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Multi-Layered Thermoplastic Polymer Films Comprising

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Multi-Layered Thermoplastic Polymer Films Comprising (19) TZZ¥__T (11) EP 3 148 796 B1 (12) EUROPEAN PATENT SPECIFICATION (45) Date of publication and mention (51) Int Cl.: of the grant of the patent: B32B 7/12 (2006.01) A61F 13/514 (2006.01) 25.07.2018 Bulletin 2018/30 B32B 27/08 (2006.01) B32B 27/32 (2006.01) B32B 27/36 (2006.01) (21) Application number: 15728357.3 (86) International application number: (22) Date of filing: 01.06.2015 PCT/US2015/033452 (87) International publication number: WO 2015/187520 (10.12.2015 Gazette 2015/49) (54) MULTI-LAYERED THERMOPLASTIC POLYMER FILMS COMPRISING POLYLACTIC ACID MEHRSCHICHTIGE THERMOPLASTISCHE POLYMERFOLIEN MIT POLYMILCHSÄURE FILMS POLYMÈRES THERMOPLASTIQUES MULTICOUCHES COMPRENANT DE L’ACIDE POLYLACTIQUE (84) Designated Contracting States: • BROWN, April Renae AL AT BE BG CH CY CZ DE DK EE ES FI FR GB Cincinnati, Ohio 45202 (US) GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO • GILBERTSON, Gary Wayne PL PT RO RS SE SI SK SM TR Cincinnati, Ohio 45202 (US) (30) Priority: 02.06.2014 US 201462006508 P (74) Representative: Hoyng Rokh Monegier LLP Rembrandt Tower, 31st Floor (43) Date of publication of application: Amstelplein 1 05.04.2017 Bulletin 2017/14 1096 HA Amsterdam (NL) (73) Proprietor: The Procter & Gamble Company (56) References cited: Cincinnati, OH 45202 (US) EP-A1- 1 567 321 WO-A2-2013/006464 US-A1- 2011 052 867 (72) Inventors: • BROYLES, Norman Scott Cincinnati, Ohio 45202 (US) Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). EP 3 148 796 B1 Printed by Jouve, 75001 PARIS (FR) EP 3 148 796 B1 Description FIELD OF THE INVENTION 5 [0001] The present invention generally relates to multi-layered thermoplastic polymer films comprising polylactic acid. BACKGROUND OF THE INVENTION [0002] Many products today utilize films. Some examples of such products include, but are not limited to, personal 10 care absorbent products such as diapers, training pants, incontinence garments, sanitary napkins, bandages, wipes and the like, as well as products such as packaging materials, and other disposable products such as trash bags and food bags. These films are typically made from thermoplastic polymers. [0003] Many thermoplastic polymers are derived from monomers that are obtained from non-renewable, fossil-based resources such as petroleum, natural gas, and coal. In recent years, as manufacturers and consumers have gained a 15 greater awareness of environmental and sustainability concerns, the demand for polymers made from renewable, non- fossil-based materials has grown significantly. Unfortunately, however, many renewable thermoplastic biopolymers are not well suited for solo use in stand-alone applications. Associated with the desire to reduce utilization of non-renewable natural resources, the ability to "down-gauge" or reduce the thickness and/or polymer content of films, products and packages while maintaining performance is also advantageous. Technologies that reduce the utilization of non-renewable 20 natural resources through incorporation of biopolymers while also enabling down gauging are highly desired. [0004] Attempts have been made in the art at producing films, fibers and other compositions from renewable biopol- ymers, such as polylactic acid (see, e.g., EP 2285892; WO 2008/149943; USPNs 5,910,545; 6,177,193; 6,309,988; 6,506,873; 7,132,490; 8,137,773; 8,461,262; 2009/0263600; 2009/0326152; 2009/0324911; 2012/0035323; 2012/0219783; 2013/0157032 and 2013/0190408). However, the use of PLA may result in deficiencies in the context 25 of making thin, flexible packaging films such as those typically used for personal hygiene articles, wipes, product bags, and for personal care products. For instance, PLA thin film exhibits high stiffness, brittleness, high rustling noise levels when handled, low extensibility, low ductility, and low toughness relative to polyolefin. As such, PLA is not typically used as a major component in films for such applications. [0005] US2011/052867 discusses a laminate film including a layer A of a resin composition composed mainly of a 30 polylactic acid-based resin, Layer B of a resin composition composed mainly of a polyolefin-based resin laminated to Layer A, and Layer C of a resin composition laminated to Layer A. The modulus in a longitudinal direction of the film is said to be 2.0 to 7.0 GPa and, after being subjected to heat treatment at 100 degrees centigrade for 5 minutes, thermal shrinkage in the longitudinal direction and in a width direction of the film is said to be 10 percent or less and 20 percent or less, respectively. 35 [0006] WO2013/006464 discusses polylactic acid based film compositions. In one form, the film composition includes from 90 to 99 wt. % of one or more polylactic acid resins and from 1 to 10 wt.