Multilayer film including odor barrier layer having sound dampening properties

Abstract

A multilayer film including an odor barrier layer having sound dampening properties is provided. The odor barrier layer is formed from a polyamide modified with a functionalized vinyl-bond rich triblock copolymer.

Claims

1. A multilayer film comprising an odor barrier layer having sound dampening properties, wherein the odor barrier layer is formed from a blend comprising about 85 wt. % polyamide and about 15 wt. % of a vinyl-bond rich triblock copolymer functionalized with a maleic anhydride, wherein the vinyl-bond rich triblock copolymer is a vinyl-bond rich styrene-isoprene-styrene (SIS) block copolymer having a chemical structure ##STR00001## or a vinyl-bond rich styrene-ethylene-propylene-styrene (SEPS) block copolymer having a chemical structure ##STR00002##

2. The multilayer film of claim 1, wherein the polyamide is an amorphous polyamide.

3. The multilayer film of claim 1, wherein the vinyl-bond rich SIS block copolymer has a glass transition temperature of about 8 C., a temperature at tangent delta peak of about 20 C., and a tangent delta of about 1.2 at room temperature.

4. The multilayer film of claim 1, wherein the vinyl-bond rich SIS block copolymer has a glass transition temperature of about 13 C., a temperature at tangent delta peak of about 3 C., and a tangent delta of about 0.7 at room temperature.

5. The multilayer film of claim 1, wherein the vinyl-bond rich SEPS block copolymer has having a glass transition temperature of about 15 C., a temperature at tangent delta peak of about 5 C., and a tangent delta of about 0.45 at room temperature.

6. The multilayer film of claim 1, wherein the multilayer film is a five layer film having additional layers forming an outer layer/tie layer/odor barrier layer/tie layer/outer layer construction.

7. The multilayer film of claim 1, wherein the multilayer film is a five layer film having additional layers forming an outer layer/inner layer/tie layer/odor barrier layer/tie layer construction.

8. The multilayer film of claim 1, wherein the multilayer film is a four layer film having additional layers forming an outer layer/tie layer/odor barrier layer/tie layer construction.

9. The multilayer film of claim 1, wherein the multilayer film is a seven layer film having additional layers forming an outer layer/inner layer/tie layer/odor barrier layer/tie layer/inner layer/outer layer construction.

10. The multilayer film of claim 1, wherein the multilayer film is a six layer film having additional layers forming an outer layer/inner layer/tie layer/odor barrier layer/tie layer/ outer layer construction.

11. The multilayer film of claim 1, wherein the multilayer film further includes at least one outer layer and at least one tie layer, wherein the at least one outer layer is a seal layer comprising ethylene vinyl acetate (EVA) copolymer, ethylene methyl acrylate (EMA) copolymer, ethylene alpha olefin copolymer, olefin block copolymer (OBC), or ethylene-propylene (EP) copolymer, or blends thereof and the at least one tie layer is formed from a maleated polyolefin.

12. The multilayer film of claim 1, wherein the multilayer film includes at least one inner layer comprising EVA, EMA, ethylene olefin copolymer, OBC, or EP copolymer.

13. The multilayer film of claim 1, wherein at least one additional layer comprises a sound dampening resin.

14. An ostomy pouch, comprising: a first wall; a second wall, wherein the first wall and the second wall are sealed along their peripheral edges to define a cavity; wherein at least one of the first wall and the second wall is formed from the multilayer film of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The benefits and advantages of the present embodiments will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

(2) FIG. 1 is a cross-sectional illustration of a five-layer film according to an embodiment;

(3) FIG. 2 is a cross-sectional illustration of a four-layer film according to an embodiment;

(4) FIG. 3 is a cross-sectional illustration of a seven-layer film according to an embodiment;

(5) FIG. 4 is an illustration of an exemplary ostomy pouch;

(6) FIG. 5 is a cross-sectional illustration of a five-layer film according to another embodiment; and

(7) FIG. 6 is a cross-sectional illustration of a six-layer film according to yet another embodiment.

