CA2099384C

CA2099384C - Micropattern-embossed oriented elastomer films and process

Info

Publication number: CA2099384C
Application number: CA002099384A
Authority: CA
Inventors: Richard John Wick
Original assignee: Exxon Chemical Patents Inc
Current assignee: ExxonMobil Chemical Patents Inc
Priority date: 1991-01-04
Filing date: 1992-01-03
Publication date: 1999-01-05
Anticipated expiration: 2012-01-03
Also published as: EP0565612A1; DE69205966D1; EP0565612B1; US5385769A; WO1992011996A1; DE69205966T2; US5182069A; CA2099384A1; JPH06504008A

Abstract

Elastomer film is extruded or coextruded against an engraved geometric micropattern roll which forms a geometric pattern of raised intersecting ridges or ribs on the film surface, and subsequently oriented in one or both directions to produce a heat-shrinkable, elastic film which retains its geometric micropattern embossment to an unexpectedly high degree, and which therefore has excellent non-blocking properties, reduced gloss and a satin appearance and feel.
.. . .

Description

~0 92/11996 2 ~99 3~ PC~r/US92~00058 MICROPATTERN-EMBOSSED ORIENTED
ELASTOMER FILMS AND PROCESS

BACKGROUND OF THE INVENTION

1. Field of the Inventlon The present invention relates to improved elastomer films, particularly heat-shrinkable films, which are used for a variety purposés including the formation of elastic waistband portions of disposable diapers.

2. Discussion of Prior Art Diapers are produced from a variety of different plastic films which are used to form different portions of the diaper. The films used to form the main portions, or backsheets of the diaper are inexpensive non-elastomer thermoplastic films such as olefin homopolymers. Such thermoplastic films conventionally are embossed during extrusion, but are not oriented, lS elastomeric or heat-shrinkable. Reference is made to U.S. Patents 4,436,520 and 4,668,463 for their disclosure of embossing such films during extrusion.

Elastomer films are used to form small areas of disposable diapers, i.e., areas such as waistbands and legbands, where elastic properties are advantageous to improve the fit of the diaper. Such films generally are oriented or stretched to impart the desired degree of heat-shrinkability thereto so that shrinking occurs upon heat application.

~ . .

~:EPA-~Iunchen 03 ;14- 1-9~; 1S:36; L~r~

~o~9384 ~
~ i Elastomer films gene~ally pre~ent high blocking pr2ble:as since they contain adhesive polymers such as ethylene-vinyl aceta~e (E~A~ and/or rubbers and olly plasticizers. l'he~efore i~ is known to extrude Cuch film~ ag~ nst ~ dblasted e~ossing rolls to for~D a rar~r~om micropat~ern embos~ment on a surfa~-e thereo~ to reduce the }: locking te~dencies of the fil.~, w~ereby it can be rolled or ~ed raore ea~ily to the tentering station for orient~nq or stretching in the ~achin~ dir~ction (Ml:1) and/or transverse d-_r~cti~r, (TD) . ~owe~er, the orient~tion draws do~
znd su~ ;tant ~ ally redU~es the randc~ sur~ace e~oss~ent ~ hat normal high blocking properties reappear. Irhe high blocXing propertie~ make it dif~icult to h~ndle the ~ilm dow~Qtre~ of ~he ten~ering static~n, and most Cliffictll~ to unwind the ela~tomer ~ilm after it ha6 been co~lected on a ~oll .

~t is 3cnow~l from U. S. Patent 4, 84~, 564 to extrusion-2 0 ~bo~3 tharmopla~tic f ilms such as polyethylene, and elastol~eric f ilms such as copolymer~ c~f e1:hylene and ~rinyl ~c~tate (EVA) t~r other c~-monome~rEi, u~ing either a sandblasted o:~ rando~ micro-rcu~hened Emkc~sing roll, or an embossing roll having its - 25 surface engraved with a geo~etric micro patter~
h~ving an embossed d~pth fro~ . 00~27 c~ ~o. oOos~ to .00635 cm ~O.Qo25"), s-lch geometric-e~nbossed rolls ~eing described in IJ.S. Patent 4,367,147.

