Multi-Layer Films And Methods Of Forming Same

Abstract

A multi-layer film having a first film layer being at least partially formed from a polymer (A) and a polymer (B) and a second film layer being at least partially formed from the polymer (A), the polymer (B), a polymer (C), and optionally an opacifying agent, wherein at least one of the polymer (A), the polymer (B) and the polymer (C) is synthetic and is at least partially derived from a renewable resource such that the multi-layer film has a bio-based content of about 10% to about 100% using ASTM D6866-10, method B. Methods of forming multi-layer films are also provided.

1 . A multi-layer film comprising:
 a) a first film layer having an upper surface and a lower surface, the first film layer being at least partially formed from a polymer (A) and a polymer (B), wherein the first film layer comprises from about 75% to about 99% by weight of the polymer (A) and from about 1% to about 25% by weight of the polymer (B), wherein the polymer (A) comprises at least one of a low density polyethylene (LDPE) and a linear low density polyethylene (LLDPE) and the polymer (B) comprises a copolymer;   b) a second film layer at least partially overlying one of the upper surface and the lower surface of the first film layer, the second film layer being at least partially formed from the polymer (A), the polymer (B), a polymer (C), and optionally an opacifying agent, wherein the polymer (C) comprises a homo polypropylene (homo-PP), and wherein at least one of the polymer (A), the polymer (B) and the polymer (C) is synthetic and is at least partially derived from a renewable resource; and   c) a bio-based content of about 10% to about 100% using ASTM D6866-10, method B.   
     
     
         2 . The multi-layer film of  claim 1  further comprising a third film layer, the third film layer at least partially overlying the second film layer such that the second film layer forms a core layer, the third film layer comprises from about 75% to about 99% by weight of the polymer (A) and from about 1% to about 25% by weight of the polymer (B). 
     
     
         3 . The multi-layer film of  claim 1 , wherein the second film layer comprises from about 20% to about 90% by weight of the polymer (A). 
     
     
         4 . The multi-layer film of  claim 3 , wherein the second film layer comprises from about 40% to about 75% by weight of the polymer (A) and the opacifying agent. 
     
     
         5 . The multi-layer film of  claim 1 , wherein the second film layer comprises from about 35% to about 60% by weight of the polymer (B). 
     
     
         6 . The multi-layer film of  claim 1 , wherein the second film layer comprises from about 1% to about 35% by weight of the polymer (C). 
     
     
         7 . The multi-layer film of  claim 5 , wherein second film layer comprises from about 25% to about 60% by weight of the polymer (B) and the polymer (C). 
     
     
         8 . The multi-layer film of  claim 1  further comprising from about 0.1% to about 5.0% by weight of additives. 
     
     
         9 . The multi-layer film of  claim 1  further comprising the opacifying agent, wherein the opacifying agent comprises one or more of titanium dioxide, calcium carbonate, or combinations thereof. 
     
     
         10 . The multi-layer film of  claim 1 , wherein the first film layer comprises from about 85% to about 95% by weight of the polymer (A) and from about 5% to about 10% by weight of the polymer (B). 
     
     
         11 . The multi-layer film of  claim 1 , wherein the copolymer is an ethylene-propylene random block copolymer. 
     
     
         12 . The multi-layer film of  claim 2 , wherein at least one of the first film layer and the third film layer comprises an indicia to communicate an environmental message to a consumer. 
     
     
         13 . The multi-layer film of  claim 1  having a tensile strength at 10% elongation from about 8 N/mm 2  to about 24 N/mm 2 . 
     
     
         14 . The multi-layer film of  claim 13  having a tensile strength at 10% elongation from about 10 N/mm 2  to about 15 N/mm 2 . 
     
     
         15 . The multi-layer film of  claim 1  having a tensile strength at break from about 20 N/mm 2  to about 60 N/mm 2 . 
     
     
         16 . The multi-layer film of  claim 15  having a tensile strength at break from about 25 N/mm 2  to about 40 N/mm 2 . 
     
     
         17 . The multi-layer film of  claim 1  having a thickness from about 10 microns to about 200 microns. 
     
     
         18 . The multi-layer film of  claim 17  having a thickness from about 20 microns to about 100 microns. 
     
     
         19 . The multi-layer film of  claim 1  having a seal strength from about 0.10 N/mm to about 2.0 N/mm. 
     
     
         20 . The multi-layer film of  claim 19  having a seal strength from about 0.20 N/mm to about 1.0 N/mm. 
     
     
         21 . The multi-layer film of  claim 2  having the bio-based content of about 20% to about 100% using ASTM D6866-10, method B. 
     
     
         22 . The multi-layer film of  claim 21  having the bio-based content of about 50% to about 100% using ASTM D6866-10, method B. 
     
     
         23 . An absorbent article package comprising the multi-layer film of  claim 1 . 
     
     
         24 . A method of forming a multi-layer film, the method comprises:
 a) processing a first film layer, wherein the first film layer having an upper surface and a lower surface, the first film layer being at least partially formed from a polymer (A) and a polymer (B), wherein the first film layer comprises from about 75% to about 99% by weight of the polymer (A) and from about 1% to about 25% by weight of the polymer (B), wherein the polymer (A) comprises at least one of a low density polyethylene (LDPE) and a linear low density polyethylene (LLDPE) and the polymer (B) comprises a copolymer;   b) processing a second film layer, the second film layer being at least partially formed from the polymer (A), the polymer (B), a polymer (C), and optionally an opacifying agent, wherein the polymer (C) comprises a homo polypropylene (homo-PP), and wherein at least one of the polymer (A), the polymer (B) and the polymer (C) is synthetic and is at least partially derived from a renewable resource; and   c) at least partially overlying the second film layer onto one of the upper surface and the lower surface of the first film layer to form a multi-layer film having a bio-based content of about 10% to about 100% using ASTM D6866-10, method B.   
     
     
         25 . The method of  claim 24 , wherein the multi-layer film is formed via a co-extrusion process. 
     
     
         26 . A multi-layer film comprising:
 a) a first film layer having an upper surface and a lower surface;   b) a second film layer at least partially overlying one of the upper surface and the lower surface of the first film layer;   c) a third film layer at least partially overlying the second film layer such that the second film layer forms a core layer;   d) a bio-based content of about 10% to about 100% using ASTM D6866-10, method B; and   e) wherein the multi-layer film has a thickness from about 10 microns to about 200 microns, a tensile strength at 10% elongation from about 8 N/mm 2  to about 24 N/mm 2 , and a seal strength from about 0.10 N/mm to about 2.0 N/mm.   
     
     
         27 . The multi-layer film of  claim 26  further comprising from about 0.1% to about 5.0% by weight of additives. 
     
     
         28 . The multi-layer film of  claim 26  further comprising an opacifying agent, wherein the opacifying agent comprises one or more of titanium dioxide, calcium carbonate, or combinations thereof. 
     
     
         29 . An absorbent article package comprising the multi-layer film of  claim 26 . 
     
     
         30 . A multi-layer film comprising:
 a) from about 40% to about 90% by weight of the polymer (A), wherein the polymer (A) comprises at least one of a low density polyethylene (LDPE) and a linear low density polyethylene (LLDPE);   b) from about 5% to about 50% by weight of a polymer (B), wherein polymer (B) is a copolymer;   c) from about 1% to about 20% by weight of a polymer (C), wherein the polymer (C) comprises a homo polypropylene (homo-PP); and   d) a bio-based content of about 10% to about 100% using ASTM D6866-10, method B.