DETAILED DESCRIPTION

(8) While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification and is not intended to limit the disclosure to the specific embodiments illustrated.

(9) FIG. 1 is a cross-sectional illustration of a multilayer film 10 including an odor barrier layer having sound dampening properties according to an embodiment. The multilayer film 10 is a five-layer film including an odor barrier layer 12, two tie layers 14, 16, and two outer layers 18, 20. As shown, each of the tie layers 14, 16 is arranged between the odor barrier layer 12 and the outer layers 18, 20, respectively, to facilitate adhesion between the odor barrier layer 12 and the outer layers 18, 20.

(10) The odor barrier layer 12 is formed from a polymeric blend comprising a polyamide and a sound dampening resin. For example, the odor barrier layer 12 may be formed from a blend comprising a polyamide and a vinyl-bond rich triblock copolymer, such as a vinyl-bond rich styrene-isoprene-styrene (SIS) block copolymer (e.g. Hybrar 5125 or 5127 from Kuraray Co. Ltd.) or a vinyl-bond rich styrene-ethylene-propylene-styrene (SEPS) block copolymer (e.g. Hybrar 7125). In such embodiments, the vinyl-bond rich triblock copolymer may be functionalized with maleic anhydride or epoxy and reacted with a polyamide to modify the polyamide. Preferably, the vinyl-bond rich triblock copolymer having suitable sound dampening properties has a glass transition temperature greater than about 25 C., more preferably between about 20 C. and about 20 C., and a temperature at tangent delta peak greater than about 15 C., more preferably between about 10 C. and about 30 C., and a tangent delta value at room temperature greater than about 0.30, more preferably between about 0.40 and about 1.5.

(11) In some embodiments, the odor barrier layer 12 may be formed from a blend comprising about 70% by weight (wt. %) to about 95 wt. % of amorphous polyamide (nylon) and about 5 wt. % to about 30 wt. % of functionalized vinyl-bond rich triblock copolymer. For example, the blend comprises about 85 wt. % of amorphous polyamide and about 15 wt. % of a vinyl-bond rich triblock copolymer functionalized with maleic anhydride, such as maleated vinyl-bond rich SEPS block copolymer.

(12) Polyamides suitable for the odor barrier layer 12 include amorphous polyamides having a partially aromatic structure, which are typically produced by the condensation of an aliphatic diamine with an aromatic diacid, or combination of diacids, in molar amounts equivalent to the diamine used. Examples of such a polyamide include a polyamide resin marketed as Selar PA3426 by DuPont Company, which is substantially amorphous with a density of about 1.19 grams per cubic centimeter (g/cc) and a glass transition temperature (dry) of about 127 C. It has high melt strength and can be used under a broader range of processing conditions than conventional crystalline nylons. Selar PA3426 is produced by the condensation of hexamethylenediamine, terephthalic acid, and isophthalic acid such that 65% to 80% of the polymer units are derived from hexamethylene isophthalamide. Another amorphous polyamide example is Grivory, such as Grivory G21, which is commercially available from EMS-Chemie of Sumter, S.C. Grivory G21 has a density of about 1.18 g/cc and a glass transition temperature (dry) of about 128 C.. Grivory HB5299, which has a density of about 1.2 g/cc and a glass transition temperature (dry) of about 95 C. and a melting point temperature of about 219 C., is also a suitable amorphous polyamide.