The films of Pa~er~ 4,8~8,564 ~re embossed in order c to im~rove their n~n-blocking or release properties with respect to rubber ~ales on whic~ they are used as wrappers. The embossed films of the patent are not oriented or stretched.

SUMMARY OF THE lNv~:r~lON

~ he present invention relates to the discovery of a S novel process for producing em'bossed and oriented, heat-shrinkable elastomer films suitable for use in diaper waistbands and other elastic structures in which the processing and handling of the films is simplified and the necessity of feeding a normally-blocking or adhesive film through a post-embossing station is avoided.

The present invention relates to a process for orienting heat-shrinkable elastomer films which have been pre-embossed with a geometric micropattern of particular dimensions which imparts properties of reduced surface gloss, excellent feel and non-blocking to the film, which properties facilitate the handling of the film through an orientation station(s) and other . downstream stations, and are retained to an unexpectedly high degree after orientation of the film in one or both directions.

The process of the present invention involves the step of producing embossed and oriented heat-shrinkable elastomer films, in which the elastomer film is extruded against or onto an engraved chill roll having a fine geometric micropattern of predetermined dimensions, to produce an embossed elastomer film having low surface gloss, good feel and excellent E~IP.WN:~iA-M~nchen C3 ;14- 1-9~; 15:37 ; ~p~ v,,~ ~
~ ~ ~ 9 3 ~ ~ ~

handling propertie~ due to the re6istance of the embo~ed surface to bloc~ or adhere to other surfaces.

ThP latter property facilitates the subsequent steps of feeding of the e~bos~ed elastomeric fil~ into the tentering or orienting -~t~ion~s~, and o~er bow rolls fo~ flattening the web for collection on a roll, an~ subsequent unr~inding of the roll for final processina, which ls th2 most important advantage.

lQ T~e mo~t criti~al fea~ure o~ ~he pre~ent invention resides ~n the ~se of an extrusion-e~bossmen~ means comprising a geometrically-engra~ed male or f~male cropattern surf~ce ha~ing from 50 to 350, p~eferably a male ~icropatt2rn having 100 to-250, most prefer~bly 1~5, repeating geometrlc units ~r lir.es per inch, measured t n the transverse direc~i~n (TD) and/or machine di~ection ~ he malP
micropattern i~ formed ~y intersecting emb~-~sed or e~graved lines, in t~ number stated ~bove, each ~o l~ne ha~rin~ a depth within the range of 0.00254 cm (C . QOlnJ to ~ . 006~5 cm ~0. 0025"), most pre~erably 0.0~572 cm (0.001&1~) o~ 18 ten thousandths r:f ~n inch .

DE~ ~n n~ P~ION ~F ~RE lNV~ 0~

The el~tome~ic film~ suit~ble for proce~sing ac~ording to the presen~ inventiGn lncl~de all ther~opla~t1c elastomers or rubbery th~rmoplas~ics, including blends of a thermoplastic material and an elastomer which are pro~essable as a mel~, at ele~ated te~peratures, and exhibit properties similar to vulca~i~ed elasto~ers at ~oom temperature.

JO92/11~6 2 0 9 9 3 8 4 PCT/US92/~58 .,_..r The preferred thermoplastic elastomer film compositions for use according to the present invention comprise three ma$n components, (1) olefinic elastomer, (2) ethylene copolymer and (3) ~ hydrocarbon process oil.

The concentrations of the three main components of the blend are as follows:
~fe.. cJ ~st C~Done~t~4 tr~t10n ~ t~ ~t~ P~cf~. .eJ
Olef1~1c El~st~er 10-~0 ~ 30 ~ 30 YtS
10 Eth~l~ Copol~r~90 ~tS SO~ ~ 5 ~t~
~rocess 0~ 15 ~ 2-12 ~t~ ~10 ~tS

The above concentration ranges may be combined in any permlssible combination, although particular combinations are shown as preferred and most preferred.

