Elastic films made from alpha-olefin/vinyl aromatic and/or aliphatic or cycloaliphatic vinyl or vinylidene

Abstract

The present invention pertains to elastic films having at least one layer comprising a substantially random interpolymer or a blend thereof. The interpolymer comprises polymer units derived from at least C 2-20 α-olefin and (i) at least one vinyl aromatic monomer, or (ii) at least one aliphatic or cycloaliphatic vinyl or vinylidene monomer, or (iii) a combination of at least one aromatic vinyl monomer and at least one aliphatic or cycloaliphatic vinyl or vinylidene monomer. The interpolymer may also comprise one or more ethylenically unsaturated polymerizable monomers other than those previously mentioned. The elastic films have a recovery in the cross direction of greater than or equal to about 80% and has a recovery in the machine direction of greater than or equal to about 60%.

What is claimed:  
     
         30 . An elastic film having at least one layer comprising; 
 (A) at least one substantially random interpolymer, which comprises; 
 (1) polymer units derived from at least one vinyl aromatic monomer; and  
 (2) polymer units derived from at least one C 2-20  α-olefin; and optionally  
 (3) polymer units derived from one or more ethylenically unsaturated polymerizable monomers other than those of (1) and (2);  
   wherein said elastic film has a recovery in the cross direction of greater than or equal to about 80% and has a recovery in the machine direction of greater than or equal to about 60%, and the substantially random interpolymer has a M w /M n  of from about 3 to about 10.    
     
     
         31 . The elastic film of  claim 30  wherein the at least one layer further comprises (B) at least one polymer other than that of Component A  
     
     
         32 . The elastic film of  claim 31  wherein; 
 (I) Component A is present in an amount from about 50 to 100 wt % based on the combined weights of Components A and B and has an I 2  of about 0.1 to about 1,000 g/10 min; and comprises; 
 (1) from about 10 to about 40 mol % of polymer units derived from at least one vinyl aromatic monomer; and  
 (2) from about 60 to about 90 mol % of polymer units derived from at least one C 2-20  α-olefin; and  
 (3) from 0 to about 20 mol % of polymer units derived from one or more of said ethylenically unsaturated polymerizable monomers other than those derived from (1) and (2); and  
 
 (II) Component B is present in an amount from 0 to about 50 wt % based on the combined weights of Components A and B.  
 
     
     
         33 . The elastic film of  claim 31  wherein; 
 (I) said substantially random interpolymer Component A is present in an amount of about 75 to 100 wt % based on the combined weights of Components A and B and has an I 2  of about 0.5 to about 200 g/10 min; and comprises 
 (1) from about 13 to about 33 mol % of polymer units derived from said vinyl aromatic monomer represented by the following formula;  
                     
 wherein R 1  is selected from the group of radicals consisting of hydrogen and alkyl radicals containing three carbons or less, and Ar is a phenyl group or a phenyl group substituted with from 1 to 5 substituents selected from the group consisting of halo, C 1-4 -alkyl, and C 1-4 -haloalkyl and n has a value from zero to about 4; and  
 (2) from about 67 to about 87 mol % of polymer units derived from said α-olefin which comprises ethylene, or ethylene and at least one of propylene, 4-methyl-1-pentene, butene-1, hexene-1 or octene-1; and  
 (3) said ethylenically unsaturated polymerizable monomers other than those derived from (1) and (2) comprises norbomene, or a C 1-10  alkyl or C 6-10  aryl substituted norbornene; and  
 
 II) Component B is present in amount from 0 to about 25 wt % based on the combined weights of Components A and B and comprises one or more of 
 A) a homogeneous interpolymer;  
 B) a heterogeneous interpolymer;  
 C) a thermoplastic olefin;  
 D) a styrenic block copolymer;  
 E) a styrenic homo- or copolymer;  
 F) an elastomer;  
 G) a thermoset polymer;  
 H) a vinyl halide polymer; or  
 I) an engineering thermoplastic.  
 
 
     
     
         34 . The elastic film of  claim 31  wherein; 
 (I) said substantially random interpolymer, Component A, is present in an amount from about 90 to about 95 wt % based on the combined weights of Components A and B and has an I 2  of about 0.5 to about 100 g/10 min; and comprises 
 (1) from about 15 to about 29 mol % of polymer units derived from said vinyl aromatic monomer which comprises styrene, α-methyl styrene, ortho-, meta-, and para-methylstyrene, and the ring halogenated styrenes;  
 (2) from about 71 to about 85 mol % of polymer units derived from said α-olefin, which comprises ethylene, or ethylene and at least one of propylene, 4-methyl-1-pentene, butene-1, hexene-1 or octene-1; or  
 (3) said ethylenically unsaturated polymerizable monomers other than those derived from (1) and (2) is norbomene; and  
 
