CROSS REFERNCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 62/802,008, filed February 6, 2019 and entitled“Films and Backsheets for Hygiene Articles,” the disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002] The invention relates to hygiene articles, such as diapers and sanitary napkins, with improved backsheets. In particular, the backsheets comprise polyethylene compositions in combination with a masterbatch to prove improved performance.

BACKGROUND OF THE INVENTION

[0003] Hygiene products such as disposable diapers for infants and adults, incontinent pads, sanitary napkins, and pantiliners constitute maj or industries and serve important functions for different demographics of the population. In general, such hygiene products are made from a skin-facing layer or an inner topsheet (also called a cover or front sheet) which is liquid- permeable to facilitate entry of the fluid exudate from the wearer into the hygiene product, a core of highly absorbent material for absorbing liquid received through the topsheet, and an outer backsheet formed of a liquid impermeable plastic to eliminate leakage of fluid from the hygiene product. The backsheet may be vapor impermeable or vapor permeable. If vapor permeable, the product is said to be“breathable”.

[0004] The typical trend in backsheets in recent years is downgauging to save material cost, usually by making the backsheets out of thinner films. However, the stiffness of the backsheet, which is important to maintain machinability of the film, drops while the film becomes thinner. Machinability is important for printing, lamination, and the assembly process of hygiene products. This aspect of the products allows manufacturers to differentiate their products in premium markets and affects overall production rates. The common approach to compensate for stiffness loss is to use a higher density polymer. However, the consequence of doing so is that the film strength also drops and/or the end users feel that the film is too stiff or noisy to use, especially when softness is an important feature for hygiene products.

[0005] Thus, a need exists for hygiene articles with improved backsheets that demonstrate a desired film strength, especially for printed or embossed hygiene products, and also provide for a good balance in tensile properties and toughness, and processability.

SUMMARY OF THE INVENTION [0006] Provided herein are films useful as backsheets comprising a polyethylene composition in an amount from about 25 wt% to about 45 wt% and a masterbatch in an amount from about 55 wt% to about 75 wt%. The films have a water vapor transmission rate of less than or equal to about 550 g/m ² per day in accordance with test method ASTM E96. The films are highly filled and comprise CaCCh in an amount greater than or equal to 45 wt%. The films have an MD trouser tear of from about 155 cN to about 160 cN as measured by ASTM 1938. The films have a dart impact from about 5.0 g/pm to about 15.0 g/pm.

[0007] In an aspect, masterbatch comprises from about 65 wt% to about 70 wt% CaCCb. In an aspect, the polyethylene composition has a melt index (MI) of about 0.5 g/10 min and a density of 0.918 g/cm ³ . In an aspect, the film has an MD 1% secant modulus of from about 270.00 mN to about 330.00 mN. In an aspect, the film has a TD 1% secant modulus from about 50 mN to about 60 mN. In an aspect, the film has an MD 10% offset from about 10 mN to about 20 mN. In an aspect, the film has an MD 5% force from about 3.0 N to about 4.0 N. In an aspect, the film has an MD tensile at break of about 20.0 mN to 24.0 mN. In an aspect, the film has an MD elongation at break of from about 66% to about 70%. In an aspect, the film has a TD 10% offset from about 1.40 mN to 1.50 mN. In an aspect, the film has a TD 5% force from about 1.35 N to about 1.45 N. In an aspect, the film has a TD tensile at break from about 1.80 mN to 1.90 mN. In an aspect, the film has a TD elongation at break of at least 500%. In an aspect, the film is a blown film. In an aspect, the film is a cast film. In an aspect, the film has a layer distribution of 1/3/1.

[0008] Further provided herein are hygiene articles comprising a breathable backsheet of any one of the present films described herein. The hygiene article can further comprise at least one top sheet and at least one absorbent core. The hygiene article can be a diaper, a sanitary napkin, an adult incontinence pad and a pantiliner.

DFTATT FD DESCRIPTION OF THE INVENTION

[0009] Before the present articles, compounds, components, compositions, devices, softwares, hardwares, equipments, configurations, schematics, systems, and/or methods or processes are disclosed and described, it is to be understood that unless otherwise indicated this invention is not limited to specific articles, compounds, components, compositions, devices, softwares, hardwares, equipments, configurations, schematics, systems, methods, processes, or the like, as such may vary, unless otherwise specified. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. [0010] All numerical values within the detailed description and the claims herein are modified by“about” or“approximately” the indicated value, considering experimental error and variations.

[0011] For the purposes of this disclosure, the following definitions will apply:

[0012] As used herein, the terms“a” and“the” as used herein are understood to encompass the plural as well as the singular.

[0013] The term“alpha-olefin” refers to an olefin having a terminal carbon-to-carbon double bond in the structure thereof (R ¹ R ² )-C=CH2, where R ¹ and R ² can be independently hydrogen or any hydrocarbyl group. In an aspect, R ¹ is hydrogen, and R ² is an alkyl group. A “linear alpha-olefin” is an alpha-olefin as defined in this paragraph wherein R ¹ is hydrogen, and R ² is hydrogen or a linear alkyl group.

[0014] A“catalyst system” as used herein may include one or more polymerization catalysts, activators, supports/carriers, or any combination thereof.

[0015] The terms“catalyst system” and“catalyst” are used interchangeably herein.

[0016] The term“composition distribution breadth index” ("CDBI") refers to the weight percent of the copolymer molecules having a comonomer content within 50% of the median total molar comonomer content. The CDBI of any copolymer is determined utilizing known techniques for isolating individual fractions of a sample of the copolymer. Exemplary is Temperature Rising Elution Fraction (“TREF”) described in Wild, et al, J. Poly. Sci., Poly. Phys. Ed., Vol. 20, pg. 441 (1982) and U.S. Pat. No. 5,008,204.

[0017] As used herein, the term“copolymer” refers to polymers having more than one type of monomer, including interpolymers, terpolymers, or higher order polymers.

[0018] The term“C _n group” or“C _n compound” refers to a group or a compound with total number carbon atoms“n.” Thus, a C _m -C _n group or compound refers to a group or a compound having total number of carbon atoms in a range from m to n. For example, a C1-C50 alkyl group refers to an alkyl compound having 1 to 50 carbon atoms.

[0019] As used herein, the terms “cyclopentadiene” and “cyclopentadienyl” are abbreviated as“Cp.”

[0020] The term“density”, unless otherwise specified, refers to the density of the polyethylene composition independent of any additives, such as antiblocks, which may change the tested value.