% of one or more polyterpene resin additives based on the total film structure. [0007] EP1567321 discusses a multi-microlayer thermoplastic film with a corrugated polymer layer and a thermoplastic elastomer layer. Filler materials may be included in either the corrugated polymer layer or the thermoplastic elastomer 40 layer. The multi-microlayer films may be formed in a co-extrusion process. [0008] Thermoplastic polymers such as polyolefins ("PO") are commonly used to produce thin films for consumer product packaging because of their excellent processability. As a result, common film-manufacturing equipment is optimally designed for making polyolefin-based films. Replacing or modifying this manufacturing equipment to run other types of polymers would require high development costs and excessive capital expenditures, making this option imprac- 45 tical for most manufacturers. [0009] Accordingly, thermoplastic polymer compositions that are not only suitable for making thin films using standard polyolefin film-manufacturing equipment, but also contain bio-based content having good mechanical properties, are highly desirable. 50 SUMMARY OF THE INVENTION [0010] A multi-layered film comprising at least 3, preferably at least 5, layers is provided in accordance with the claims. BRIEF DESCRIPTION OF THE DRAWINGS 55 [0011] FIGURE is a cross-sectional view of one example of a multi-layer film described herein. 2 EP 3 148 796 B1 DETAILED DESCRIPTION I. DEFINITIONS 5 [0012] As used herein, the following terms shall have the meanings specified thereafter: "Absorbent article" refers to any absorbent consumer product or portion thereof, including absorbent personal hygiene articles (e.g., wipes, diapers, diaper components such as a backsheets or portion of a backsheet, training pants, absorbent underpants, adult incontinence products, feminine hygiene products such as pads and tampons; coverings (e.g., floor coverings, table cloths, picnic area covers); medical products (e.g., surgical gowns and drapes, face masks, head 10 coverings, shoe coverings, wound dressings, bandages, sterilization wraps, and the like for medical, dental or veterinary applications); and garments (any type of apparel which may be worn, e.g., industrial work wear and coveralls, under- garments, pants, shirts, jackets, gloves, socks, head coverings, shoe coverings, aprons, surgical clothing, and the like). [0013] "Bio-polymers" refers to polymers derived from biological materials, typically plant materials. [0014] "Copolymer" refers to a polymer derived from two or more polymerizable monomers. When used in generic 15 terms the term "copolymer" is also inclusive of more than two distinct monomers, for example, ter-polymers. The term "copolymer" is also inclusive of random copolymers, block copolymers, and graft copolymers. [0015] "Contiguous" means in direct contact with. Where a layer is "contiguous," it is in direct contact with at least one adjacent layer. [0016] "Cross machine direction" or "CD" refers to the width of film, i.e. a direction generally perpendicular to the MD. 20 [0017] "Film" refers to a sheet-like material wherein the length and width of the material far exceed the thickness of the material. As used herein, the terms "film" and "sheet" are used interchangeably. [0018] "Joined to" encompasses configurations in which an element is directly secured to another element by affixing the element directly to the other element, and configurations in which the element is indirectly secured to the other element by affixing the element to intermediate member(s) which in turn are affixed to the other element. 25 [0019] "Machine direction" or MD means the length of film as it is produced. [0020] "Renewable" refers to a material that can be produced or is derivable from a natural source which is periodically (e.g., annually or perennially) replenished through the actions of plants of terrestrial, aquatic or oceanic ecosystems (e.g., agricultural crops, edible and non-edible grasses, forest products, seaweed, or algae), or microorganisms (e.g., bacteria, fungi, or yeast). 30 [0021] "Substantially no", "substantially free of’, and/or "substantially free from" mean that the indicated material is at the very minimum not deliberately added to the composition to form part of it, or, most desirably, is not present at analytically detectable levels. It is meant to include compositions whereby the indicated material is present only as an impurity in one of the other materials deliberately included. In some embodiments, substantially free of means that the layer or film comprises less than 5%, 3%, 2%, 1%, 0.5%, 0.1% or 0.01% by weight of the ingredient or material. 35 [0022] As used herein, articles such as "a" and "an" are understood to mean one or more of what is claimed or described. [0023] As used herein, the terms "include", "contain", and "has", as well as their various verb tenses, are meant to be non-limiting.
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