 II) Component B is present in amount from about 5 to about 10 wt % based on the combined weights of Components A and B and comprises one or more of; 
 A) a substantially linear ethylene/α-olefin interpolymer;  
 B) a heterogeneous ethylene/C 3 -C 8  α-olefin interpolymer;  
 C) an ethylene/propylene rubber (EPM), ethylene/propylene diene monomer terpolymer (EPDM), isotactic polypropylene;  
 D) a styrene/ethylene-butene copolymer, a styrene/ethylene-propylene copolymer, a styrene/ethylene-butene/styrene (SEBS) copolymer, a styrene/ethylene-propylene/styrene (SEPS) copolymer;  
 E) the acrylonitrile-butadiene-styrene (ABS) polymers, styrene-acrylonitrile (SAN), polystyrene, high impact polystyrene;  
 F) polyisoprene, polybutadiene, natural rubbers, ethylene/propylene rubbers, ethylene/propylene diene (EPDM) rubbers, styrene/butadiene rubbers, thermoplastic polyurethanes;  
 G) epoxies, vinyl ester resins, polyurethanes, phenolic resins;  
 H) homopolymers or copolymers of vinyl chloride or vinylidene chloride; or  
 I) poly(methylmethacrylate), polyester,nylon-6, nylon-6,6, poly(acetal); poly(amide), poly(arylate), poly(carbonate), poly(butylene) and polybutylene, polyethylene terephthalates.  
 
 
     
     
         35 . The elastic film of  claim 34  wherein Component A1 is styrene, Component A2 is ethylene, and Component B is polystyrene.  
     
     
         36 . The elastic film of  claim 34  wherein Component A1 is styrene; and Component A2 is ethylene and at least one of propylene, 4-methyl-1-pentene, butene-1, hexene-1 or octene-1; and Component B is polystyrene.  
     
     
         37 . A fabricated article comprising the elastic film of  claim 31 .  
     
     
         38 . The fabricated article of  claim 37  in the form of a tape, bandage, incontinence garment, disposable diaper, disposable and protective clothing and fabrics, a food wrap, meat wrap or a household wrap.  
     
     
         39 . A multilayer film comprising at least two layers wherein at least one of said layers has a recovery in the cross direction of greater than or equal to about 80% and has a recovery in the machine direction of greater than or equal to about 60% and comprises a polymer composition which comprises; 
 (A) at least one substantially random interpolymer, which comprises; 
 (1) polymer units derived from at least one vinyl aromatic monomer, and  
 (2) polymer units derived from at least one C 2-20  α-olefin; and optionally,  
 (3) polymer units derived from one or more ethylenically unsaturated polymerizable monomers other than those of (1) and (2),  
 wherein the substantially random interpolymer has a M w /M n  of from about 3 to about 10.  
   
     
     
         40 . The multilayer film of  claim 39  further comprising (B) at least one polymer other than that of Component A.  
     
     
         41 . The multilayer film of  claim 40  wherein; 
 (I) said substantially random interpolymer, Component A, is present in an amount from about 50 to 100 wt % based on the combined weights of Components A and B and has an I 2  of about 0.1 to about 1,000 g/10 min; and comprises; 
 (1) from about 10 to about 40 mol % of polymer units derived from at least one vinyl aromatic monomer, and  
 (2) from about 60 to about 90 mol % of polymer units derived from at least one C 2- 20  α-olefin; or  
 (3) from 0 to about 20 mol % of polymer units derived from one or more of said ethylenically unsaturated polymerizable monomers other than those derived from (1) and (2); and  
 
 (II) Component B is present in an amount from 0 to about 50 wt % based on the combined weights of Components A and B.  
 
     
     
         42 . The multilayer film of  claim 40  wherein; 
 (I) said substantially random interpolymer, Component A, is present in an amount of about 75 to 100 wt % based on the combined weights of Components A and B and has an I 2  of about 0.5 to about 200 g/10 min; and comprises 
 (1) from about 13 to about 33 mol % of polymer units derived from said vinyl aromatic monomer represented by the following formula;  
                     
 wherein R 1  is selected from the group of radicals consisting of hydrogen and alkyl radicals containing three carbons or less, and Ar is a phenyl group or a phenyl group substituted with from 1 to 5 substituents selected from the group consisting of halo, C 1-4 -alkyl, and C 1-4 -haloalkyl, and n has a value from zero to about 4; and  
 (2) from about 67 to about 87 mol % of polymer units derived from said α-olefin which comprises ethylene, or ethylene and at least one of propylene, 4-methyl-1-pentene, butene-1, hexene-1 or octene-1;  
 (3) said ethylenically unsaturated polymerizable monomers other than those derived from (1) and (2) comprises norbornene, or a C 1-10  alkyl or C 6-10  aryl substituted norbomene; and  
 
 II) Component B is present in amount from 0 to about 25 wt % based on the combined weights of Components A and B and comprises one or more of 
 A) a homogeneous interpolymer;  
 B) a heterogeneous interpolymer;  
 C) a thermoplastic olefin;  
 D) a styrenic block copolymer;  
 E) a styrenic homo- or copolymer;  
 F) an elastomer;  
 G) a thermoset polymer;  
 H) a vinyl halide polymer; or  
 I) an engineering thermoplastic.  
 
