Multi-layered meltblown composite and methods for making same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-005/26
B32B-005/06
D01F-006/30
B32B-005/04
B32B-005/08
D01D-005/098
D04H-003/12
D04H-003/14
D04H-003/16
B32B-005/02
B32B-005/22
출원번호
US-0894955
(2010-09-30)
등록번호
US-9498932
(2016-11-22)
발명자
/ 주소
Richeson, Galen C.
Westwood, Alistair D.
Ferry, William Michael
출원인 / 주소
ExxonMobil Chemical Patents Inc.
대리인 / 주소
Prasad, Priya G.
인용정보
피인용 횟수 :
1인용 특허 :
279
초록▼
Multilayer meltblown composites, articles made therefrom, and methods for making same. One method can include meltblowing a first material to form a first meltblown layer; meltblowing a second material to form a second meltblown layer; and meltblowing a third material to form a third meltblown layer
Multilayer meltblown composites, articles made therefrom, and methods for making same. One method can include meltblowing a first material to form a first meltblown layer; meltblowing a second material to form a second meltblown layer; and meltblowing a third material to form a third meltblown layer, wherein each material is the same or different, each material includes at least one resin having a MFR of about 2,000 dg/min or less, as measured by ASTM D1238, 2.16 kg, 230° C., and at least one of the first, second, and third materials comprises an elastomer having a recovery of at least 70% after 100% deformation, as determined by ASTM D412.
대표청구항▼
1. A method for forming a multilayer meltblown composite, consisting of: meltblowing a first material to form a first meltblown layer, wherein the first material comprises one or more resins having an Ultimate Elongation (UE) of from about 50% to about 250%;meltblowing a second material to form a se
1. A method for forming a multilayer meltblown composite, consisting of: meltblowing a first material to form a first meltblown layer, wherein the first material comprises one or more resins having an Ultimate Elongation (UE) of from about 50% to about 250%;meltblowing a second material to form a second meltblown layer, wherein the second material comprises one or more resins having an Ultimate Elongation (UE) of 200% or more; andmeltblowing a third material to form a third meltblown layer, wherein the third material comprises one or more resins having an Ultimate Elongation (UE) of from about 50% to about 250%;wherein each resin has a MFR of about 2,000 dg/min or less, as measured by ASTM D1238, 2.16 kg, 230° C., and at least one of the first, second, and third materials comprises a propylene-α-olefin copolymer having a heat of fusion of 75 J/g or less and having a recovery of at least 70% after 100% deformation, as measured by ASTM D412,wherein the first, second, and third meltblown layers are formed in situ such that the layers form an in situ laminate;wherein the first and the third meltblown layers are facing layers; andwherein at least one of the facing layers consists of (a) polypropylene, wherein the polypropylene has a heat of fusion ranging from 60 J/g to 189 J/g, and (b) about 0.5 wt % of a blend component, wherein the blend component is selected from the group consisting of impact copolymers, random copolymers, polyethylenes, polyethylenes with a weight average molecular weight of less than 20,000 g/mol, polypropylenes having a weight average molecular weight of less than 20,000 g/mol, polyalphaolefins, and combinations thereof. 2. The method of claim 1, wherein each meltblown layer has a basis weight within the range of from 5 g/m2 to 300 g/m2. 3. The method of claim 1, wherein each meltblown layer has a basis weight within the range of from 10 g/m2to 150 g/m2. 4. The method of claim 1, wherein the first meltblown layer has a basis weight within the range of from 5 g/m2 to 300 g/m2; the second meltblown layer has a basis weight within the range of from 15 g/m2 to 150 g/m2; and the third meltblown layer has a basis weight within the range of from 5 g/m2 to 300 g/m2. 5. The method of claim 1, wherein the second meltblown layer comprises at least 5 wt % of the propylene-α-olefin copolymer having a heat of fusion of 75 J/g or less. 6. The method of claim 5, wherein the second meltblown layer comprises at least 10 wt % of the propylene-α-olefin copolymer having a heat of fusion of 75 J/g or less. 7. The method of claim 1, wherein the melt temperature of the second meltblown layer is about 325° C. or less. 8. The method of claim 1, wherein each material has a MFR (ASTM D1238, 2.16 kg, 230° C.) of less than 50 dg/min. 9. The method of claim 1, wherein the second meltblown layer is at least 10 wt % of the total weight of the multilayer composite. 10. The method of claim 1, wherein the second meltblown layer is disposed between the first and third meltblown layers. 