[0021] As used herein, in reference to Periodic Table Groups" of Elements, the "new" numbering scheme for the Periodic Table Groups are used as in the CRC HANDBOOK OF CHEMISTRY AND PHYSICS (David R. Lide ed., CRC Press 81 ^st ed. 2000). [0022] As used herein, the term“masterbatch” is a solid or liquid additive used to impart certain properties to polyethylene compositions and alleviate issues with insufficient dispersion. The concentration of the additive (such as CaCCL) in the masterbatch is typically much higher than in the end-use polymer.

[0023] As used herein, the term“metallocene catalyst” refers to a catalyst having at least one transition metal compound containing one or more substituted or unsubstituted Cp moiety (typically two Cp moieties) in combination with a Group 4, 5, or 6 transition metal. A metallocene catalyst is considered a single site catalyst. Metallocene catalysts generally require activation with a suitable co-catalyst, or activator, in order to yield an "active metallocene catalyst", i.e., an organometallic complex with a vacant coordination site that can coordinate, insert, and polymerize olefins. Active catalyst systems generally include not only the metallocene complex, but also an activator, such as an alumoxane or a derivative thereof (preferably methyl alumoxane), an ionizing activator, a Lewis acid, or a combination thereof. Alkylalumoxanes (typically methyl alumoxane and modified methylalumoxanes) are particularly suitable as catalyst activators. The catalyst system can be supported on a carrier, typically an inorganic oxide or chloride or a resinous material such as, for example, polyethylene or silica. When used in relation to metallocene catalysts, the term“substituted” means that a hydrogen group has been replaced with a hydrocarbyl group, a heteroatom, or a heteroatom containing group. For example, methylcyclopentadiene is a Cp group substituted with a methyl group.

[0024] The term“melt index” (“MI”) is the number of grams extruded in 10 minutes under the action of a standard load and is an inverse measure of viscosity. A high MI implies low viscosity and a low MI implies high viscosity. In addition, polymers are shear thinning, which means that their resistance to flow decreases as the shear rate increases. This is due to molecular alignments in the direction of flow and disentanglements.

[0025] As provided herein, MI is determined according to ASTM D-1238-E (190°C/2.16 kg), also sometimes referred to as h or I2 _. 16.

[0026] The“melt index ratio” (“MIR”) provides an indication of the amount of shear thinning behavior of the polymer and is a parameter that can be correlated to the overall polymer mixture molecular weight distribution data obtained separately by using Gas Permeation Chromatography (“GPC”) and possibly in combination with another polymer analysis including TREF. MIR is the ratio of I21/I2.

[0027] The term “melt strength” is a measure of the extensional viscosity and is representative of the maximum tension that can be applied to the melt without breaking. Extensional viscosity is the polyethylene composition’s ability to resist thinning at high draw rates and high draw ratios. In melt processing of polyolefins, the melt strength is defined by two key characteristics that can be quantified in process-related terms and in rheological terms. In extrusion blow molding and melt phase thermoforming, a branched polyolefin of the appropriate molecular weight can support the weight of the fully melted sheet or extruded portion prior to the forming stage. This behavior is sometimes referred to as sag resistance.

[0028] As used herein,“M _n ” is number average molecular weight,“M _w ” is weight average molecular weight, and“M _z ” is z-average molecular weight. Unless otherwise noted, all molecular weight units (e.g., M _w , M _n , M _z ) including molecular weight data are in the unit of g-moT ¹ .

[0029] As used herein, unless specified otherwise, percent by mole is expressed as “mole%,” and percent by weight is expressed as“wt%.”

[0030] As used herein, molecular weight distribution ("MWD") is equivalent to the expression M _w /M _n and is also referred to as polydispersity index (“PDI”). The expression M _w /Mn is the ratio of M _w to Mn. M _w is given by

M _n is given by

M _z is given by

[0031] where in the foregoing equations is the number fraction of molecules of molecular weight Mi. Measurements of M _w , M _z , and M _n are typically determined by Gel Permeation Chromatography as disclosed in Macromolecules, Vol. 34, No. 19, pg. 6812 (2001).

[0032] As used herein, the term“olefin” refers to a linear, branched, or cyclic compound comprising carbon and hydrogen and having a hydrocarbon chain containing at least one carbon-to-carbon double bond in the structure thereof, where the carbon-to-carbon double bond does not constitute a part of an aromatic ring. The term olefin includes all structural isomeric forms of olefins, unless it is specified to mean a single isomer or the context clearly indicates otherwise.

[0033] As used herein, the term“polymer” refers to a compound having two or more of the same or different“mer” units. A“homopolymer” is a polymer having mer units that are the same. A“copolymer” is a polymer having two or more mer units that are different from each other. A“terpolymer” is a polymer having three mer units that are different from each other. “Different” in reference to mer units indicates that the mer units differ from each other by at least one atom or are different isomerically.

[0034] As used herein, when a polymer or copolymer is referred to as comprising an olefin, the olefin present in such polymer or copolymer is the polymerized form of the olefin. For example, when a copolymer is said to have a“propylene” content of 35 wt% to 55 wt%, it is understood that the mer unit in the copolymer is derived from propylene in the polymerization reaction and said derived units are present at 35 wt% to 55 wt%, based upon the weight of the copolymer. A copolymer can be terpolymers and the like.

[0035] As used herein, the term“shear thinning ratio” refers to the complex viscosity at 190°C at 0.01 rad/s over the complex viscosity at 190°C at 100 rad/s (or the nearest measured point).

[0036] The term“substantially uniform comonomer distribution” is used herein to mean that comonomer content of the polymer fractions across the molecular weight range of the ethylene-based polymer vary by < 10.0 wt%. In an aspect, a substantially uniform comonomer distribution refers to < 8.0 wt%, < 5.0 wt%, or < 2.0 wt%.

[0037] As used herein, the term“supported” refers to one or more compounds that are deposited on, contacted with, vaporized with, bonded to, incorporated within, adsorbed or absorbed in, or on, a support or carrier. The terms“support” and“carrier” can be used interchangeably and include any support material including, but not limited to, a porous support material or inorganic or organic support materials. Non-limiting examples of inorganic support materials include inorganic oxides and inorganic chlorides. Other carriers include resinous support materials such as polystyrene, functionalized or crosslinked organic supports, such as polystyrene, divinyl benzene, polyolefins, or polymeric compounds, zeolites, talc, clays, or any other organic or inorganic support material and the like, or mixtures thereof.

[0038] In an extrusion process,“viscosity” is a measure of resistance to shearing flow. Shearing is the motion of a fluid, layer-by-layer, like a deck of cards. When polymers flow through straight tubes or channels, the polymers are sheared and resistance is expressed in terms of viscosity.

