film comprises a thickness from about 10 microns to about 50 microns, such as from about 10 microns to about 30 microns, or from about 10 microns to about 25 microns, or from about 10 microns to about 20 microns.

20. The film of any of the preceding claims, wherein the core layer has a core-layer thickness, the first skin layer has a first-skin-layer thickness, the second skin layer has a second-skin-layer thickness, and the core-layer thickness is greater than each of the first-skin-layer thickness and the second-skin-layer thickness.

21. The film of claim 20, wherein the core-layer thickness is greater than an aggregate of the first-skin-layer thickness and the second-skin-layer thickness.

22. The film of any of the preceding claims, wherein the core layer comprises a top surface and a bottom surface, and the first skin layer is positioned above and at least one of proximate or adjacent to at least a portion of the top surface of the core layer.

23. The film of any of the preceding claims, wherein the second skin layer is

positioned below and at least one of proximate or adjacent to at least a portion of the bottom surface of the core layer.

24. The film of any of the preceding claims, wherein the multilayer film comprises no more than 50% by weight of the first skin layer, the second skin layer, or an aggregate of the first skin layer and the second skin layer, such as no more than about 25% by weight, no more than about 20% by weight, no more than about 10% by weight, no more than about 5% by weight, or no more than about 3% by weight of the first skin layer, the second skin layer, or an aggregate of the first skin layer and the second skin layer.

25. The film of any of the preceding claims, wherein the core-layer highly breathable polymer comprises at least one of a thermoplastic urethane, a poly ether-block- amide copolymer, a polyether-block-ester copolymer, polyester-block-amide copolymer, or a copoly ester thermoplastic elastomer.

26. The film of claim 25, wherein the core-layer highly breathable polymer comprises a polyether-block-ester copolymer including (i) soft blocks comprising polyethylene glycol and (ii) hard blocks comprising polybutylterephthalate.

27. The film of any of the preceding claims, wherein the first skin layer, the second skin layer, or both are less hygroscopic than the core layer.

28. The film of any of the preceding claims, wherein at least the first skin lay

tacky than the monolithic core layer.

29. The film of any of the preceding claims, wherein at least the first skin lay

tacky than the second skin layer.

30. The film of any of the preceding claims, wherein the first-skin-layer highly breathable polymer, the second-skin-layer highly breathable polymer, or both comprise at least one of a thermoplastic urethane, a poly ether-block-amide copolymer, a poly ether-block-ester copolymer, polyester-block-amide copolymer, or a copoly ester thermoplastic elastomer.

31. A laminate, comprising:

(a) a breathable multilayer film according to any of the preceding claims; and

(b) at least a first fibrous layer.

32. The laminate of claim 31, wherein the first fibrous layer comprises a first

nonwoven material.

33. The laminate of claims 31-32, wherein the first nonwoven material comprises a spunbond layer, a meltblown layer, a sub-micron layer, or any combination thereof.

34. The laminate of claims 31-33, wherein the breathable multilayer film and the first fibrous layer are laminated via a first adhesive layer positioned between the breathable multilayer film and the first fibrous layer.

35. The laminate of claim 34, wherein the first adhesive layer comprises a

discontinuous coating of adhesive.

36. The laminate of claim 35, wherein the discontinuous coating of adhesive comprises a fiberized or nebulized hotmelt adhesive.

37. The laminate of claim 35, wherein the discontinuous coating of adhesive comprises an aqueous or solvent-based adhesive.

38. The laminate of claims 31-33, wherein the first adhesive layer comprises a

continuous coating of adhesive; wherein the adhesive comprises a hotmelt adhesive, solvent-based adhesive, or aqueous-based adhesive.

39. The laminate of any one of claims 31-33, wherein the breathable multilayer film is melt-extruded directly onto the first fibrous layer.

40. The laminate of any one of claims 31-39, wherein the laminate comprises an item of protective apparel or a portion thereof.

41. The laminate of claim 40, wherein the item of protective apparel or portion thereof comprises a surgical gown, a surgical drape, or a protective apron.