11. The method of claim 1, wherein each material is meltblown onto a moving surface. 12. A multilayer meltblown composite, consisting of: a first meltblown layer comprising one or more resins wherein said one or more resins has an Ultimate Elongation (UE) of from about 50% to about 250%;a second meltblown layer comprising one or more resins wherein said one or more resins has an Ultimate Elongation (UE) of 200% or more; anda third meltblown layer comprising one or more resins wherein said one or more resins has an Ultimate Elongation (UE) of from about 50% to about 250%;wherein each resin has a MFR of about 2,000 dg/min or less, as measured by ASTM D1238, 2.16 kg, 230° C., and at least one of the first, second, and third meltblown layers comprises a propylene-α-olefin copolymer having a heat of fusion of 75 J/g or less and having a recovery of at least 70% after 100% deformation, as determined by ASTM D412;wherein the first, second, and third meltblown layers are formed in situ such that the layers form an in situ laminate;wherein the first and the third meltblown layers are facing layers; andwherein at least one of the facing layers consists of (a) polypropylene, wherein the polypropylene has a heat of fusion ranging from 60 J/g to 189 J/g, and (b) about 0.5 wt % of a blend component, wherein the blend component is selected from the group consisting of impact copolymers, random copolymers, polyethylenes, polyethylenes with a weight average molecular weight of less than 20,000 g/mol, polypropylenes having a weight average molecular weight of less than 20,000 g/mol, polyalphaolefins, and combinations thereof. 13. The meltblown composite of claim 12, wherein each meltblown layer has a basis weight within the range of from 5 g/m2 to 300 g/m2. 14. The meltblown composite of claim 12, wherein the first meltblown layer has a basis weight within the range of from 5 g/m2 to 300 g/m2; the second meltblown layer has a basis weight within the range of from 15 g/m2 to 150 g/m2; and the third meltblown layer has a basis weight within the range of from 5 g/m2 to 300 g/m2. 15. The meltblown composite of claim 12, wherein the second meltblown layer comprises at least 10 wt % of the propylene-α-olefin copolymer having a heat of fusion of 75 J/g or less. 16. The meltblown composite of claim 12, wherein one of the first and third meltblown layers comprises at least 5 wt % of the propylene-α-olefin copolymer having a heat of fusion of 75 J/g or less. 17. The meltblown composite of claim 12, wherein the melt temperature of the second meltblown layer is about 325° C. or less. 18. The meltblown composite of claim 12, wherein each resin has a MFR (ASTM D1238, 2.16 kg, 230° C.) of less than 50 dg/min. 19. The meltblown composite of claim 12, wherein the second meltblown layer is at least 10 wt % of the total weight of the multilayer composite. 20. The meltblown composite of claim 12, wherein the second meltblown layer is disposed between the first and third meltblown layers. 21. An article of manufacture, incorporating as one or more components, a multilayer meltblown composite consisting of: a first meltblown layer comprising one or more resins wherein said one or more resins has an Ultimate Elongation (UE) of from about 50% to about 250%;a second meltblown layer comprising one or more resins wherein said one or more resins has an Ultimate Elongation (UE) of 200% or more; anda third meltblown layer comprising one or more resins wherein said one or more resins has an Ultimate Elongation (UE) of from about 50% to about 250%,wherein each resin has a MFR of about 2,000 dg/min or less, as measured by ASTM D1238, 2.16 kg, 230° C., and at least one of the first, second, and third meltblown layers comprises a propylene-α-olefin copolymer having a heat of fusion of 75 J/g or less and having a recovery of at least 70% after 100% deformation, as determined by ASTM D412;wherein the first, second, and third meltblown layers are formed in situ such that the layers form an in situ laminate;wherein the first and the third meltblown layers are facing layers; andwherein at least one of the facing layers consists of (a) polypropylene, wherein the polypropylene has a heat of fusion ranging from 60 J/g to 189 J/g, and (b) about 0.5 wt % of a blend component, wherein the blend component is selected from the group consisting of impact copolymers, random copolymers, polyethylenes, polyethylenes with a weight average molecular weight of less than 20,000 g/mol, polypropylenes having a weight average molecular weight of less than 20,000 g/mol, polyalphaolefins, and combinations thereof.
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