[0039] “Extensional” or“elongational viscosity” is the resistance to stretching. In fiber spinning, film blowing and other processes where molten polymers are stretched, the elongational viscosity plays a role. For example, for certain liquids, the resistance to stretching can be three times larger than in shearing. For some polymeric liquids, the elongational viscosity can increase (tension stiffening) with the rate, although the shear viscosity decreased.

[0040] As used herein, the“bending stiffness” is a measure of the resistance of film deformation when bent, and can be calculated the by following equation:

where S _b is the bending stiffness, measured in mN*mm, M is the moment width, b is the width, and R is the radius of the curvature. Bending stiffness can be measured by applying opposing forces at various points on a beam and measuring the resulting curvature of the beam. For example, in the 3 -point method, force is applied in one direction on the ends and in the opposite direction in the center, and the resulting radius of the curvature is measured.

[0041] Various measurements described herein are based on certain test standards. For example, measurements of tensile strength in the machine direction (MD) and transverse direction (TD) are based on ASTM D882. Measurements of MD Trouser Tear and TD Trouser Tear are based on by ASTM 1938. Measurements for 1% Secant Modulus are based on ASTM D 790A. Methods of tensile tests are set out in ASTM D-882-02 and ASTM D- 6693. Methods for testing Elmendorf tear strength are set out in ASTM D-l 922-09. Methods for testing hot tack and heat seal mode are set out in ASTM F-1921. Measurements for puncture resistance are based on ASTM D 5748, which is designed to provide load versus deformation response under biaxial deformation conditions at a constant relatively low test speed (change from 250 mm/min to 5 mm/min after reach pre-load (0.1 N)). Measurements of dart-drop (dart impact) are made in accordance with ASTM D1709 and/or ISO 7765-1, method "A". Density is determined using test methods set out in ASTM D-4703 and ASTM D-1505/ISO 1183. Light transmission percent (or haze) measurements are based on ASTM D1003 using a haze meter Haze-Guard Plus AT-4725 from BYK Gardner and defined as the percentage of transmitted light passing through the bulk of the film sample that is deflected by more than 2.

[0042] The present hygiene articles generally comprise a) at least one top sheet; b) at least one absorbent core; and c) at least one backsheet. The backsheet generally has a body-facing side oriented towards the body of the wearer of the article and a garment-facing side oriented towards the undergarment of the wearer of the article.

[0043] As provided herein, the at least one backsheet can comprise a film. The subject films comprise a polyethylene composition in an amount from about 25 wt% to about 45 wt% and a masterbatch in an amount from about 55 wt% to about 75 wt%. The films can be blown or cast films and are highly filled, comprising CaCCb in an amount greater than or equal to 45 wt%. In addition, the present films have an MD trouser tear of from about 155 cN to about 160 cN as measured by ASTM 1938. The film has a water vapor transmission rate of less than or equal to about 550 g/m ² per day in accordance with test method ASTM E96. The film has a dart impact from about 5.0 g/ pm to about 15.0 g/ pm. In an aspect, the masterbatch comprises from about 65 wt% to about 70 wt% CaCCh. In an aspect, the polyethylene composition has a melt index (MI) of about 0.5 g/10 min and a density of 0.918 g/cm ³ .

[0044] The hygiene articles are useful items and may be diapers (e.g., infants and adults), sanitary pads, sanitary napkins, and pantiliners. An exemplary multi-layered hygiene article is provided below, having seven total layers. The number of layers is not critical and may vary from several layers, for example, three or more, to many more layers, for example, five or more, ten or more, fifteen or more, and twenty or more layers.

Topsheet

[0045] The topsheet is typically the layer of the hygiene article which is oriented towards and contacts the body of the wearer, and is therefore the first layer to receive the bodily discharges. The topsheet is normally made of a single layer, but may also comprise more than one layer (e.g., a central topsheet layer and two overlapping lateral stripes). For example, a single non-woven material may be used but the topsheet may be composed of several layers and treated to become hydrophilic so the liquid can pass through. [0046] The topsheet is normally permeable to liquids, i.e., allow liquids to pass through the topsheet without significantly retarding or obstructing the transmission of such liquids therethrough.

[0047] Any conventional topsheet materials may be used. Suitable topsheets may be made, for example, from nonwoven materials or perforated polyolefmic films. An exemplary topsheet is a relatively hydrophobic 20 gsm spunbonded nonwoven web comprising bicomponent fibers of the sheath/core type (e.g., polypropylene/polyethylene polymers). If desired, the topsheet may be treated with a surfactant to enhance liquid penetration to the core. The surfactant may be non-ionic and should be nonirritating to the skin. The topsheet may have a plurality of apertures to permit liquids deposited thereon to pass through to the core more quickly.

Absorbent Core

[0048] The hygiene articles further comprise an absorbent core disposed between the topsheet and the backsheet. As used herein, the term "absorbent core" refers to a material or combination of materials suitable for absorbing, trapping, distributing, and/or storing fluids, for example, urine, blood, menses, and/or other exudates. It may optionally be separately wrapped.

[0049] The size and shape of the absorbent core may be such that the surface of the core in the horizontal plane is substantially smaller than the surface of the topsheet. By“substantially smaller”, it is meant that the surface of the absorbent core is at least about 10% smaller than the surface of the topsheet or at least about 25% smaller than the surface of the topsheet. The absorbent core may be generally centered in the middle of the article. The absorbent core may be disposed away from the periphery of the article to provide improved flexibility along the edges of the article.

[0050] By providing an absorbent core having a substantially smaller surface than the topsheet, several benefits may be achieved. The amount of core material used is reduced, lowering the overall costs of manufacturing the article. A core having a smaller surface also increases the overall flexibility of the article because the regions of the article not provided with a core are generally less rigid than the region where the core is situated.

[0051] The absorbent core may be fashioned into many shapes, for example, rounded, oval, rectangular, and square. For example, it is typical for absorbent cores to be rectangular for ease of manufacturing. However, flexibility and compatibility with various styles of undergarments may be better with cores having a curved shape (such as an oval shape) without comprising right angles. [0052] The absorbent core may be made of any suitable materials. Nonlimiting examples of suitable liquid-absorbent materials include comminuted wood pulp which is generally referred to as airfelt; creped cellulose wadding; absorbent gelling materials including superabsorbent polymers such as hydrogel-forming polymeric gelling agents; chemically stiffened, modified, or cross-linked cellulose fibers; meltblown polymers including co- form; synthetic fibers including crimped polyester fibers; tissue including tissue wraps and tissue laminates; capillary channel fibers; absorbent foams; absorbent sponges; synthetic staple fibers; peat moss; foamed polyethylene or polypropylene compositions; nonwoven polyethylene or polypropylene materials; or any equivalent material; or combinations thereof. The absorbent core can comprise superabsorbent polymers (SAP), normally distributed within a matrix of cellulosic fibers, for example, in order to reduce the thickness of the absorbent core.