(13) In one embodiment, the odor barrier layer 12 is formed from a blend comprising about 85 wt. % of amorphous polyamide and about 15 wt. % of a functionalized vinyl-bond rich SIS block copolymer having a glass transition temperature of about 8 C., a temperature at tangent delta peak of about 20 C., and a tangent delta of about 1.2, for example, Hybrar 5127 resin functionalized with maleic anhydride. In another embodiment, the odor barrier layer 12 is formed from a blend comprising about 85 wt. % of amorphous polyamide and about 15 wt. % of a functionalized vinyl-bond rich SIS block copolymer having a glass transition temperature of about 13 C., a temperature at tangent delta peak of about 3 C., and a tangent delta of about 0.7, for example, Hybrar 5125 resin functionalized with maleic anhydride. In yet another embodiment, the odor barrier layer 12 is formed from a blend comprising about 85 wt. % of amorphous polyamide and about 15 wt. % of a functionalized vinyl-bond rich SEPS block copolymer having a glass transition temperature of about 15 C., a temperature at tangent delta peak of about 5 C., and a tangent delta of about 0.45, for example, Hybrar 7125 resin functionalized with maleic anhydride.

(14) The tie layers may be provided adjacent the odor barrier layer to facilitate adhesion of the odor barrier layer to the other layers of the multilayer film. In the embodiment of FIG. 1, the tie layer 14 is arranged between the odor barrier layer 12 and the outer layer 18, while the tie layer 16 is arranged between the odor barrier layer 12 and the outer layer 20. The tie layers 14, 16 may be formed from a same material or different materials depending on the composition of the odor barrier layer 12 and the outer layers 18, 20. Suitable materials for the tie layers 14, 16 include maleated polyolefins, such as a maleated ethylene methyl acrylate copolymers (EMA-MAH) having maleic anhydride present at about 0.3 wt. % and methyl acrylate present at about 20 wt. % of the resin. One such material is available from Arkema, Inc. as Lotader 4503. In one embodiment, the tie layers 14, 16 are formed from a blend comprising 80 wt. % EMA (Lotryl 18MA02 from Arkema, Inc.) and 20 wt. % maleated compound (BynelCXA41E710 from DuPont.)

(15) In some embodiments, the tie layers 14, 16 may also provide sound absorbing properties. In such embodiments, the tie layer 46 may comprise a vinyl-bond rich triblock copolymer, such as Hybrar to enhance mechanical properties and sound absorbing properties of the film 10. For example, the tie layers 14, 16 may be formed from a blend of a vinyl-bond rich SEPS block copolymer (e.g. Hybrar 7125) and a maleated compound (such as BynelCXA41E710).

(16) The outer layers 18, 20 may be formed from the same material or different materials. Preferably, at least one of the outer layers 18, 20 is a seal layer having suitable heat sealability, such that the seal layers may be heat sealed together to form a pouch. Suitable materials for the outer layers 18, 20 include ethylene based polymers, such as copolymers of ethylene with vinyl esters, e.g. ethylene vinyl acetate (EVA) and ethylene methyl acrylate (EMA), ethylene alpha olefin copolymers (ethylene based plastomers), ethylene based elastomers (olefin block copolymers, OBC), and ethylene-propylene (EP) copolymers (PP-elastomer), and blends thereof. Suitable EVA copolymers include those containing about 5 wt. % to 35 wt. % vinyl acetate, preferably about 18 wt. % vinyl acetate. One such EVA copolymer is available from ExxonMobil as product Escorene Ultra FL00218. Such EVA copolymers may have a melting point temperature of 86 C. and a Shore A hardness of about 91. EVA copolymers are known to exhibit the necessary characteristics for joining to another EVA member, as by heat sealing, to provide an air-tight, liquid-tight seal at the joint or seal. EVA copolymer may be blended to facilitate formation and film extrusion. For example, an EVA blend may contain about 98 wt. % EVA copolymer, and about 2 wt. % anti-block and slip additives in an EVA carrier. One such additive is available from A. Schulman Inc., as Polybatch SAB-1982VA.