Elastomer Component: The olefinic elastomer component of the composltion preferably comprises an ethylene copolymer elastomer, such as a copolymer of ethylene with hiqher alpha-olefin. Preferred ethylene elastomer copolymers include EPM (ASTM D-1418-72a designation for an ethylene-propylene elastomer copolymer) or EPDM
(ASTM D-1418-72a designation for an ethylene-propylene diene elastomer terpolymer). Also usable are high molecular weight polyisobutylene, butyl rubbers and halogenated butyl rubbers.

Preferred ethylene elastomer copolymers for use herein comprise from 30 to 90 percent ethylene, more preferably from 35 to 80 weight percent ethylene, and . , . . . , . ~ . .. ..

1-93 , 15:3~ i BFC~ 498923994465;~ 9 EMP.VGN'EPA-~unche~ 03 ,14-6 ~ 3 ~
mo~t p~e~erably from 50 ~o 80 weight percent ethylene and have a Mooney Visco~ity 40-60 (ML 1~4 at 125~C o~ 257CF).

EP~M is a terpolymer of eth~lene, a higher aipha-5 olefin such as p~opylene, and a non conjugated diene. In such ela~tome~s, the nonconjugated diolefin may be ~traight chain, branched c~ain or cy~lic hydrocarbon di~lefins havi~g fro~ o to 15 carbon atoms.

Of the nonconjugated dienes typically used to - p~epare these copoly~ers, preferred are di~yclopentadiene, 1, 4-hexadiene, S-methylene-2-nor~ornene and 5-ethylidene-2-norbornene; S-ethyliden~-2-norbornene (ENB) and l, 4-hexa~ie~e are par~icularly p~ef2rred d~olefins. EPDM elasto~ers and t~eir m~thod of manufactu~e are ~ell kno~n to ~hose skilled in the art. Oil extended EPDM

~lastcmerY may also ~e used. Preferred EPDM
el~stomer~ contain from 30 to gO weight per~ent ethyl~ne, and from 0. 5 to lS weigkt percent of the nonco~ugated diolefin.

As me~tioned abo~e, the olefinic elastomer useful in thiS in~ention may also be palyi~obuty'ene, a copolymer of iso~utylene 2nd isoprene (genarally known as ~utyl rubber) or a halogenated copolymer of iso~utylene and isoprene ~gene~ally known as halogenated ~utyl rub~er, ~uch as c~lorinated, bro~inated a~d c~lorobrominated butyl rubber).
~ u~yl rub~r iB vulcanizable r~bber copolymer containlng fro~ 85 to 5g.5 percent co~bined i~oolefin ha~ing from 4 to 8 carbon atom~ and from 0.5 tQ lS perCent co~ined con~ugated diolefin ha~i~g from 4 t~ 8 car~on atcms. SuCh copolymerr-and their preparation are well known, and generally the isoole~in ~ 8 ' BPC ~ ~9~9'~'~Y440~.~1.1 E~lP, \~N:EpA-Muncnen Oi ;14- 1-93 . I~ U

7 ~ Q ~
is a compound s~ch as isobutylene and the diolefin i8 co~pound ~uch as butadien~ or isoprene.
Halogen~ted ~tyl ~ubber~ are also well known:
chlor~nate~ and brominate~ kutyl rubber generally c~ntalns from 1.~ to 3.0 weight percent b~omine and f~om 0.05 ~o 0.5 weight percent chlorine.

Et~Ylene ~o~olYmer Component: The ethylene cop~ly~ers inclu~e those of ethylene ~nd alpha-olefin~ having 3 to 16 car~on atom~ ~uch as propylene or 1-b~tene. Also included are copolymers ~f ethylene with an ~nsaturated carboxyli~ acid. Tn par~icular, r-opolymers of e~hylene wit~ vinyl acetat~ ~E~A), ~r with acrylic acid (EAA}, or methac~yli~ acid (EMA), are pr~erred. The ethylene copolymer~ to be employed gener~lly cont~in fro~ 50 t~ 9g weisht percent ethylene, mo~t prefer~ly from 60 to g5 percent ethylene.