[0053] The absorbent core can be a monolayer or can be a laminate of two or more layers. For example, the core may comprise a fluid impermeable barrier layer on its backsheet-facing side to prevent fluids retained by the absorbent core from striking through the hygiene article. General information regarding absorbent cores may be found in, for example, WO 2002/007662 and WO 1991/019471.

Backsheet

[0054] The general function of the backsheet is to prevent discharges absorbed by the core from escaping the hygiene article. The backsheet may include any suitable material. Typically, these materials are generally flexible, liquid resistant, and impermeable to liquids. The backsheet generally comprises at least a film that may be monolayer or two or more layers. The films may be cast or blown films, optionally, embossed and/or oriented or stretched, in either direction: Machine Direction (MD) or Transverse Direction (TD), either on-line or off line. The films may also be co-extruded. This backsheet may also contain fillers, pigment, various additives, and any combination thereof. The backsheet may also be a laminate with non-woven fabric.

[0055] Typically, a thinner backsheet film is desired to save on material costs and for design considerations of the final article. For example, the backsheet film may have an average backsheet thickness of 24 pm or less, alternatively, 20 pm or less, 15 pm or less, alternatively, 14 pm or less, 12 pm or less, 11 pm or less, and alternatively, 10 pm or less. As used herein “average backsheet thickness” refers to the thickness of a film, typically, expressed in microns of the film, prior to any additional conversion or treatments such as embossing. As thickness measurements on embossed films are difficult to obtain, the gauge of the film is may be expressed in gram per square meter or gsm, equal to the weight of one square meter of film. Typically, 10 pieces of 10 square centimeters each are cut out of the film and the weight is multiplied by 10 to obtain gsm.

[0056] Thus, alternatively, the backsheet film may have an average backsheet thickness of 35 grams per square meter (gsm) or less, alternatively, 30 gsm or less, 25 gsm or less, 20 gsm or less, 15 gsm or less, 12 gsm or less, or 10 gsm or less.

[0057] There are both“breathable” and regular hygiene articles. Breathable hygiene articles tend to extract premiums in the market place. Thus, the backsheets which are permeable to vapor are known as breathable backsheets and are used in breathable hygiene articles. These breathable backsheets provide a cooler garment and permit some drying of the article while being worn. In general, these breathable backsheets are intended to allow the passage of vapor, typically expressed as Water Vapor Transmission Rate (“WVTR”) through them while retarding the passage of liquid.

[0058] Breathable backsheets may be obtained by creating microvoids in one or more layers of the backsheet. Microcavities may be created by the incorporation of fillers, such as calcium carbonate (CaCCb) or other suitable materials, into one or more layers of the backsheet followed by an orientation or stretching process. Other suitable materials include organic fillers such as polystyrene in polyethylene or water-swellable fillers such as silica or hydrogel.

[0059] The backsheet has a garment-facing side and an opposite body-facing side. The garment-facing side of the backsheet can comprise a non-adhesive area and an adhesive area. The adhesive area may be provided by any conventional means. Pressure sensitive adhesives have been commonly found to work well for this purpose.

Polyethylene Compositions

[0060] As described herein, the polyethylene compositions useful in the subject films can comprise from about 50.0 mol% to about 100.0 mol% of units derived from ethylene. The lower limit on the range of ethylene content can be from 50.0 mol%, 75.0 mol%, 80.0 mol%, 85.0 mol%, 90.0 mol%, 92.0 mol%, 94.0 mol%, 95.0 mol%, 96.0 mol%, 97.0 mol%, 98.0 mol%, or 99.0 mol% based on the mol% of polymer units derived from ethylene. The polyethylene composition can have an upper limit on the range of ethylene content of 80.0 mol%, 85.0 mol%, 90.0 mol%, 92.0 mol%, 94.0 mol%, 95.0 mol%, 96.0 mol%, 97.0 mol%, 98.0 mol%, 99.0 mol%, 99.5 mol%, or 100.0 mol%, based on polymer units derived from ethylene.

[0061] Further the polyethylene compositions can be produced by polymerization of ethylene and, optionally, an alpha-olefin comonomer having from 3 to 10 carbon atoms. Alpha-olefin comonomers are selected from monomers having 3 to 10 carbon atoms, such as C ₃ -C ₁₀ alpha-olefins or C ₄ -C ₈ alpha-olefins. Alpha-olefin comonomers can be linear or branched or may include two unsaturated carbon-carbon bonds, i.e., dienes. Examples of suitable comonomers include linear C ₃ -C ₁₀ alpha-olefins and alpha-olefins having one or more C ₁ -C ₃ alkyl branches or an aryl group. Comonomer examples include propylene, 1-butene, 3- methyl-1 -butene, 3, 3-dimethyl-l -butene, 1-pentene, 1-pentene with one or more methyl, ethyl, or propyl substituents, 1 -hexene, 1 -hexene with one or more methyl, ethyl, or propyl substituents, 1-heptene, 1-heptene with one or more methyl, ethyl, or propyl substituents, 1- octene, 1-octene with one or more methyl, ethyl, or propyl substituents, 1-nonene, 1-nonene with one or more methyl, ethyl, or propyl substituents, ethyl, methyl, or dimethyl-substituted 1-decene, 1-dodecene, and styrene.

[0062] Exemplary combinations of ethylene and comonomers include: ethylene 1 -butene, ethylene 1-pentene, ethylene 4-methyl- 1-pentene, ethylene 1 -hexene, ethylene 1-octene, ethylene decene, ethylene dodecene, ethylene 1 -butene 1 -hexene, ethylene 1 -butene 1-pentene, ethylene 1 -butene 4-methyl- 1-pentene, ethylene 1 -butene 1-octene, ethylene 1 -hexene 1- pentene, ethylene 1 -hexene 4-methyl- 1-pentene, ethylene 1 -hexene 1-octene, ethylene 1- hexene decene, ethylene 1 -hexene dodecene, ethylene propylene 1-octene, ethylene 1-octene 1-butene, ethylene 1-octene 1-pentene, ethylene 1-octene 4-methyl- 1-pentene, ethylene 1- octene 1 -hexene, ethylene 1-octene decene, ethylene 1-octene dodecene, and combinations thereof. It should be appreciated that the foregoing list of comonomers and comonomer combinations are merely exemplary and are not intended to be limiting. Often, the comonomer is 1 -butene, 1 -hexene, or 1-octene

[0063] During copolymerization, monomer feeds are regulated to provide a ratio of ethylene to comonomer, e.g., alpha-olefin, so as to yield a polyethylene having a comonomer content, as a bulk measurement, of from about 0.1 mol% to about 20 mol% comonomer. In other aspects the comonomer content is from about 0.1 mol% to about 4.0 mol%, or from about 0.1 mol% to about 3.0 mol%, or from about 0.1 mol% to about 2.0 mol%, or from about 0.5 mol% to about 5.0 mol%, or from about 1.0 mol% to about 5.0 mol%. The reaction temperature, monomer residence time, catalyst system component quantities, and molecular weight control agent (such as Eh) may be regulated so as to provide desired LLDPE compositions. For linear polyethylenes, the amount of comonomers, comonomer distribution along the polymer backbone, and comonomer branch length will generally delineate the density range.

