WO2025219975A1 - Polymeric multilayer film and article and related process - Google Patents

Abstract

A polymeric multilayer film (100) includes a first polymeric layer (101) and a second polymeric layer (102). The first polymeric layer (101) comprises a porous random network of strands and connective regions, and the second polymeric layer (102) is a continuous polymeric film layer. The polymeric multilayer film (100) is water vapor permeable. An article includes a pressure-sensitive adhesive (105) disposed on at least one of a first major major surface or a second major surface of the polymeric multilayer film (100). A process for making the polymeric multilayer film (100) including coextruding the first polymeric layer (101) and the second polymeric layer (102) is also disclosed.

Description

POLYMERIC MULTILAYER FILM AND ARTICLE AND RELATED PROCESS

Cross-Reference to Related Application

This application claims priority to U.S. Provisional Application Nos. 63/635,837 and 63/635,815, fded April 18, 2024, the disclosures of which are incorporated by reference in their entirety herein.

Background

Polymeric multilayer films in which at least one layer is in the form of a random network of strands and connective regions are described in U.S. Pat. Nos. 10,953,573 (Emslander et al.), 10,953,574 (Y oung et al.), 10,953,623 (Y oung et al.), 10,987,894 (Emslander et al.). The polymeric multilayer films are said to be useful, for example, for tapes, graphic articles, and anti-slip surfaces.

In unrelated technologies, water-vapor-permeable air and water barrier articles are disclosed in U.S. Pat. Nos. 10,704,254 (Seabaugh et al.), 11,105,089 (Widenbrant et al.), 11,365,328 (Seabaugh et al.), 11,512,463 (Widenbrant et al.), and 11,731,394 (Seabaugh et al.), and U.S. Pat. Appl. Pub. Nos. 2017/0173916 (Widenbrant et al.), 2021/0207005 (Seabaugh et al.), and 2022/0282476 (Widenbrant et al.). Self-adhesive permeable membrane sheets for use in buildings are disclosed in U.S. Pat. Nos. 10,899,107 (Bess) and 9,562,174 (Russell).

Summary

In one aspect, the present disclosure provides a polymeric multilayer fdm that includes a first polymeric layer and a second polymeric layer. The first polymeric layer comprises a porous random network of strands and connective regions, and the second polymeric layer is a continuous polymeric film layer. The polymeric multilayer film is water vapor permeable.

In another aspect, the present disclosure provides an article, which includes a pressure-sensitive adhesive disposed on at least one of a first major surface or a second major surface of the polymeric multilayer film.

In another aspect, the present disclosure provides a process for making a polymeric multilayer film. The process includes coextruding a first polymeric layer and a second polymeric layer. The first polymeric layer comprises a porous random network of strands and connective regions, and the second polymeric layer is a continuous polymeric film layer. The polymeric multilayer film is water vapor permeable.

In this application, terms such as "a", "an" and "the" are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration. The terms "a", "an", and "the" are used interchangeably with the term "at least one". The phrases "at least one of and "comprises at least one of followed by a list including the conjunction “or” refers to any one of the items in the list and any combination of two or more items in the list. All numerical ranges are inclusive of their endpoints and non-integral values between the endpoints unless otherwise stated (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.8, 4, and 5, and the like).

The term “water vapor permeable” as used herein means an article having a permeance of more than 1 perm (inch-pounds units) (57.2135 nanograms per second per meter squared per Pascal (ng s m² Pa)) according to ASTM E 96 Procedure A (Desiccant Method).

The term “continuous” as used herein means a coating having an uninterrupted extension along a two-dimensional surface. For example, in some embodiments, in an air and water barrier article having a continuous water-permeable polymer coating, the water-permeable polymeric coating covers a major surface of the fibrous layer.

The term “discontinuous” as used herein means a coating having an interrupted extension along a two-dimensional surface. For example, in some embodiments, in an air and water barrier article having a discontinuous coating of pressure sensitive adhesive, the pressure -sensitive adhesive does not cover a major surface of a polymeric layer or a major surface of a fibrous layer.