(17) Suitable EMA copolymers include about 5 wt. % to about 35 wt. % methyl acrylate, and preferably about 15 wt. % to about 30 wt. % methyl acrylate. One such EMA copolymer is Lotryl28AM02 supplied by Arkema Inc. This copolymer has a melting point of about 83 C. and specific gravity of about 0.841. EMA copolymers may be blended with anti-block and/or slip additives in an EVA carrier. One such suitable additive is the aforementioned Polybatch SAB-1982VA. The blend may contain 98 wt. % EMA copolymer, and about 2 wt. % Polybatch SAB-1982VA anti-block and slip additive.

(18) Another suitable material for the outer layers 18, 20 is ethylene alpha olefin copolymers (ethylene based plastomers). An example of suitable ethylene alpha olefin copolymers is Exact 0203 resin, supplied by ExxonMobil Corporation, which has a specific gravity of about 0.88, a Shore A hardness of about 95, a melting point temperature of about 95 C., and specific gravity of about 0.902. This resin is designed for both monolayer and multilayer co-extruded cast film applications and is suitable in applications that require toughness and heat sealing performance.

(19) Still another suitable material for the outer layers 18, 20 is ethylene based elastomers (olefin block copolymers, OBC), for example, Infuse 9107 supplied by Dow Chemical. This material has a specific gravity of about 0.866, a Shore A hardness of about 60 and a melting point of about 121 C.

(20) Still another suitable material for the outer layers 18, 20 is an ethylene-propylene copolymer (PP-elastomer) resin. It has a low modulus and thus exhibits low noise characteristics. It has excellent compatibility with polypropylene (PP) and polyethylene (PE). Preferably, ethylene-propylene copolymers include about 6 wt. % to about 18 wt. % ethylene. An example of suitable ethylene-propylene copolymers is Versify2200 available from Dow Chemical. This resin is a PP-elastomer including about 9 wt. % ethylene and has melting point of about 82 C., a Shore A hardness of about 94 and a Shore D hardness of about 42. It has a specific gravity of about 0.878. Another example is Vistamaxx 3980FL from Exxon, which is a PP-elastomer including about 8.5 wt. % ethylene.

(21) Polymer blends comprising EVA copolymer, EMA copolymer, ethylene alpha olefin copolymers (ethylene based plastomers), ethylene based elastomers (olefin block copolymers, OBC), and ethylene-propylene (EP) copolymers (PP-elastomer) are also suitable for the outer layers. Examples include, but are not limited to, a blend of EVA copolymer (EscoreneFL00218 present at 49 wt. %) and ethylene-propylene copolymer (PP-elastomer, Versify2200 present at 49 wt. %) with anti-block and slip additives, and a blend of EMA copolymer (Elvaloy1330AC present at 49 wt. %) and PP-elastomer (Versify2200 present at 49 wt. %) also with anti-block and slip additives. Blends of various EP copolymer resins are also suitable, for example, blends of Versify2200 and Versify3400, which is a similar EP copolymer resin, but has a higher melting point of about 97 C., a Shore A hardness of 72 and a Shore D hardness of 22, and a specific gravity of about 0.865. Suitable blends can have ratios of about 50 wt. % of Versify2200 to about 75 wt. % of Versify2200 of the blend. PP-elastomers such as Versify, Vistamaxx, and Notio from Mitsui, and PP-EP rubber such as Adflex Q100F from LyondellBasell are also suitable.

(22) In one embodiment, the outer layers 18, 20 may be formed from a blend including about 49 wt. % EVA copolymer (e.g. Escorene Ultra FL00218), about 49 wt. % EP copolymer (e.g. Vistamaxx 3980FL), and about 2 wt. % anti-block and slip additive (e.g. Polybatch SAB-1982VA.)

(23) The outer layers 18, 20 may also provide sound absorbing properties. In such an embodiment, the outer layers 18, 20 may comprise a vinyl-bond rich triblock copolymer, such as Hybrar to enhance mechanical properties and sound absorbing properties. For example, the outer layers 18, 20 may be formed from a blend of vinyl-bond rich styrene-isoprene-styrene (SIS) block copolymer (e.g. Hybrar 5127), PP-elastomer (e.g. Vistamaxx), and EMA copolymer (e.g. Lotryl 20MA08).