42. The laminate of claims 31-41, further comprising a second fibrous layer

comprising a second nonwoven material, wherein the breathable multilayer film is directly or indirectly sandwiched between the first fibrous layer and the second fibrous layer.

43. The laminate of claim 42, wherein the second nonwoven material comprises a spunbond layer, a meltblown layer, a sub-micron layer, or any combination thereof.

44. The laminate of claim 43, wherein the breathable multilayer film and the second fibrous layer are laminated via a second adhesive layer positioned between the breathable multilayer film and the second fibrous layer.

45. The laminate of claim 44, wherein the adhesive layer comprises a discontinuous coating of adhesive, such as a fiberized or nebulized hotmelt adhesive or an aqueous or solvent-based adhesive.

46. The laminate of claims 42-43, wherein the adhesive layer comprises a continuous coating of adhesive, wherein the adhesive comprises a hotmelt adhesive, solvent- based adhesive, or aqueous-based adhesive.

47. The laminate of any one of claims 42-43, wherein the breathable multilayer film is melt-extruded directly between the first fibrous layer and the second fibrous layer.

48. The laminate of any one of claims 42-47, wherein the laminate comprises an item of protective apparel or a portion thereof.

49. The laminate of claim 48, wherein the item of protective apparel or portion thereof comprises a surgical gown, a surgical drape, or a protective apron.

50. The laminate of claims 31-49, wherein at least the first fibrous layer, the breathable multilayer film, and optionally the second fibrous layer all have substantially the same width.

51. The laminate of claims 31-49, wherein the first fibrous layer includes a first width and the breathable multilayer film has a second width, wherein the first width is different than the second width.

52. The laminate of claim 51, wherein the first width is greater than the second width, and the first fibrous layer and the breathable multilayer film are adhesively bonded together along only the second width.

53. The laminate of claim 51, wherein the first width is smaller than the second width, and the first fibrous layer and the breathable multilayer film are adhesively bonded together along only the first width.

54. The laminate of claims 31-49, wherein the first fibrous layer includes a first width, the breathable multilayer film has a second width, the second fibrous layer has a third width; wherein the second width is different than the first width and the third width.

55. The laminate of claim 54, wherein the first fibrous layer and the breathable

multilayer film are adhesively bonded together along only the second width; and the second fibrous layer and the breathable multilayer film are adhesively bonded together along only the second width.

56. The laminate of claim 54, wherein the first width and the third width are substantially the same and greater than the second width; and wherein the laminate is adhesively bonded together about the first width.

57. A process for forming a breathable multilayer film, comprising co-extruding a multilayer film according to any of claims 1 -30.

58. The process of claim 57, further comprising:

(a) forming a core-layer polymer melt;

(b) forming a first-skin-layer polymer melt;

(c) co-extruding the core-layer polymer melt and the first-skin-layer polymer melt to form a monolithic core layer and a first skin layer.

The process of claims 57-58, further comprising:

(a) forming a second-skin-layer polymer melt;

(b) co-extruding the core-layer polymer melt, the first-skin-layer polymer melt, and the second-skin-layer polymer melt to form the monolithic core layer, the first skin layer, and a second skin layer.

60. A process for forming a laminate according to claims 31-56, comprising:

(a) forming a core-layer polymer melt;

(b) forming a first-skin-layer polymer melt;

(c) co-extruding the core-layer polymer melt and the first-skin-layer polymer melt to form a monolithic core layer and a first skin layer to form a multilayer film; and

(d) laminating the first skin layer of the multilayer film to a first fibrous layer.

The process of claim 60, further comprising:

(a) forming a second-skin-layer polymer melt;

(b) co-extruding the core-layer polymer melt, the first-skin-layer polymer melt, and the second-skin-layer polymer melt to form the monolithic core layer, the first skin layer, and a second skin layer to form a multilayer film; and

(c) laminating the second skin layer of the multilayer film to a second fibrous layer.

62. A process for forming a laminate according to claims 31-56, comprising:

(a) providing the breathable multilayer film; and

(b) laminating the first skin layer of the breathable multilayer film to the first fibrous layer.