The term "polymer" refers to a molecule having a structure which includes the multiple repetition of units derived, actually or conceptually, from one or more monomers. The term “monomer” refers to a molecule of low relative molecular mass that can combine with others to form a polymer. The term “polymer” includes homopolymers and copolymers, as well as homopolymers or copolymers that may be formed in a miscible blend, e.g., by coextrusion or by reaction. The term “polymer” includes random, block, graft, and star polymers. The term “polymer” encompasses oligomers.

A “monomer unit” of a polymer or oligomer is a segment of a polymer or oligomer derived from a single monomer. As an example, the monomeric unit of acrylic acid (H2C=CH-(C=0)-0H) is where the asterisks (*) indicate the attachment site to another group such as another monomeric unit in the polymer.

The term “acrylic” refers to both acrylic and methacrylic polymers, oligomers, and monomers.

The term "(meth)acryl" refers to acryl (also referred to in the art as acryloyl and acrylyl) and/or methacryl (also referred to in the art as methacryloyl and methacrylyl).

"Alkyl group" and the prefix "alk-" are inclusive of both straight chain and branched chain groups and of cyclic groups having up to 30 carbons (in some embodiments, up to 20, 15, 12, 10, 8, 7, 6, or 5 carbons) unless otherwise specified. Cyclic groups can be monocyclic or polycyclic and, in some embodiments, have from 3 to 10 ring carbon atoms.

"Alkylene" is the multivalent (e.g., divalent or trivalent) form of the "alkyl" groups defined above. Pressure-Sensitive Adhesives (PSAs) are well known to those of ordinary skill in the art to possess properties including the following: (1) aggressive and permanent tack, (2) adherence with no more than finger pressure, (3) sufficient ability to hold onto an adherend, and (4) sufficient cohesive strength to be cleanly removable from the adherend. Materials that have been found to function well as PSAs are polymers designed and formulated to exhibit the requisite viscoelastic properties resulting in a desired balance of tack, peel adhesion, and shear holding power. One useful method for identifying pressure sensitive adhesives is the Dahlquist criterion. This criterion defines a pressure sensitive adhesive as an adhesive having a creep compliance of greater than 3 x 10’⁶ cm²/dyne as described in Handbook of Pressure Sensitive Adhesive Technology, Donatas Safas (Ed.), 2nd Edition, p. 172, Van Nostrand Reinhold, New York, NY, 1989. Alternatively, since modulus is, to a first approximation, the inverse of creep compliance, pressure sensitive adhesives may be defined as adhesives having a storage modulus of less than about 3 x 10⁵ N/m².

Brief Description of the Drawings

FIG. 1 is a side view of an embodiment of the article of the present disclosure including an embodiment of the polymeric multilayer film of the present disclosure.

FIG. 2 is a top view schematic of a porous random network of strands and connective regions in the first polymeric layer.

FIG. 3 is an example of an apparatus for making polymeric multilayer film described herein. FIG. 3A is an example of an annular die used in the apparatus shown in FIG. 3.

FIG. 4 is a photograph of Example 6.

FIG. 5 is a perspective view of another embodiment of an article of the present disclosure, applied to a window frame.

Detailed Description

The present disclosure describes a polymeric multilayer film comprising at least two polymeric layers, wherein at least one of the polymeric film layers comprises a porous random network of strands and connective regions. In some embodiments, the strands are elongated strands. In some embodiments, the random network has a first optical density, and the connective regions have a second optical density, wherein the first optical density is greater than the second optical density. Optical density can be visually determined. A person skilled in the art can determine if the first optical density is greater than the second optical density if the random network of strands appears to have higher opacity than the connective regions. There are openings (i.e., through holes) in at least some of the connective regions. In some embodiments there are no openings (i.e., no through holes) in some of the connective regions. In some embodiments, there are at least 2, 3, 4, 5, 6, or 7 polymeric layers exhibiting a random network of strands and connective regions. In some embodiments, some of the layers are adjacent to another layer exhibiting a random network of strands and connective regions. In some embodiments, at least one of the first or second (in some embodiments each of the first and second) major surfaces of a polymeric multilayer film exhibits a random network of strands and connective regions.