(24) Although, the multilayer film 10 of FIG. 1 is shown as a five-layer film having an outer layer/tie layer/odor barrier layer/tie layer/outer layer construction, in other embodiments, a multilayer film may have a different film construction or may have more than five layers or less than five layers. For example, a four-layer film 100 including an odor barrier layer having sound dampening properties is shown in FIG. 2. The four-layer film 100 has an outer layer 108/tie layer 104/odor barrier layer 102/tie layer 106 construction. FIG. 5 illustrates a five-layer film having a different film construction. The five-layer film 300 has an outer layer 310/inner layer 308/tie layer 304/odor barrier layer 302/tie layer 306 construction.

(25) FIG. 3 is a cross-sectional illustration of a multilayer film 200 including an odor barrier layer having sound dampening properties according to another embodiment. The multilayer film 200 is a seven-layer film including an odor barrier layer 202, two tie layers 204, 206, two inner layers 208, 210, and two outer layers 212, 214. The seven-layer film 200 is similarly constructed as the five-layer film 100 of FIG. 100, except the inner layers 208, 210 are provided between the tie layers 204, 206 and the outer layers 212, 214.

(26) As shown, the inner layer 208 is arranged between the tie layer 204 and the outer layer 212, while the inner layer 210 is arranged between the tie layer 206 and the outer layer 214. The inner layers 208, 212 may provide improved film properties. For example, the inner layers 208, 212 may impart additional mechanical properties, such as improved tear strength to the multilayer film 200. The aforementioned materials for the outer layers 18, 20 of the five-layer film 10 are also suitable for the inner layers 208, 210. For example, ethylene based polymers, such as copolymers of ethylene with vinyl esters, e.g. EVA copolymer and EMA copolymer, ethylene alpha olefin copolymers (ethylene based plastomers), ethylene based elastomers (olefin block copolymers, OBC), and ethylene-propylene (EP) copolymers (PP-elastomer), and blends thereof are suitable for the inner layers 208, 210.

(27) In one embodiment, the inner layers 208, 210 may be formed from a blend including about 65 wt. % EP copolymer (e.g. Vistamaxx 3980FL) and about 35 wt. % PP-EP rubber (e.g. Adflex Q100F.)

(28) In some embodiments, the inner layers 208, 210 may also provide sound absorbing properties. In such an embodiment, the inner layers 208, 210 may comprise a vinyl-bond rich triblock copolymer, such as Hybrar, to enhance mechanical properties and sound absorbing properties of the multilayer film 200. For example, the inner layers 208, 210 may be formed from a blend of vinyl-bond rich styrene-ethylene-propylene-styrene (SEPS) block copolymer (e.g. Hybrar7125) and PP-elastomer (Vistamaxx).

(29) FIG. 6 is a cross-sectional illustration of a multilayer film 400 including an odor barrier layer having sound dampening properties according to yet another embodiment. The multilayer film 400 is a six-layer film including an outer layer 410/inner layer 408/tie layer 404/odor barrier layer 402/tie layer 406/outer layer 412.

(30) The multilayer films according to various embodiments of the present disclosure may be used to manufacture, for example, an ostomy pouch, such as that illustrated in FIG. 4. The pouch 300 is formed from two sheets of film 302, 304 that are heat or otherwise sealed, as at 306 to one another to form an air-tight, liquid-tight pouch 300. An opening 308 in the pouch permits the accommodation of, for example, a surgically formed stoma (not shown) for the inflow of waste into the pouch. The configuration of such a pouch can be in accordance with the disclosure of the aforementioned U.S. Pat. No. 7,270,860 to Giori. Other configurations of pouches or other containers, as well as other uses, will be recognized by those skilled in the art.