The most preferred ethylen copolymer us~ful in th~
present invention i~ EVA. The EVA may have a ~inyl acetate t~A) content ~etween g% and 40% by weight, with 15 to 35 weight percent VA being preforred.

~VA conients below ~ wt~ do not posse~s s~fficient fle:~ibility and orien~ability ~or p~rposes of the present- in~entlon and VA contents above ~0 ~t%
~5 exhibit excessi~e tacktr~ss. The best ~alance of ~rient~ility and non-t~ckines~ occurs at the VA
conten~ s between 15 and 35 wt%.

Preferred Meit Index (AST~l-D-1238, Condi~i~n E) fcr EVA i~ from 1 to 20, with 2 to 1~ being most 3 o p~e~erred .

E~AP. ~N'EPA-Mun~en ~3 ;14- 1-33; 15:3~ ; 3PC ~ ~9~923994455;$11 The ethylene copolymer component nor~al~y ~ill determin~ the operating tamperatures of the tentering and annealing operations. Thes~
ope~ations may be ca~ied o~t ~t temperatures not less than 37.7~C (100~F~ and below ~he crystallins melting pcint of the ethylene copolyme~ component.
The crystalline meltir.g point o~ ~VA ranges fro~
~pproximately A~O~ S~c tlG5~F) and 53 . 3~C (2G0~F), depend~ng on t~e ~A content ~nd MI, with the prefe~red EV~'s ha~Jing crystalline melting points between 5~.4~~ tl30CF) and 71.1~C ~1~0~F)~ For economic reasons, orienting temperatures ~f 71.1~~
(1~0~F) ~nd below are preferred.

Pro~ess oil Compcnent: Hydrocarbon oils use~ul in the present lnvention funotion as process aid~ whose act~vity is enhance~ in the presence of vinyl acetate copolymers, as plasticizer~ producing low modulus and enhanced elasticity in the ~olid ~tate.
Usaful o~ls are ~he normally liguid hyd~ocarban processing and extender oils (AST~ D 2226) ca~egorized as aromatic, highly arcmatic, naphthenic and pa~arfinic proces6 oils of a mediu~ visc03ity range. Oils ~old under the trademarks "Flexon" and "Arco Pri~s" have ~een found especially u~eful.

other Additives; T~e composition may also include pigments, a ~iller material, an antiblock a~ent, proczssing aids, s~abilizers and other con~Jentional additives .

~ ER~PP~TION

Resin/~len~ Pr~aration: Preparation of co~positions usable in this invention can ~e ach~e~ed in se~eral _ ~Og2/11~6 2 0 9 9 3 8 ~ PCT/US92/~058 different ways. The various components may be brought into intimate contact by, for example, dry blending the components and additives and then passing the overall composition through a compounding extruder.
Alternatively, the components may be fed directly to a mixing device such as a compounding extruder, high shear continuous mixer, two roll mill or an internal mixer such as a Banbury mixer. The optional ingredients previously described can be added to the composition during this mixing operation. Overall, the objective is to obtain a uniform dispersion of all ingredients and this is readily achieved by inducing sufficient shear and heat to cause the plastics component(s) to melt. However, time and temperature of mixing should be controlled as is normally done by one skilled in the art so as to avoid molecular weight degradation.

Film Extrusion: Film from the resin compound is manufactured by conventional cast extrusion. The molten resin is extruded from a coathanger die in the form of a web which is then cast onto a geometrically-etched, micropatterned, embossing chill roller, which solidifies the polymer. The embossed web is moved directly into the tentering station for orientation.

The extrusion temperatures, die temperatures, and chill roll temperatures will depend on the composition employed, but generally will be in the following ranges for the compositions of the present invention prepared 3Q by cast extrusion:

. :. I -:' .'' ~

BPC ) 498923994465;~12 EM~. V~N:~PA-~.unchen 03 ;14- 1-93, 15.39 Melt Te~p ~C/ (~F) 176. 7-232 . 2/ (3so-450) ~ie Temp ~C/ (~F) 176. 7-232 . 2J (350-450) Chill Roll Te~p ~C/ (~F) 2~ S4 . 4~ ~70-13Q) ~he process de~cr~ bed above may include one or two e~ossing rolls to chill and emboss the film on one or ~cth surf ace~ .