Referring to FIGS. 1 and 2, polymeric multilayer film 100 includes a first polymeric layer 101 and a second polymeric layer 102, wherein the first polymeric layer 101 comprises a porous random network of strands and connective regions (not shown in FIG. 1), and the second polymeric layer 102 is a continuous polymeric film layer. Referring to FIG. 2, an example of random network of strands 203 and connective regions 204 in the first polymeric layer of polymeric multilayer film 200 is shown.

The first polymeric layer is not a fibrous layer. A fiber can be defined as an elongated material having a substantially uniform transverse cross-sectional diameter or thickness, and an aspect ratio, defined as the ratio of fiber length to fiber cross-sectional diameter or thickness, greater than about 100. A fiber has an identifiable length in only one dimension. “Substantially uniform” means that the cross- sectional dimension does not vary by more than 10 percent. Typically, the diameter or thickness of a fiber is less than 250 pm. Thus, the first polymeric layer is not a nonwoven, woven, or knitted fabric layer. The term “nonwoven” refers to a material having a structure of individual fibers or threads that are interlaid but not in an identifiable manner such as in a knitted fabric. In contrast to a layer made of fibers (i.e., a fibrous layer), the first polymeric layer is a two-dimensional random network of strands and connective regions without one-dimensional fibers. Furthermore, most microporous membranes such as those described in U.S. Pat. No. 5,120,594 (Mrozinski) have generally uniform thicknesses and do not have identifiable strands and connective regions like the first polymeric layer.

In some embodiments, each polymeric layer that comprises a porous random network of strands and connective regions, independently comprises at least one of a polyolefinic material (e.g., polypropylene and/or polyethylene), modified polyolefinic material, polyvinyl chloride, polycarbonate, polystyrene, polyester (including co-polyester), polylactide, polyvinylidene fluoride, (meth)acrylic (e.g., polymethyl methacrylate), thermoplastic polyurethane (TPU), acrylic urethane, ethylene vinyl acetate copolymer, acrylate-modified ethylene vinyl acetate polymer, ethylene acrylic acid copolymers, nylon, engineering polymer (e.g., a polyketone and/or polymethylpentane), or elastomer (e.g., natural rubber; synthetic rubber; styrene block copolymer containing isoprene, butadiene, or ethylene (butylene) blocks; metallocene-catalyzed polyolefin, polyurethanes; or polydiorganosiloxane). A TPU is a thermoplastic block copolymer composed of a soft segment and a hard segment alternately connected, wherein the hard segment is an isocyanate segment (e.g., including an aliphatic isocyanate segment, an aromatic isocyanate segment, or a combination thereof), and the soft segment is a polyether polyol segment or a polyester polyol segment, described in further detail below. The soft segments and uncrystallized hard segments form an amorphous phase, and a portion of the hard segment crystallizes to form crystalline microdomains, which can function as physical crosslinking domains. Useful TPUs for the first polymeric layer can have a high percentage of hard segments. In some embodiments, each polymeric layer that comprises a porous random network of strands and connective regions comprises a vapor impermeable resin. In some embodiments, each polymeric layer that comprises a porous random network of strands and connective regions comprises a polyolefin. In some embodiments, each polymeric layer that comprises a porous random network of strands and connective regions comprises at least one of polyethylene or polypropylene. In some embodiments, the polymeric layer that comprises a porous random network of strands and connective regions comprises low density polyethylene, high density polyethylene, an ethylene-containing copolymer, or a combination thereof. In some embodiments, the polymeric layer that comprises a porous random network of strands and connective regions comprises a thermoplastic polyolefin resin available under the trade designation “ADFLEX KS 021 P” from LyondellBasell, Houston, TX.