 
     
     
         43 . The multilayer film of  claim 40  wherein; 
 (I) said substantially random interpolymer, Component A, is present in an amount from about 90 to about 95 wt % based on the combined weights of Components A and B and has an I 2  of about 0.5 to about 100 g/10 min; and comprises 
 (1) from about 15 to about 29 mol % of polymer units derived from said vinyl aromatic monomer which comprises styrene, α-methyl styrene, ortho-, meta-, and para-methylstyrene, and the ring halogenated styrenes;  
 (2) from about 71 to about 85 mol % of polymer units derived from said α-olefin, which comprises ethylene, or ethylene and at least one of propylene, 4-methyl-1-pentene, butene-1, hexene-1 or octene-1; or  
 (3) said ethylenically unsaturated polymerizable monomers other than those derived from (1) and (2) is norbomene; and  
 
 II) Component B is present in amount from about 5 to about 10 wt % based on the combined weights of Components A and B and comprises one or more of, 
 A) a substantially linear ethylene/α-olefin interpolymer;  
 B) a heterogeneous ethylene/C 3 -C 8  α-olefin interpolymer;  
 C) an ethylene/propylene rubber (EPM), ethylene/propylene diene monomer terpolymer (EPDM), isotactic polypropylene;  
 D) a styrene/ethylene-butene copolymer, a styrene/ethylene-propylene copolymer, a styrene/ethylene-butene/styrene (SEBS) copolymer, a styrene/ethylene-propylene/styrene (SEPS) copolymer;  
 E) the acrylonitrile-butadiene-styrene (ABS) polymers, styrene-acrylonitrile (SAN), polystyrene, high impact polystyrene;  
 F) polyisoprene, polybutadiene, natural rubbers, ethylene/propylene rubbers, ethylene/propylene diene (EPDM) rubbers, styrene/butadiene rubbers, thermoplastic polyurethanes;  
 G) epoxies, vinyl ester resins, polyurethanes, phenolic resins;  
 H) homopolymers or copolymers of vinyl chloride or vinylidene chloride, or  
 I) poly(methylmethacrylate), polyester,nylon-6, nylon-6,6, poly(acetal); poly(amide), poly(arylate), poly(carbonate), poly(butylene) and polybutylene, polyethylene terephthalates.  
 
 
     
     
         44 . The multilayer film of  claim 43  wherein Component A1 is styrene, Component A2 is ethylene, and Component B is polystyrene.  
     
     
         45 . The multilayer film of  claim 43  wherein Component A1 is styrene; and Component A2 is ethylene and at least one of propylene, 4-methyl-1-pentene, butene-1, hexene-1 or octene-1; and Component B is polystyrene.  
     
     
         46 . A fabricated article comprising the multilayer film of  claim 40 .  
     
     
         47 . The fabricated article of  claim 46  in the form of a tape, bandage, incontinence garment, disposable diaper, disposable and protective clothing and fabrics, a food wrap, meat wrap or a household wrap.  
     
     
         48 . The elastic film of  claim 31  wherein Component A is cross-linked.  
     
     
         49 . The multilayer film of  claim 40  wherein Component A is cross-linked.  
     
     
         50 . An elastic film comprising: 
 at least one layer having a thickness of from 1 mil to 3 mils, the layer consisting essentially of a substantially random interpolymer which comprises: 
 (1) polymer units derived from at least one vinyl aromatic monomer; and  
 (2) polymer units derived from at least one C 2-20  α-olefin; and optionally  
 (3) polymer units derived from one or more ethylenically unsaturated polymerizable monomers other than those of (1) and (2),  
 wherein said elastic film has a recovery in the cross direction of greater than or equal to about 80% and has a recovery in the machine direction of greater than or equal to about 60%.  
   
     
     
         51 . The elastic film of  claim 50 , further comprising a second layer.  
     
     
         52 . The elastic film of  claim 50 , wherein the vinyl aromatic monomer is represented by the following formula:  
       
         
           
           
               
               
           
         
       
       wherein R 1  is selected from the group of radicals consisting of hydrogen and alkyl radicals containing three carbons or less, and Ar is a phenyl group or a phenyl group substituted with from 1 to 5 substituents selected from the group consisting of halo, C 1-4 -alkyl, and C 1-4 -haloalkyl and n has a value from zero to about 4.  
     
     
         53 . The elastic film of  claim 50 , wherein the vinyl aromatic monomer is styrene, α-methyl styrene, otho-, meta-, and para-methyl styrene, or ring-halogenated styrene.  
     
     
         54 . The elastic film of  claim 50 , wherein the substantially random polymer has a M w /M n  from about 3 to about 10.  
     
     
         55 . The elastic film of  claim 50 , wherein the substantially random interpolymer is an ethylene styrene interpolymer.