In ~rac~ice, the proce~s of the present in~ention is car~ied ou~ using an in-l~ ne operation wherein the rxtrud~r and orientation ~y~tem (e.g., tente~) ~re arranged in tandem to forrh the film by casting or me~t embo6sing followed by film orientat~ on.

In ~ preferr~d e~bodiment, the compound~ad extrudzble composition ~:ontaining the elastcmer ingredients - along with the other additives is introdtlced into an ex~ruder and extruded ir.to a web fro~ a ~lat die and melt-~m~os~ed through count~r rotati~g chill and e~bossing ro~ ls. The film thickness may vary from 50 t~ 400 micrcns ~efore orientation. Preferably the film will have a ~inal stabilized thickness of be' ween 10 and 100 microns aft~r orientation and anneal ing., Sinc~ ~ome thermopla~tic el~stome~ic film~ are quite tacky and present blocking pro~lems which ~ake the~
difficult to handle and feed, such as th~ preferred el~stomars discussed above, it is preferabla to co-extrude such elastomers as a core layer bet~een su~ace or cap layers of thermoplastic ela6tomer~
ha-~ing reduced ~loc~ing propertie6, generally dua to a lQwer contant of a~h~sive vinyl acetate in the '~g2/11996 , 2 0 9 9 3 8 ~ PCT/US92/~58 ethylene-vinyl acetate (EVA) component and the absence of the process oil component.

It is important that the surface layer(s) be sufficiently elastic and thin to avoid interference with the higher shrink and elastic properties of the thermoplastic elastomer.

As formed on the core or base layer, each of the surface layer(s) will comprise between 2 to 15, preferably 2 to lO weight percent of the composite and not more than 25 microns thick. Following the orientation, the surface layer(s) will be reduced to a thickness of not more than 7 microns and as thin as possible. Preferred thickness after orientation is between l and 5 microns.

The surface layer may be coextruded onto only one side of the core layer but preferably is extruded onto both sides.

The critical extrusion-embossment step is accomplished by extruding the thermoplastic elasomer layer, or co-extruding an AB or ABA structure of a core layer B
having exceptional elasticity and heat-shrink properties, and one or more surface or cap layers A of thermoplastic elastomeric composition having lower tack and lower blocking properties than the core layer. The extruded layer or coextrudate is passed in the form of a continuous molten web in the nip between the geometrically-engraved micropattern surface of a chilled embossing roll and a support roll which is W092/11996 2~3~ PCT/US92/00' coated with rubber, silicone or other release surface, or between two similar chilled embossing rolls.

After embossment, the film is moved to an in-line tenter or orienting device. orientation of the film may be carried out in the machine direction (MD) or the transverse directlon (TD) or both directions (biaxially) using conventional equipment and processes.

For orientation in the MD, the embossed film at an elevated temperature tbut below the crystalline melting point of the polymer) is passed around two rollers driven at different surface speeds, over a pair of bow rolls to flatten the film, and finally to a takeup roller. The driven roller closest to the takeup roll is driven faster than the driven roller closest to the feed roll, such that the film is stretched between the driven rollers. The assembly may include a roller intermediate the second roller and takeup roller to further cool the film. If supplementary cooling is not used, the film will cool to ambient temperature on 2Q the take up roll.

The degree of stretch, generally between 50% and 500%, will depend upon the relative peripheral speeds of the driven rollers and the distance between the rollers.
Stretch rates of 50 to 500 percent/minute will be satisfactory for most MD orientation applications.