[0064] Comonomer content is based on the total content of all monomers in the polymer. The polyethylene copolymer has minimal long chain branching (i.e., less than 1.0 long-chain branch/1000 carbon atoms, preferably particularly 0.05 to 0.50 long-chain branch/1000 carbon atoms). Such values are characteristic of a linear structure that is consistent with a branching index (as defined below) of g' _vis > 0.980, 0.985, > 0.99, > 0.995, or 1.0. While such values are indicative of little to no long chain branching, some long chain branches can be present (i.e., less than 1.0 long-chain branch/1000 carbon atoms, preferably less than 0.5 long-chain branch/1000 carbon atoms, particularly 0.05 to 0.50 long-chain branch/1000 carbon atoms).

[0065] The polyethylene compositions can have a density greater than or equal to (“>”) about 0.930 g/cm ³ , > about 0.935 g/cm ³ , > about 0.940 g/cm ³ , > about 0.945 g/cm ³ , > about 0.950 g/cm ³ , > about 0.955 g/cm ³ , and > about 0.960 g/cm ³ . Alternatively, polyethylene compositions can have a density less than or equal to (“<”) about 0.960 g/cm ³ about 0.945 g/cm ³ , e.g., < about 0.940 g/cm ³ , < about 0.937 g/cm ³ , < about 0.935 g/cm ³ , and < about 0.930 g/cm ³ . These ranges include, but are not limited to, ranges formed by combinations any of the above-enumerated values, e.g., from about 0.930 to about 0.945 g/cm ³ , about 0.930 to about 0.935 g/cm ³ , about 0.9350 about to 0.940 g/cm ³ , about 0.935 to about 0.950 g/cm ³ , etc. Density is determined using chips cut from plaques compression molded in accordance with ASTM D- 1928-C, aged in accordance with ASTM D-618 Procedure A, and measured as specified by ASTM D-1505.

[0066] The polyethylene compositions have an MI according to ASTM D-1238-E (190°C/2.16 kg) reported in grams per 10 minutes (g/10 min), of > about 0.10 g/10 min, e.g.,

> about 0.15 g/10 min, > about 0.18 g/10 min, > about 0.20 g/10 min, > about 0.22 g/10 min,

> about 0.25 g/10 min, > about 0.28 g/10 min, or > about 0.30 g/10 min.

[0067] Also, the polyethylene compositions can have an MI (I2 _. 16) < about 3.0 g/10 min, < about 2.0 g/10 min, < about 1.5 g/10 min, < about 1.0 g/10 min, < about 0.75 g/10 min, < about 0.50 g/10 min, < about 0.40 g/10 min, < about 0.30 g/10 min, < about 0.25 g/10 min, < about 0.22 g/10 min, < about 0.20 g/10 min, < about 0.18 g/10 min, or < about 0.15 g/10 min. The ranges, however, include, but are not limited to, ranges formed by combinations any of the above-enumerated values, for example: from about 0.1 to about 5.0; about 0.2 to about 2.0; and about 0.2 to about 0.5 g/10 min.

[0068] The polyethylene compositions can have a melt index ratio (“MIR”) that is a dimensionless number and is the ratio of the high load MI to the MI, or I21 _. 6/I2 _. 16, as measured in accordance with ASTM D-1238. The MIR of the polyethylene compositions described herein is from about 25 to about 80, alternatively, from about 25 to about 70, alternatively, from about 30 to about 55, and alternatively, from about 35 to about 50. [0069] The polyethylene compositions can have High Load Melt Index (“HLMI”) also referred to herein as or hi as measured in accordance with ASTM D-1238, condition F (190°C/21.6 kg). Any given polymer composition has an MI and an MIR. As such, the HLMI is fixed and can be calculated if the MI and MIR are known.

[0070] In an aspect, polyethylene compositions can have minimal long chain branching (i.e., less than 1.0 long-chain branch/1000 carbon atoms, particularly 0.05 to 0.50 long-chain branch/1000 carbon atoms). Such values are characteristic of a linear structure that is consistent with a branching index of g' _v is ³ 0.980, 0.985, > 0.99, > 0.995, or 1.0. While such values are indicative of little to no long chain branching, some long chain branches may be present (i.e., less than 1.0 long-chain branch/1000 carbon atoms, or less than 0.5 long-chain branch/1000 carbon atoms, particularly 0.05 to 0.50 long-chain branch/1000 carbon atoms).

[0071] The polyethylene compositions can have an orthogonal comonomer distribution. The term“orthogonal comonomer distribution” is used herein to mean across the molecular weight range of the ethylene polymer, comonomer contents for the various polymer fractions are not substantially uniform and a higher molecular weight fraction thereof generally has a higher comonomer content than that of a lower molecular weight fraction. Both a substantially uniform and an orthogonal comonomer distribution may be determined using fractionation techniques such as gel permeation chromatography-differential viscometry (“GPC-DV”), temperature rising elution fraction-differential viscometry (“TREF-DV”) or cross-fractionation techniques.

[0072] As described herein, the present polyethylene compositions typically have a broad composition distribution as measured by Composition Distribution Breadth Index (“CDBI”) or solubility distribution breadth index (“SDBI”). For details of determining the CDBI or SDBI of a copolymer, see, for example, PCT Patent Application WO 93/03093, published Feb. 18, 1993. Polymers produced using a catalyst system described herein have a CDBI less than 50%, or less than 40%, or less than 30%. In an aspect, the polymers have a CDBI of from 20% to less than 50%. In an aspect, the polymers have a CDBI of from 20% to 35%. In an aspect, the polymers have a CDBI of from 25% to 28%.

