# US 11,028,241 B2 · Breathable films and method of making the same

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- Number: US 11,028,241 B2
- Document ID: US11028241B2
- Status: Granted
- Kind: B2
- Application number: 16/081,529
- Filed: 2017-03-03
- Published: 2021-01-14
- Granted: 2021-06-08
- Earliest claimed: 2016-03-03
- Assignees: Dow Global Technologies LLC
- Applicants: Dow Global Technologies LLC
- Inventors: Barbara Bonavoglia; Selim Bensason; Jesus Nieto; Cornelis F. J. Den Doelder
- Web page: https://patentgrep.com/patent/US11028241B2

## CPC

- C08J 5/18: Manufacture of films or sheets
- B29C 48/0017: {combined with blow-moulding or thermoforming}
- B29C 48/08: flexible, e.g. films
- B32B 7/04: Interconnection of layers
- B32B 7/08: by mechanical means
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/327: {comprising polyolefins obtained by a metallocene or single-site catalyst}
- C08K 3/26: Carbonates; Bicarbonates
- C08L 23/06: Polyethylene
- C08L 23/0815: {with aliphatic 1-olefins containing one carbon-to-carbon double bond}
- C08L 23/12: Polypropene
- B29K 2023/0625: {LLDPE, i.e. linear low density polyethylene}
- B29K 2995/005: Oriented
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 2250/24: All layers being polymeric
- B32B 2264/102: Oxide or hydroxide
- B32B 2307/21: Anti-static
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/71: Resistive to light or to UV
- B32B 2307/7145: Rot proof, resistant to bacteria, mildew, mould, fungi
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/7248: Odour barrier
- B32B 2307/746: Slipping, anti-blocking, low friction
- B32B 2439/70: Food packaging
- B32B 2555/00: Personal care
- B32B 2555/02: Diapers or napkins
- C08F 4/65908: {in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+}
- C08J 2323/08: Copolymers of ethene (C08J2323/16 takes precedence)
- C08J 2423/06: Polyethene
- C08J 2423/12: Polypropene
- C08K 2003/265: {Calcium, strontium or barium carbonate}
- C08L 2207/066: LDPE (radical process)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS

## Abstract

The present disclosure provides breathable films and method of making the same. The breathable films according to the present disclosure comprise a film layer comprising polymeric composition comprising equal to or less than 60 wt % of a linear low density polyethylene resin which exhibits each of the following properties: (1) a CEF fraction from 70 to 90 C of equal to or greater than 80% of the total CEF fractions; (2) a melt index, I2, measured according to ASTM D 1238 (2.16 kg @190C), in the range of equal to or greater than 2.0 g/10 min and equal to or less than 5.0 g/10 min; and (3) a melt flow ratio, 110/12, of equal to or less than 6.7.

## Claims

### Claim 1

A film layer comprising:
a polymeric composition comprising greater than 0 wt. % and less than or equal to 60 wt. % of a linear low density polyethylene which exhibits each of the following properties:
a CEF fraction from 70° C. to 90° C. of greater than or equal to 80% of the total CEF fractions;
a melt index (I2) measured according to ASTM D 1238 at 190° C., of greater than or equal to 2.0 g/10 min and less than or equal to 5.0 g/10 min; and
a melt flow ratio (I10/I2) of less than or equal to 6.7.

### Claim 2 (depends on 1)

The film layer of claim 1, wherein the linear low density polyethylene further exhibits a density from 0.915 g/cm3 to 0.94 g/cm3, when measured according to ASTM D792.

### Claim 3 (depends on 1)

The film layer of claim 1, wherein the linear low density polyethylene comprises units derived from ethylene and units derived from at least one α-olefin comonomer.

### Claim 4 (depends on 3)

The film layer of claim 3, wherein the α-olefin comonomer is 1-hexene.

### Claim 5 (depends on 1)

The film layer of claim 1, wherein the linear low density polyethylene comprises no units derived from 1-octene.

### Claim 6 (depends on 1)

The film layer of claim 1, wherein the polymeric composition further comprises from greater than 0 wt. % to less than or equal to 5 wt. % one or more compounds selected from the group consisting of pigments and antioxidants.

### Claim 7 (depends on 1)

The film layer of claim 1, wherein the polymeric composition further comprises from greater than 0 wt. % to less than or equal to 10 wt. % one or more compounds selected from the group consisting of polypropylene and low density polyethylene.

### Claim 8 (depends on 1)

The film layer of claim 1, wherein the polymeric composition further comprises from 40 wt. % to 60 wt. % calcium carbonate (CaCO3).

### Claim 9 (depends on 1)

A breathable film comprising at least one film layer according to claim 1.

### Claim 10 (depends on 9)

The breathable film of claim 9, wherein the breathable film further comprises filler.

### Claim 11 (depends on 9)

The breathable film of claim 9, wherein the at least one film layer comprises a polymeric composition comprising from 30 wt. % to 60 wt. % of the linear low density polyethylene.

### Claim 12 (depends on 9)

The breathable film of claim 9, wherein the at least one film layer comprises polymeric composition comprising from 45 wt. % to 55 wt. % of the linear low density polyethylene.

### Claim 13 (depends on 9)

An article of manufacture comprising at least one component comprising the breathable film of claim 9, wherein the article of manufacture is selected from the group consisting of diapers, feminine hygiene, adult incontinence products, bed liners, animal training products and animal incontinence products.

### Claim 14

A method for producing a breathable film comprising:
cast extruding a polymeric composition which comprises from greater than 0 wt. % to 60 wt. % of a linear low density polyethylene which exhibits each of the following properties:
a CEF fraction from 70° C. to 90° C. of equal to or greater than 80% of the total CEF fractions;
a melt index (I2) measured according to ASTM D 1238 at 190° C., of greater than or equal to 2.0 g/10 min and less than or equal to 5.0 g/10 min; and
a melt flow ratio (I10/I2) of less than or equal to 6.7 to produce a cast extruded film layer; and
machine direction orienting the cast extruded film layer.

### Claim 15 (depends on 14)

The method according to claim 14, wherein the machine direction orienting is conducted with a stretch ratio of equal to or greater than 1.5.

### Claim 16 (depends on 14)

A breathable film produced according to the method of claim 14.

### Claim 17

A method for producing a breathable film comprising:
blow extruding a polymeric composition which comprises from greater than 0 wt. % to 60 wt. % of a linear low density polyethylene which exhibits each of the following properties:
a CEF fraction from 70° C. to 90° C. of greater than or equal to 80% of the total CEF fractions;
a melt index (I2) measured according to ASTM D 1238 at 190° C., of greater than or equal to 2.0 g/10 min and less than or equal to 5.0 g/10 min; and
a melt flow ratio (I10/I2) of less than or equal to 6.7 to produce a blown film layer; and
machine direction orienting the blown film layer.

### Claim 18 (depends on 17)

The method according to claim 17, wherein the machine direction orienting is conducted with a stretch ratio of equal to or greater than 1.5.

### Claim 19 (depends on 17)

A breathable film produced according to the method of claim 17.