Preferably, however, film orientation is carried out in a tentering device to impart TD orientation to the film. The film is extrusion embossed as described above and then gripped by the edges for processing E~P.~N:EPA~ incher, ~3 ;14- 1-9~ ; 15:4C ; ~PC~ 49892~994465;~13 through the orientation step~ . The f ilm i~ pas~ed succe~sively through a preheat step, a stretching step at elevated te~peratures (e . g. from 37 . 7~C
~ lGO~F] to a tempe~ture slightly }~elow the crystalline melting pcint of the ethylene copolymer), an annealing step, and finally a cooling step. ~Although cooling may be considered part of the an~ealing ~tep, ~o~ convenience it is described as a separate step herein. ) The preheat, lû ori entation, and a portiQn of the ~nnea~ng ~empera~ure is controlle~ at an elevated tem~erature bu~ belo~ t~e crystalline melting point of t~e -- polymer. Alth~ugh not es~enti~l, it is preferred that tension ~e maintained on the f ilm during the annealing and cooling steps to pre~ent sag and to mlnim~ze shrinkbac3~. up~n cooling to ambient ter.pe~atu~e ( i . e ., roo~ ~e~nperature) c~ near a~bient, t~e ~oldi~g force may be released. The film may ~ontract somewhat (snap~ack) in the TD but will r~tain a su~s~anti~l po~ion of itfi stretche~
width .

The ten~er op~rating conditions can Yary within relati~rely wide ranges and ~ill depend on the several ~ariable6 ir.cluding fil~ composition, fil~
~- 25 t~ic3~r.ess, degrze of orientation desire~, ~nnealing condit~ons, etc. Ihe following is exemplary of ~
p~oc~s~; for ~tretrhing 10~ micron thlck A~A
coextrude~ fillc (containing EVA) fro~ 109.2 cs~ (43 ~nches~ wid~ to a finai width of 223.5 cm (~;a inches) ~ us~ng a t~nter manufactured by M~rshall and William~ CQmpany of P~c~vidence, R~ode Island.

~ ~ BPC~ 49~923994465;~14 EMP,VON:EPA-Munchen ~3 ;14- 1-93 ; 15.4C

' 14 ".

FSnMATFn F~ F

~_I ~.7~ C ~1.1' C ~.~- C ~

b~ho ;~.~-r~.l' C ~ C ~72' C ~LO
~ 1~n ~ u~
~ D.7-~1.1' C ~W- C ~a~.4 C

As indiczt~d ~arlier, it is hiyhly desirable to employ ~n ~nnealins step in the process. ~nnealing partially relie~es the internal stress in the S stre~ched film and di~ensionally stabilizes th~ ~ilm for storage. It has been fo~nd ~hat by ~nnealing t~e film at a temperature o~ + 4.45C (40~F), preferably + 6.7~C ~20~F) o~ the orientation t~mperature ~but sligh~ly below ~he crystalline mel~in~ point of the ethylene copolymer), eli.minate~
undesirable shrinkage during storage. The preferred ~nnealing ~PmpPtature is }:e~ween 43.3~C ~llo~F) and ~o~C (140~F). Tempera~u~es wnich r~sult in excessiv~
stress rel~ eving should be avoided, sinc.-~ubctantial frozen-in ~tresses and ~trains shculd remain aft~r the process is completed.

Annealing can l:e accompl~shed by m~intaining the ~ilm in t~e nearly-complete ~y ~tretched c~ndition ~t th.e annealing temperature. ~referably, th~
annealing ~nd cooling is carried out while permitting the film to cont~act slightly, bu. ~
~nder stress. The guide rails of the tenter can be arra~gecl irl a con~erging r~anner to provide the ann~aling and cooling while the ~ilm contrac.s. The controlled shrinkbacX of from 5 to-.

~ PC ~ 49~923994465 ;;1 5 ~P. ~N ' EPA-~unc~en ~3 ; 1 4- 1 -93; 1 5 : 41;

30~, preferably between 10 and 25%, of the maximum ~tretched width has ~iven particularly gocd results ln eliminating storage shrinkage. ~his annealing ~d pre~hrir~ing remove6 some of the film stresses and ~trains 80 that shrinkage will noi occur a~
eto ase temperature. However, the annealing 2nd c~eling ~oes not re~.o~ all the froze~-in s~res~ and ,train, ~ince upon heating to elevated temperatures above storage t~mperat~re the fil~ will ~hrink.

rhe degre~ of ~iret~hing may vary within wid~
range~. nra~ ~atios sf 1.3:1 to S:l are possi~le with 2 :1 to 4:1 ~eing prefer~ed for TD 'entering.
Orientation in the -trans~erse direction only, and to an ext~nt o~ betwe~r 200% and 400~ preferred.