In some embodiments, the first polymeric layer, which comprises a porous random network of strands and connective regions, comprises an ethylene-containing copolymer. The copolymer can include a polar comonomer. Examples of ethylene -containing copolymers including a polar comonomer include ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, and ethylene-methacrylic acid copolymer. In some embodiments, the ethylene -containing copolymer of the first polymeric layer includes at least 70 weight percent (wt.%), at least 75 wt.%, or at least 80 wt.%, of ethylene. In some embodiments, the ethylene-containing copolymer of the first polymeric layer includes up to 99 wt.%, up to 95 wt.%, up to 90 wt.%, or up to 85 wt.% of ethylene. In some embodiments, the ethylene-containing copolymer includes at least 1 wt.%, at least 5 wt.%, at least 10 wt.%, or at least 15 wt.% of one or more polar comonomers. In some embodiments, the ethylene -containing copolymer includes up to 30 wt.%, up to 25 wt.%, or up to 20 wt.%, of one or more polar comonomers. Ethylene -vinyl acetate copolymers are commercially available from various suppliers including DuPont Packaging and Industrial Polymers under the trade designations “ELVAX”, for example, grades 750, 550, and 350. Ethylene-acrylic acid copolymers are available from various suppliers such as Dow Chemical Company under the trade designation “PRIMACOR”, for example, grade 1410 or 3460. Ethylene-methacrylic acid copolymers are available from various suppliers such as DuPont Packaging and Industrial Polymers under the trade designations “NUCREL”, for example, grades 0403 and 0903. Useful ethylene-containing copolymers can also contain two or more polar comonomers. Examples of such ethylene-containing copolymers include carbon monoxide-modified ethylene -vinyl acetate or anhydride modified ethylene -vinyl acetate. Such ethylene-containing copolymers are commercially available from various suppliers including DuPont Packaging and Industrial Polymers under the trade designations “BYNEL E418” and “ELVALOY 741”. Mixtures of at least two different ethylene -containing copolymers (e.g., each having different polar comonomers or each having the same polar comonomer but in different amounts) can also be useful.

In some embodiments, the first and second polymer film layers are coextruded. Coextrusion means, for the purposes of the present disclosure, the simultaneous melt processing of multiple molten streams and combination of such molten streams into a single unified structure, or coextruded film, for example, from a single extrusion die. The polymeric multilayer film of the present disclosure can be coextruded using any suitable type of coextrusion die and any suitable method of film making such as blown film extrusion or cast film extrusion. In some embodiments, a multilayer melt stream can be formed by a multilayer feedblock, such as that shown in U.S. Pat. No. 4,839, 131 (Cloeren) or other specialized feedblock or a specialized die such as those made by Cloeren Co., Orange, TX. The feed block and die used are typically heated to facilitate polymer flow and layer adhesion, with the temperature of the die depending on the polymers used. Techniques of coextrusion are found in many polymer processing references, including Progelhof, R. C., and Throne, J. L., "Polymer Engineering Principles", Hanser/Gardner Publications, Inc., Cincinnati, Ohio, 1993. To facilitate coextrusion, in some embodiments, the melt viscosity of the polymer in the continuous polymeric film layer is similar to the melt viscosity of the polymer in the polymer layer that comprises a porous random network of strands and connective regions.