[0073] Certain of the polyethylene compositions are currently sold as Exceed XP™ metallocene polyethylene (“mPE”) are commercially available from ExxonMobil Chemical Company, Houston, TX. Exceed XP™ mPE can provide step-out performance with respect to, for example, dart drop impact strength, flex-crack resistance, and machine direction (“MD”) tear, as well as maintaining stiffness at lower densities. Exceed XP™ mPE can provide optimized solutions for a good balance of melt strength, toughness, stiffness, and sealing capabilities which makes this family of polymers well-suited for blown film/sheet solutions.

[0074] More specifically, Exceed XP™ 8358 polyethylene compositions comprise ethylene 1 -hexene copolymer. This polyethylene composition offers step-out toughness, high flex-crack resistance and increased output with excellent bubble stability for a range of film applications. Exceed™ XP 8358ML has a density of .918 g/cm ³ and a melt index of 0.5 g/10 min.

[0075] Exceed XP™ 1018 polyethylene compositions may comprise ethylene 1 -hexene copolymers. This polyethylene composition offers step-out toughness, high flex-crack resistance and increased output with excellent bubble stability for a range of film applications. Exceed™ XP 8358ML may have a density of .918 g/cm ³ and a melt index of 1.0 g/10 min

[0076] Certain of the present polyethylene compositions are sold under the ENABLE® trademark, including metallocene polyethylene compositions (“ENABLE® mPE”), which are available from ExxonMobil Chemical Company. ENABLE® mPE polyethylene compositions balance processability and mechanical properties, including tensile strength and elongation to break with advanced drawdown and enhanced pipe rupture (failure) time and toughness. Applications for ENABLE products include food packaging, form fill and seal packaging, heavy duty bags, lamination film, stand up pouches, multilayer packaging film, and shrink film.

[0077] For example, an ENABLE™ 20-05 polyethylene compositions are ethylene 1- hexene copolymers designed for blown film, formulated and non-formulated. ENABLE 20- 05™ polymer has a density of 0.920 g/cm ³ and a melt index of 0.5 g/10 min.

[0078] Materials and processes for making EXCEED™ and ENABLE™ polyethylene compositions have been described in U.S. Patent No. 6,956,088, Example 1. Other publications describing the materials and processes include U.S. Patent Application Publication No. 2009/0297810, Example 1; U.S. Patent Application Publication No. 2015/0291748, particularly PE1-PE5 in the Examples; and WO 2014/099356, particularly PE3 referenced on page 12 and in the Examples, including the use of a silica supported hafnium transition metal metallocene/methylalumoxane catalyst system described in, for example, U.S. Patent Nos. 6,242,545 and 6,248,845, particularly Example 1.

Conventional Catalysts

[0079] Conventional catalysts refer to Ziegler Natta catalysts or Phillips-type chromium catalysts. Examples of conventional-type transition metal catalysts are discussed in U.S. Patent Nos. 4,115,639, 4,077,904 4,482,687, 4,564,605, 4,721,763, 4,879,359 and 4,960,741. The conventional catalyst compounds that may be used in the processes disclosed herein include transition metal compounds from Groups 3 to 10, preferably 4 to 6 of the Periodic Table of Elements.

[0080] These conventional-type transition metal catalysts may be represented by the formula:

MRx

where M is a metal from Groups 3 to 10, or Group 4, or titanium; R is a halogen or a hydrocarbyloxy group; and x is the valence of the metal M, preferably x is 1, 2, 3 or 4, or x is 4. Non-limiting examples of R include alkoxy, phenoxy, bromide, chloride and fluoride. Non limiting examples of conventional-type transition metal catalysts where M is titanium include TiC13, TiC14, TiBr4, Ti(OC2H5)3Cl, Ti(OC2H5)C13, Ti(OC4H9)3Cl, Ti(OC3H7)2C12, Ti(OC2H5)2Br2, TiC13.1/3AlC13 and Ti(OC12H25)C13.

[0081] Conventional chrome catalysts, often referred to as Phillips-type catalysts, may include Cr03, chromocene, silyl chromate, chromyl chloride (Cr02C12), chromium-2-ethyl- hexanoate, chromium acetylacetonate (Cr(AcAc)3). Non-limiting examples are disclosed in U.S. Patent Nos. 2,285,721, 3,242,099 and 3,231,550. For optimization, many conventional- type catalysts require at least one cocatalyst. A detailed discussion of cocatalysts may be found in U.S. Patent No. 7,858,719, Col. 6, line 46, to Col. 7, line 45.

Metallocene Catalysts

[0082] Metallocene catalysts (also referred to herein sometimes as metallocenes or metallocene compounds) are generally described as containing one or more ligand(s) and one or more leaving group(s) bonded to at least one metal atom, optionally with at least one bridging group. The ligands are generally represented by one or more open, acyclic, or fused ring(s) or ring system(s) or a combination thereof. These ligand(s) and the ring(s) or ring system(s) can comprise one or more atoms selected from Groups 13 to 16 atoms of the Periodic Table of Elements. In an aspect, the atoms are selected from the group consisting of carbon, nitrogen, oxygen, silicon, sulfur, phosphorous, germanium, boron and aluminum or a combination thereof. Further, in an aspect, the ring(s) or ring system(s) comprise carbon atoms including, but not limited to, Cp ligands or Cp-type ligand structures or other similarly functioning ligand structures such as pentadiene, cyclooctatetraendiyl, or imide ligands. In an aspect, the metal atom is selected from Groups 3 through 15 and the lanthanide or actinide series of the Periodic Table of Elements. In an aspect, the metal is a transition metal from Groups 4 through 12. In an aspect, the metal is a transition metal from Groups 4, 5 or 6. In an aspect, the metal is a transition metal from Group 4. [0083] Exemplary metallocene catalysts and catalyst systems are described in, for example, U.S. Patent Nos. 4,530,914, 4,871,705, 4,937,299, 5,017,714, 5,055,438, 5,096,867, 5,120,867,

5,124,418, 5,198,401, 5,210,352, 5,229,478, 5,264,405, 5,278,264, 5,278,119, 5,304,614,

5,324,800, 5,347,025, 5,350,723, 5,384,299, 5,391,790, 5,391,789, 5,399,636, 5,408,017,

5,491,207, 5,455,366, 5,534,473, 5,539,124, 5,554,775, 5,621,126, 5,684,098, 5,693,730,

5,698,634, 5,710,297, 5,712,354, 5,714,427, 5,714,555, 5,728,641, 5,728,839, 5,753,577,

5,767,209, 5,770,753, 5,770,664; EP-A-0 591 756, EP-A-0 520-732, EP-A-0 420 436, EP-B1 0 485 822, EP-B1 0 485 823, EP-A2-0 743 324, EP-B1 0 518 092; WO 91/04257, WO 92/00333, WO 93/08221, WO 93/08199, WO 94/01471, WO 96/20233, WO 97/15582, WO 97/19959, WO 97/46567, WO 98/01455, WO 98/06759, and WO 98/011144.