~ilms pr~duced 3c~rding to the -~impli~i~d in-line extrusion-embo,~er~t ~nd orient~isn process of ~he presen~ invention r~ain to 2n unexpectedly high degree the aes~hetic and fun~tional pr~perties impa~ted durir.~ the geometric e~boss~ng step, i.e, a micro~attern ~ e ~ur~ace wh~ch has the appearance and ~e~l of Eatin and which has excellent ~n-~locklng proL~tties which facilitate the unwinding of the .~ om a roll and ~ubstantially i~prove the handli.lg propert~es o~ the ~ilm for ~inal 4 5 procC~ssin~ l-5~o diaper waistband5 and/o~ other str~tc~akle co~p~nents or produ~ts.

ThPse --esuit, are obtained t~roug~ the use of the geo~e-ric ~icropattern-engraved e~b~s~in~ rolls ider~..ifie~. herein, having the stated num~er of 3~ ircerseotin~ lines or cut valleys per inch, ea~h ;~a~in~ a depth between 0.00254 cm ~0.001 inch) and 0.00~35 cm Ø00~5 inch), forming 93 ' 15~41 ~ BPC~ 49~923594435;~1 E~P.~N:EPA-~unchen ~ ;14- 1~

between ~aid lines ~ale pins or uncut peak areas having height~ between about 0.00254 cm (0.~01 inch) and 0.00635 cm (0.0025 in~h). Random-engrav~d or ~an~1asted embossing rolls produce a matte surface on the f ilm but the appearance and functional propsrties thereof are minimiz~d or degraded ~uring the orienta'cion or ten' ering step, so that the fir~al film has a high-gloss surfacs which doe~ not have thP apDearance or feel of cloth and h~s high blocking or adhesion properties.

~n ~pparent expl~nation for the unexp~cted advantag~s obt~ined from the use of the prese~t geometri~ e~bos~ing rolls in the pr~sent process is that a gecmetric e~bos~ing ~surface ccmpri~ing geom~tricaily-aligned pins or peak araas form6 a g~om~tric repetltive pattern of ~epressions, valleys or recesse~ in the elasto~er surface ~urrounded by int~r~ecting a~d connected peak lines, ridges or ribs which provide a ~keletal 6Upport network during orientation. Such structure uniformly relieves or ~bsorbs the o~ientation ~re~ses, and the raised portlons, peaks, r~dges or ri~s of the film s~rface are retained. In othe~ words, the geometric valleys or depre~s1ons in the film surface are widened - 2 s~ewhat during ori~ntation while the surrounding raiaed peak areaq, forming the uppermost surf~ce of the fllm, are st~etchPd and drawn do~n ~omewhat so ~hat th~ film surfa~e retains its em~os~ed appe~rance and feel and its non-bloc~ing p~operties.

3Q It is ~o ~ understood th2t the above de~cribed embodiments o~ the invention are illustrative only and that ~od~fications throughout may occur to those 209938~
VO92/11996 PCT/US92~058 ,.~. .

skilled in the art. Accordingly, this invention is not to be regarded as limited to the embodiments disclosed herein but is to be limited as defined by the appended claims.

.,,~ , ., ~ .
, . ~

Claims

I claim:

1. An in-line process for producing an embossed and oriented film of thermoplastic elastomer, comprising the steps of:

(a) producing an extrudable composition comprising at least one thermoplastic elastomer;

(b) extruding said composition in the form of a continuous molten web;

(c) passing said web in the nip between rolls, at least one of which is a chilled embossing roll having an engraved geometric micropattern surface comprising between 50 and 350 lines per 2.54 cm (per inch), each having a depth between 0.00254 cm (0.001 inch) and 0.00635 cm (0.0025 inch), to emboss said geometric micropattern into one or both surfaces of said web while solidifying said web, and (d) passing said embossed, solidified web into an orientation device to stretch said web in the transverse direction and/or in the machine direction to an extent between 50% and 500%, to produce an embossed and oriented thermoplastic elastomer film having excellent elastic and heat-shrink properties and having embossed surface(s) which retain the effects of the embossment, after orientation of the film, so as to have an appearance and feel similar to satin and excellent non-blocking properties.