In some embodiments, the polymeric multilayer film comprising at least two polymeric layers, with at least one of the polymeric layers exhibiting a random network of strands and connective regions described herein, can be made by foaming a layer in a blown film process that uses an annular die to form a molten tube of film oriented radially via air pressure in a “bubble” and also pulled lengthwise in the molten area to thin the film to the final desired thickness. For example, referring to FIG. 3, an apparatus 300 for making the polymeric multilayer film includes hopper 304, extruder 306, annular die 308, air ring 310, collapsing frame 314, rollers 316A, 316B that form nip 317, slitting station 323, and idler rolls 318, 319. Referring to FIG. 3A, further details of nine-layer annular die 308 are shown, including stacked die plates, with each individual die plate stack layer having machined polymer flow channels 309A, 309B, 309C, 309D, 309E, 309F, 309G, 309H, 3091. During the film making process the molten polymer passes through the flow channels 309A, 309B, 309C, 309D, 309E, 309F, 309G, 309H, 3091 and contacts central die cylinder 310 and then flows upward combining with other layers and exits annular die opening 311 to form multilayered film tube 312. The number of layers in the polymeric multilayer film can be adjusted by the number of stacking die plates in the annular die.

In operation, resin 302 (typically in the form of pellets) and other additives are added to hopper 304. Molten or otherwise flowable resin exits extruder 306 into annular die 308. Air ring 310 provides uniform air flow over the molten polymer bubble which stabilizes and aids in cooling of the polymer bubble forming circular film bubble 312 into a collapsed film tube 320 by passing through nip 317 formed by contacting nip rolls 316A and 316B. The collapsed film tube traverses idler rolls 318 and passes through slitting station 323 resulting in the formation of two flat films 320A and 320B that are passed over additional idler roll 319. Films 320A and 320B are then wound into individual rolls 321A and 32 IB, respectively. A layer(s) of the polymeric multilayer film can be foamed or overfoamed, for example, by introducing a gas into the molten polymer inside the extruder. The gas is readily absorbed into the polymer under the heat and pressure of the extrusion process. When the molten polymer exits the extrusion die, the absorbed, pressurized gas rapidly expands and forms voids. The proper process conditions can be adjusted so that when the polymer solidifies, the void structure is “locked in” resulting in a foam structure in the polymeric film. Foaming of a layer(s) can be facilitated, for example, by including or injecting a foaming agent in the resin for that layer(s). Foaming agents are known in the art and include injecting gases (e.g., nitrogen or carbon dioxide); a blend of alkaline earth metal carbonates and alkaline metal acid salts that are described in U.S. Pat. No. 8,563,621 (Lapierre), the disclosure of which is incorporated herein by reference; hydrazine; hydrazide; and azodicarbonamide materials (e.g., 4,4’-oxybis (benzene sulfonyl hydrazide) (OBSH) (available, for example, in a masterbatch form under the trade designation “CELOGEN OT” from ChemPoint, Bellevue, WA). Further examples of commercially available blowing agents include those under the trade designation “ECOCELL H” from Polyfd Corp., Rockaway, NJ, an endothermic foaming agent, available as a masterbatch under the trade designation “FCX111263” from RTP Company, Winona, MN, and “HYDROCEROL CF 40 E”, from Avient, Avon Lake, OH.

In some embodiments, the foaming agent is added to the resins that is fed into the extruder. The foaming agent and other processing conditions are selected or adjusted to provide a desired or acceptable polymeric multilayer fdm comprising a layer(s) exhibiting a random network of strands and connective regions.

The polymeric multilayer fdm according to the present disclosure further comprises at least one second polymeric layer which is a continuous (i.e., does not containing openings extending from one major surface to another major surface) polymeric fdm layer. In some embodiments, a continuous layer adjacent to a layer exhibiting a random network of strands and connective regions becomes textured from the random network of strands and connective regions (e.g., the continuous layer may conform at least in part to the texture of the random network of strands and connective regions). The continuous polymeric fdm layer is water vapor permeable. The water vapor permeability of the second polymeric layer can be influenced by the hydrophilic nature of at least a portion of the polymer. A higher degree of swelling in water may be useful to enhance the water vapor permeability of the second polymeric layer. In some embodiments, at least a portion of the polymer in the second polymeric layer includes polyether segments (e.g., polytetrahydrofuran, polypropylene oxide, polyethylene oxide, or combinations thereof).