Polymerization Processes

[0084] The catalysts described above are suitable for use in any olefin pre-polymerization or polymerization process or both. Suitable polymerization processes include solution, gas phase, slurry phase, and a high-pressure process, or any combination thereof. A desirable process is a gas phase polymerization of one or more olefin monomers having from 2 to 30 carbon atoms, from 2 to 12 carbon atoms in an aspect, and from 2 to 8 carbon atoms in an aspect. Other monomers useful in the process include ethylenically unsaturated monomers, diolefms having 4 to 18 carbon atoms, conjugated or nonconjugated dienes, polyenes, vinyl monomers and cyclic olefins. Non-limiting monomers may also include norbomene, norbomadiene, isobutylene, isoprene, vinylbenzocyclobutane, styrenes, alkyl substituted styrene, ethylidene norbomene, dicyclopentadiene and cyclopentene.

[0085] Hydrogen gas is often used in olefin polymerization to control the final properties of the polyolefin. See, Polypropylene Handbook 76-78 (Hanser Publishers, 1996). Increasing concentrations (partial pressures) of hydrogen increase the melt flow rate (“MFR”) and/or MI of the polyolefin generated. The MFR or MI can thus be influenced by the hydrogen concentration. The amount of hydrogen in the polymerization can be expressed as a mole ratio relative to the total polymerizable monomer (ethylene, for example) or to the blend of ethylene and hexane or propene. The amount of hydrogen used in the polymerization process is an amount necessary to achieve the desired MFR or MI of the final polyolefin resin. The mole ratio of hydrogen to total monomer (¾: monomer) is in a range of from greater than 0.0001 in an aspect, from greater than 0.0005 in an aspect, from greater than 0.001 in an aspect, less than 10 in an aspect, less than 5 in an aspect, less than 3 in an aspect, and less than 0.10 in an aspect, wherein a desirable range may comprise any combination of any upper mole ratio limit with any lower mole ratio limit described herein. Expressed another way, the amount of hydrogen in the reactor at any time may range to up to 5000 ppm, up to 4000 ppm in an aspect, up to 3000 ppm in an aspect, from 50 ppm and 5000 ppm in an aspect, and from 100 ppm and 2000 ppm in an aspect.

[0086] In a gas phase polymerization process, a continuous cycle is often employed where one part of the cycle of a reactor system, a cycling gas stream, otherwise known as a recycle stream or fluidizing medium, is heated in the reactor by the heat of polymerization. This heat is removed from the recycle composition in another part of the cycle by a cooling system external to the reactor. Generally, in a gas fluidized bed process for producing polymers, a gaseous stream containing one or more monomers is continuously cycled through a fluidized bed in the presence of a catalyst under reactive conditions. The gaseous stream is withdrawn from the fluidized bed and recycled back into the reactor. Simultaneously, polymer product is withdrawn from the reactor and fresh monomer is added to replace the polymerized monomer. Production of Blown Film

[0087] Blown film extrusion involves the process of extruding the polyethylene composition (also referred to sometimes as a resin) through a die (not shown) followed by a bubble-like expansion. Advantages of manufacturing film in this manner include: (1) a single operation to produce tubing; (2) regulation of film width and thickness by control of the volume of air in the bubble; (3) high extruder output and haul-off speed; (4) elimination of end effects such as edge bead trim and nonuniform temperature that can result from flat die film extrusion; and (5) capability of biaxial orientation (allowing uniformity of mechanical properties).

[0088] As part of the process, a melt comprising the polyethylene composition with or without a blend partner is extruded through an annular slit die (not shown) to form a thin walled tube. Air is introduced via a hole in the center of the die to blow up the tube like a balloon. Mounted on top of the die, a high-speed air ring (not shown) blows onto the hot film to cool it. The foam film is drawn in an upward direction, continually cooling, until it passes through nip rolls (not shown) where the tube is flattened to create what is known as a 'lay -flat' tube of film. This lay-flat or collapsed tube is then taken back down the extrusion tower (not shown) via more rollers. For high output lines, air inside the bubble may also be exchanged. The lay-flat film is either wound or the edges of the film are slit off to produce two flat film sheets and wound up onto reels to produce a tube of film

Optional Additives

[0089] The polymer blends described above and/or the extrudate comprising the polymer blend as further described herein may be used in combination with other polymers, additives, PPAs, etc. For example, each layer may comprise a“neat” polymer with optional processing aids and/or additives or may comprise a blend of polymers with optional processing aids and/or additives.

[0090] In an aspect, an additive may be present up to 1.0, or 2.0, or 3.0 wt% by weight of the polymer composition described herein. An additive may be added before, during, or after the formation of the polyethylene composition and/or resulting article/extrudate

[0091] As provided herein, the relationship of the dart impact (also referred to as dart drop or dart impact strength) to the averaged 1% secant modulus is thought to be one indicator of long-chain branching in the ethylene-based polymer. Thus, alternatively ethylene-based polymers of certain embodiments may be characterized as having long-chain branches. Long- chain branches can represent the branches formed by reincorporation of vinyl-terminated macromers. The number of carbon atoms on the long-chain branches ranges from a chain length of at least one carbon more than two carbons less than the total number of carbons in the comonomer to several thousands. For example, a long-chain branch of an ethylene/hexene ethylene-based polymer is at least five (5) carbons in length (i.e., 6 carbons less 2 equals 4 carbons plus one equals a minimum branch length of five carbons for long-chain branches).

[0092] Particular ethylene-based polymers can have a 0.05 to 1.0, particularly 0.05 to 0.5, 0.1 to 0.4, or 0.2 to 0.3, long-chain branches per 1000 carbon atoms. Ethylene-based polymers having levels of long-chain branching greater than 1.0 long-chain branch per 1000 carbon atoms may have some beneficial properties, e.g., improved processability, shear thinning, and/or delayed melt fracture, and/or improved melt strength.