2. A process according to claim 1 in which said thermoplastic elastomer comprises an ethylenevinyl acetate copolymer having a vinyl acetate content of from 9% to 40% by weight.

3. A process according to claim 1 in which said thermoplastic elastomer comprises a blend of an olefinic component, an ethylene copolymer component and a process oil component.

4. A process according to claim 3 in which said thermoplastic elastomer comprises an ethylenepropylene polymer, an ethylene-vinyl acetate copolymer, and hydrocarbon process oil.

5. A process according to claim 1 which comprises:

(a) producing at least two different extrudable compositions, at least one of which contains a thermoplastic elastomer;

(b) co-extruding said compositions as a composite molten web having a core layer of one composition having high blocking properties and at least one surface layer of a different composition having lower blocking properties;

(c) passing said web in said nip so that said surface layers(s) is embossed with said geometric micropattern, and (d) orienting said co-extruded, embossed web.

6. A process according to claim 5 which comprises co-extruding said different compositions in the form of said core layer of one composition, and inner and outer surface layers of said different composition.

7. A process according to claim 6 which comprises embossing only one of said surface layers.

8. A process according to claim 1 in which said embossing roll is a male embossing roll on which the engraved geometric micropattern surface comprises between 100 and 250 lines per cm (inch), each having a height between 0.00254 cm (0.001 inch) and 0. 00635 cm (0. 0025 inch).

9. A process according to claim 1 which comprises stretching the embossed web in step (d) only in the transverse direction, and only to an extent between 200% and 400%.

10. A geometric-pattern-embossed and oriented, heat-shrinkable, elastic, thermoplastic elastomer film produced by an in-line process, said film comprising at least one thermoplastic elastomer which is extrusion-embossed with a geometric micropattern surface comprising between 50 and 350 lines per cm (inch), each having a depth between .00254 cm (0.001 inch) and 0. 00635 cm (0. 0025 inch) and forming a geometric pattern of recessed surface areas and surrounding, intersecting raised surface areas on said film, and said film is oriented inline in the transverse direction and/or the machine direction to an extent between 50% and 500%, whereby the film is uniformly stretched in the geometric recessed areas and in the geometric intersecting raised areas of the film, surrounding said recessed areas, whereby said film substantially retains the effects of the embossment, after orientation, and has the surface appearance and feel of satin and excellent non-blocking properties.

11. A film according to claim 10 in which said thermoplastic elastomer comprises an ethylene-vinyl acetate copolymer having a high vinyl acetate content.

12. A film according to claim 10 in which said thermoplastic elastomer comprises a blend of an olefinic component, an ethylene copolymer component and a process oil component.

13. A film according to claim 12 in which said thermoplastic elastomer comprises an ethylene-propylene polymer, an ethylene-vinyl acetate copolymer, and hydrocarbon process oil.

14. A film according to claim 10 which comprises a co-extrudate of least two different extrudable compositions, each comprising at least one thermoplastic elastomer, comprising a core layer of one elastomer composition having high blocking properties and at least one surface layer of a different elastomer composition having lower blocking properties.

15. A film according to claim 14 which comprises said core layer of one elastomer composition, and inner and outer surface layers of said different elastomer composition.

16. A film according to claim 15 which is embossed only on one of said surface layers.

17. A film according to claim 10 in which said embossed geometric micropattern on said film surface comprises between 100 and 250 lines per cm (inch), each having a depth between 0.00254 cm (0.001 inch) and 0.00635 cm) 0.0025 inch.

18. A film according to claim 10 which is stretched only in the transverse direction, and only to an extent between 200% and 400%.