Porous film composites
AssigneeAmoco Corporation
InventorWilliam T. Tapp
Life of this patent
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Abstract
A porous film composite comprising at least one layer of an oriented polymeric porous film comprising an ethylene-propylene block copolymer having an ethylene content of about 10 to about 50 wt %, a polypropylene homopolymer or random copolymer of propylene having up to about 10 wt % of a comonomer of ethylene or an .alpha.-olefin of 4 to 8 carbon atoms, and at least one component selected from a low molecular weight polypropylene, a beta-spherulite nucleating agent and calcium carbonate adhered to at least one layer of a polymeric foam product, a woven fabric, or a nonwoven fabric such as a carded web of staple fibers, a spunbond fabric, meltblown fabric and a self-bonded, fibrous, nonwoven web.
Claims20
A porous film composite comprising,
- at least one layer of an oriented microporous film having microvoid cells and interconnecting pores between the cells prepared by a process comprising the steps of:
- (1) forming a film from a polymeric composition comprising,
- about 30 to about 90 parts by weight of a component A comprising an ethylene-propylene block copolymer having an ethylene content of about 10 to about 50 wt %,
- about 5 to about 40 parts by weight of a component B comprising a polypropylene homopolymer or random copolymer of propylene having up to about 10 wt % of a comonomer of ethylene or an .alpha.-olefin of 4 to 8 carbon atoms,
- about 1 to about 20 parts by weight of a component C comprising a low molecular weight polypropylene having a melt viscosity of about 50 to about 1,000 poise measured at a shear rate of 136 sec.sup.-1 and 190.degree. C.,
- 0 to about 30 parts by weight, per 100 parts by weight of components A, B and C, of a component D comprising calcium carbonate, and
- 0 to about 50 ppm, per 100 parts by weight of components A, B and C, of a component E comprising a beta-spherulite nucleating agent with the proviso that component C is present at
- (a) about 5 to about 20 parts by weight when the polymeric composition is substantially free of component D or of components D and E, and
- (b) about 1 to about 10 parts by weight when the polymeric composition has about 0.1 to about 10 ppm of component E and about 5 to about 30 parts by weight of component D,
- (2) heating said film at a temperature of about 35.degree. to about 135.degree. C., and
- (3) stretching said heated film in at least one direction at a stretch ratio of about 1.5 to about 10, wherein said oriented microporous film layer is adhered to
- at least one layer of a material selected from the group consisting of a carded web, a polymeric foam product, a woven fabric, a spunbond fabric, a meltblown fabric and a self-bonded, fibrous, nonwoven web.
A porous film composite comprising,
- at least one layer of an oriented polymeric porous film having polygonal cells with average dimensions of about 5 to about 30 microns and interconnecting pores between the cells having average diameters of about 0.2 to about 20 microns prepared by a process comprising the steps of:
- (a) forming a film from a polymeric composition comprising about 70 to about 95 parts by weight of a homopolymer or random copolymer of propylene having up to about 10 wt % of a comonomer of ethylene or an .alpha.-olefin of 4 to 8 carbon atoms, about 5 to about 30 parts by weight of an ethylene-propylene block copolymer having an ethylene content of about 10 to about 50 wt % and a nucleating agent capable of producing beta-spherulites;
- (b) cooling said film below the crystallization temperature of said composition to form at least 20 wt % of beta-spherulites in the film;
- (c) extracting selectively said beta-spherulites in an amount corresponding up to 15 wt % of the composition from the cooled film with an extraction solvent selected from the group consisting of toluene, carbon tetrachloride and xylene to form a porous film;
- and
- (d) orienting the porous film by heating the porous film at a temperature of about 110.degree. to about 135.degree. C. and stretching the heated porous film in at least one direction at a stretch ratio of about 1.5 to about 7.5 adhered to
- at least one layer of a material selected from the group consisting of a carded web, a polymeric foam product, a woven fabric, a spunbond fabric, a meltblown fabric and a self-bonded nonwoven web.
Dependencies are inferred from the claim text.