[0093] Various methods are known for determining the presence of long-chain branches. For example, long-chain branching can be determined using ¹³ C nuclear magnetic resonance (NMR) spectroscopy and to a limited extent; e.g., for ethylene homopolymers and for certain copolymers, and it can be quantified using the method of Randall Journal ofMacromolecular Science, Rev. Macromol. Chem. Phys., C29 (2&3), p. 285-297). Although conventional ¹³ C NMR spectroscopy cannot determine the length of a long-chain branch in excess of about six carbon atoms, there are other known techniques useful for quantifying or determining the presence of long-chain branches in ethylene-based polymers, such as ethylene/l-octene interpolymers. For those ethylene-based polymers wherein the ¹³ C resonances of the comonomer overlap completely with the ¹³ C resonances of the long-chain branches, either the comonomer or the other monomers (such as ethylene) can be isotopically labeled so that the long-chain branches can be distinguished from the comonomer. For example, a copolymer of ethylene and 1-octene can be prepared using ¹³ C-labeled ethylene. In this case, the resonances associated with macromer incorporation will be significantly enhanced in intensity and will show coupling to neighboring ¹³ C carbons, whereas the octene resonances will be unenhanced.

[0094] The branching index, g' is inversely proportional to the amount of branching. Thus, lower values for g' indicate relatively higher amounts of branching. The amounts of short and long-chain branching each contribute to the branching index according to the formula: g'=g'LCB ^x g'scB. Thus, the branching index due to long-chain branching may be calculated from the experimentally determined value for g' as described by Scholte, et al, in J. App. Polymer ScL, 29, pp. 3763-3782 (1984).

[0095] Alternatively, the degree of long-chain branching in ethylene-based polymers may be quantified by determination of the branching index. The branching index g' is defined by the following equation:

lV _Br

9 = IV _Li

w

where g' is the branching index, IV _BI is the intrinsic viscosity of the branched ethylene-based polymer and IVun is the intrinsic viscosity of the corresponding linear ethylene-based polymer having the same weight average molecular weight and molecular weight distribution as the branched ethylene-based polymer, and in the case of copolymers and terpolymers, substantially the same relative molecular proportion or proportions of monomer units. A method for determining intrinsic viscosity of polyethylene is described in Macromolecules, 2000, 33, 7489-7499. Intrinsic viscosity may be determined by dissolving the linear and branched polymers in an appropriate solvent, e.g., trichlorobenzene, typically measured at 135°C. Another method for measuring the intrinsic viscosity of a polymer is ASTM D-5225-98 - Standard Test Method for Measuring Solution Viscosity of Polymers with a Differential Viscometer, which is incorporated by reference herein in its entirety.

[0096] The average intrinsic viscosity, of a sample can be calculated by:

where the summations are over the chromatographic slices, i, between the integration limit.

Methods of Manufacture

[0097] The hygiene articles of the present invention may be produced by any conventional means. The different layers may thus be assembled using standard means such as embossing (e.g. thermal bonding), ultrasonic bonding, gluing/using adhesives or any combination of the aforementioned. The converting line may comprise a printing step wherein the ink is applied to the backsheet of the article. The backsheet may also comprise dyes or colorants. [0098] In an aspect, provided herein is a process to produce a hygiene article, the process comprising disposing the following layers, in order, unto one another to produce the hygiene article:

a) at least one top sheet;

b) at least one absorbent core; and

c) at least one backsheet;

wherein the at least one backsheet comprises film comprising a polyethylene composition in an amount from about 25 wt% to about 45 wt% and a masterbatch in an amount from about 55 wt% to about 75 wt%, wherein the film is highly filled and comprises CaCCb in an amount greater than or equal to 45 wt% and the film has an MD trouser tear of from about 155 cN to about 160 cN as measured by ASTM 1938. In an aspect, the masterbatch comprises from about 65 wt% to about 70 wt% CaCCb. In an aspect, the film comprises the polyethylene composition having a melt index of about 0.5 g/10 min and a density of 0.918 g/cm ³ . The film has a dart impact from about 5.0 g/pm to about 15.0 g/pm.

[0099] The at least one backsheet may further be oriented, optionally, in the machine direction (MD) and/or transverse direction (TD). This may be done in-line with the film production or off-line on a stand-alone unit.

[00100] In an aspect, the at least one backsheet is cast film, optionally, a monolayer cast film or multilayer cast film.

[00101] In an aspect, the at least one backsheet is blown film, optionally, a coextruded blown film. The blown film may be a monolayer blown film or a multilayer blown film.

[00102] In another class of embodiments, the at least one backsheet may be embossed, either in-line with film production or off line in a stand-alone embossing unit. The embossing may be done with heated rollers or at ambient temperature.

[00103] It is to be understood that while the invention has been described in conjunction with the specific embodiments thereof, the foregoing description is intended to illustrate and not limit the scope of the invention. Other aspects, advantages and modifications will be apparent to those skilled in the art to which the invention pertains.

[00104] Therefore, the following examples are put forth so as to provide those skilled in the art with a complete disclosure and description and are not intended to limit the scope of that which the inventors regard as their invention.

EXAMPLE

[00105] The backsheet is an important functional layer in diaper, feminine care and adult incontinence products, and provides barrier to bio-fluids while providing breathability at the same time. The films described herein can be produced from cast film or blown film processing followed by machine direction orientation (“MDO”). During stretching at machine direction, microcavities are formed around Calcium Carbonate particles in the film leading to breathability. While the MDO process improves film stiffness, it can result in detrimental tear properties. Tear is a key property in this application as it provides mechanical strength during assembly.

[00106] EXCEED™ is the trademark for a family of polyethylene compositions where we have demonstrated its superior tear performance in films. As shown in Tables 1A and IB below, we tested EXCEED™ polyethylene compositions in highly filled films. Blown breathable film was produced with a die diameter of 180 mm and die gap of 1.5 mm having an output of 130 kg/hr. Film samples were run at 50 grams per square meter (gsm) with layer distribution at 1/3/1. The film was then stretched approximately 2.7 times with offline MDO to 20 gsm. The films were then test for various mechanical properties, liquid barrier and breathability.

Table 1A

Table IB

[00107] As shown in Tables 2A and 2B below, compared to the market reference, improved MD trouser tear was shown by almost 10 times resulting in tough film and solving the low tear problems in the films.

Table 2A

Table 2B

[00108] The phrases, unless otherwise specified,“consists essentially of’ and“consisting essentially of’ do not exclude the presence of other steps, elements, or materials, whether or not, specifically mentioned in this specification, so long as such steps, elements, or materials, do not affect the basic and novel characteristics of the invention, additionally, they do not exclude impurities and variances normally associated with the elements and materials used.

[00109] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, within a range includes every point or individual value between its end points even though not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[00110] All priority documents are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted and to the extent such disclosure is consistent with the description of the present invention. Further, all documents and references cited herein, including testing procedures, publications, patents, journal articles, etc. are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted and to the extent such disclosure is consistent with the description of the present invention.

[00111] While the invention has been described with respect to a number of embodiments and examples, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the invention as disclosed herein.