Elastomeric Film With Anti-Skid Additive

Abstract

The present invention provides an elastomeric film having anti-skid properties. The film comprises one or more layers, wherein at least one of the layers comprises from 0.1 to 10% (by weight) of an anti-skid additive, which does not melt, or has a melt temperature greater than 500° F., and has a particle size between 50 and 500 microns. Suitable anti-skid additives may be sand, clay, silica, crosslinked polyethylenes, other polymers or ultra high molecular weight polyethylene (UHMWPE). Also provided is a resin composition and a method for manufacturing an elastomeric film having anti-skid properties.

1 - 33 . (canceled) 
   
   
       34 . A method for manufacturing an elastomeric film comprising one or more layers and having a total thickness of from about 1 mil to about 15 mil, said method comprising the steps of:
 (a) providing a resin composition for each of the one or more layers, wherein the resin composition for at least one of said one or more layers comprises from 0.1 to 10% by weight of an anti-skid additive that has a particle size of between 50 and 500 microns and does not melt or has a melt temperature greater than 500° F.; and   (b) extruding at least the anti-skid-containing resin composition or compositions using a blown-film processing machine and a blow-up ratio of from 1.0 to 5.0.   
   
   
       35 . The method according to  claim 34 , wherein each of said one or more layers comprises one or more resin components selected from the group consisting of an ethylene-vinyl acetate (EVA) copolymer, a polyolefin plastomer (POP), a linear low density polyethylene (LLDPE) and a low density polyethylene (LDPE). 
   
   
       36 . The method according to  claim 34 , wherein the film comprises between 2 and 11 layers and each layer makes up from 5 to 95% of the total thickness. 
   
   
       37 . The method according to  claim 34 , wherein at least one layer of the film comprises 10 to 100% by weight of an ethylene-vinyl acetate (EVA) copolymer. 
   
   
       38 . The method according to  claim 37 , wherein the EVA copolymer has from 2 to 45% vinyl acetate by weight. 
   
   
       39 . The method according to  claim 37 , wherein each EVA copolymer-containing layer or layers comprises 10 to 95% of the EVA copolymer by weight. 
   
   
       40 . The method according to  claim 39 , wherein each EVA copolymer-containing layer or layers comprises 25 to 85% of the EVA copolymer by weight. 
   
   
       41 . The method according to  claim 34 , wherein at least one layer of the film comprises a polyolefin plastomer (POP) having a density of 0.910 g/cm 3  or lower. 
   
   
       42 . The method according to  claim 41 , wherein the POP is a metallocene catalyzed copolymer having a density of less than or equal to 0.910 g/cm 3  and a melt index of from 0.1 to 30 g/10 minutes. 
   
   
       43 . The method according to  claim 41 , wherein the POP is a Ziegler-Natta-catalyzed copolymer having a density of less than or equal to 0.910 g/cm 3  and a melt index between 0.1 and 30 g/10 minutes. 
   
   
       44 . The method according to  claim 41 , wherein the POP is a copolymer of ethylene and a C 4 -C 20  alpha-olefin. 
   
   
       45 . The method according to  claim 34 , wherein at least one layer of the film comprises 5 to 100% by weight of a copolymer of linear low density polyethylene (LLDPE) having a density of greater than 0.910 g/cm 3 . 
   
   
       46 . The method according to  claim 45 , wherein the copolymer of LLDPE is a pure copolymer of a C 4 -C 20  alpha-olefin. 
   
   
       47 . The method according to  claim 45 , wherein the copolymer of LLDPE has a melt index between 0.1 and 30 g/10 min. 
   
   
       48 . The method according to  claim 45 , wherein each LLDPE copolymer-containing layer or layers comprises 10 to 95% of the copolymer of LLDPE by weight. 
   
   
       49 . The method according to  claim 45 , wherein each LLDPE copolymer-containing layer or layers comprises 15 to 75% of the copolymer of LLDPE by weight. 
   
   
       50 . The method according to  claim 34 , wherein at least one layer of the film comprises 5 to 100% by weight of low density polyethylene (LDPE) having a density between 0.910 and 0.930 g/cm 3 . 
   
   
       51 . The method according to  claim 50 , wherein the LDPE has a melt index of 0.1-30 g/10 min. 
   
   
       52 . The method according to  claim 50 , wherein each LDPE-containing layer or layers comprises 10 to 95% of the LDPE by weight. 
   
   
       53 . The method according to  claim 50 , wherein each LDPE-containing layer or layers comprises 15 to 75% of the LDPE by weight. 
   
   
       54 . The method according to  claim 34 , wherein at least one layer of the film comprises a combination of at least two of said resin components selected from the group consisting of EVA copolymer, POP, LLDPE and LDPE. 
   
   
       55 . The method according to  claim 34 , wherein the anti-skid additive has a particle size between 60 and 250 microns. 
   
   
       56 . The method according to  claim 55 , wherein the anti-skid additive has a particle size between 60 and 180 microns. 
   
   
       57 . The method according to  claim 34 , wherein the anti-skid additive is a polymer-based additive. 
   
   
       58 . The method according to  claim 34 , wherein the anti-skid additive is an inorganic based additive. 
   
   
       59 . The method according to  claim 57 , wherein the anti-skid additive is an ultra high molecular weight polyethylene (UHMWPE) or a cross-linked polyethylene. 
   
   
       60 . The method according to  claim 58 , wherein the anti-skid additive is a sand, clay or silica. 
   
   
       61 . The method according to  claim 34 , wherein at least one layer of the film comprises a UV stabilizer, a pigment, a slip agent, a blocking agent, an antistatic agent or any combination thereof. 
   
   
       62 . The method according to  claim 34 , wherein step (a) includes providing resin compositions for each of an inside layer, a core layer and an outside layer of said film. 
   
   
       63 . The method according to  claim 34 , which additionally comprises the step of folding the film to produce a pre-folded U-film, J-film, tube or gussetted film. 
   
   
       64 . The method according to  claim 63 , wherein the pre-folded gussetted film has two opposing film panels, a closed edge and a parallel open edge extending along the length opposite the closed edge, wherein the two opposing film panels are connected at the closed edge and the gusset is formed along the length of the film at the closed edge. 
   
   
       65 . The method according to  claim 64 , wherein the parallel open edge of the film corresponds to an edge of the first film panel and an edge of the second film panel and an inwardly folded lip is formed at each edge of the film panels. 
   
   
       66 . The method according to  claim 34 , wherein the film comprises two or more layers and the resin compositions for each of said two or more layers are co-extruded. 
   
   
       67 . The method according to  claim 34 , wherein the blow-up ratio is from 2.0 to 5.0. 
   
   
       68 . The method according to  claim 67 , wherein the blow-up ratio is from 2.5 to 4.5. 
   
   
       69 . The method according to  claim 34 , wherein step (b) is performed using a die gap of 45-120 mil. 
   
   
       70 . The method according to  claim 69 , wherein the die gap is 55-100 mil. 
   
   
       71 . The method according to  claim 34 , wherein the draw down ratio is between 6 and 40. 
   
   
       72 . The method according to  claim 71 , wherein the draw down ratio is between 10 and 30.