In some embodiments, the second polymeric layer comprises at least one of a polyurethane, polyamide, polylactic acid, an acrylic block copolymer, or an amorphous polyester. In some embodiments, the second polymeric layer is not a polyoxyalkylene polymer crosslinked with siloxane bonds. In some embodiments, the second polymeric layer is not a poly oxyalkylene polymer having at least one crosslink site derived from an alkoxy silane. In some embodiments, the second polymeric layer is not covalently crosslinked, but in some embodiments, the second polymeric is a thermoplastic elastomer having physical crosslinks.

In some embodiments, the continuous polymeric fdm layer is a polyurethane. Polyurethanes may be formed using any suitable reactants and any suitable process. Polyurethanes are typically formed from starting materials that include one or more isocyanates, one or more polyols, and optionally one or more additional reactants (e.g., having one or more active hydrogen groups). In some cases, a stoichiometric excess of isocyanate is reacted with the polyol. For example, a ratio of isocyanate groups to hydroxyl groups can range from about 1.1: 1 to 3: 1 (NCO:OH), from about 1.2: 1 to 2.5: 1, or from about 1.3: 1 to 2: 1. The polyurethane may have any suitable molecular weight, for example, a number average molecular weight from about 1,000 to about 10,000 or from about 2,500 to about 7,500.

Suitable isocyanates include those having one, two, three, or four isocyanate groups and mixtures thereof. Suitable diisocyanates include isophoronediisocyanate (i.e., 5 -isocyanato- 1-isocyanatomethyl- 1 ,3 ,3 -trimethylcyclohexane); 5 -isocyanato- 1 -(2-isocyanatoeth- 1 -yl)- 1 ,3 ,3 -trimethylcyclohexane; 5 - isocyanato- 1 -(3 -isocyanatoprop- 1 -yl)- 1 ,3 ,3 -trimethylcyclohexane; 5 -isocyanato-(4-isocyanatobut- 1 -yl)- 1 ,3 ,3 -trimethylcyclohexane; 1 -isocyanato-2-(3 -isocyanatoprop- 1 -yl)cyclohexane ; 1 -isocyanato-2-(3 - isocyanatoeth- 1 -yl)cyclohexane; 1 -isocyanato-2-(4-isocyanatobut- 1 -yl)cyclohexane ; 1 ,2- diisocyanatocyclohexane; l,3-diisocyanatocyclohexane;l,4-diisocyanatocyclohexane; dicyclohexylmethane 2,4'-diisocyanate; trimethylene diisocyanate; tetramethylene diisocyanate; pentamethylenediisocyanate; hexamethylene diisocyanate; ethylethylene diisocyanate;trimethylhexane diisocyanate; heptamethylene diisocyanate;2-heptyl-3,4-bis(9-isocyanatononyl)-l-pentyl-cyclohexane; 1,2-, 1,4-, andl,3-bis(isocyanatomethyl)cyclohexane; 1,2-, 1,4-, and l,3-bis(2-isocyanatoeth-l- yl)cyclohexane; l,3-bis(3-isocyanatoprop-l-yl)cyclohexane; 1,2-, 1,4- or l,3-bis(4-isocyanatobuty-l- yl)cyclohexane; liquid bis(4-isocyanatocyclohexyl)-methane; and derivatives or mixtures thereof. In some embodiments, the isocyanate or mixture of isocyanates is non-aromatic (e.g., aliphatic). In some embodiments, the isocyanate comprises at least one of isophorone diisocyanate (IPDI) or hexamethylene diisocyanate (HMDI). In some embodiments, HMDI is the predominant isocyanate used to prepare the polyurethane, in other words, more HMDI units are present than any other isocyanate units.

In some embodiments, the polyurethane of the continuous polymeric fdm layer is formed using aliphatic isocyanates, which may provide improved stability to ultraviolet light (UV) exposure compared to aromatic isocyanates. In some embodiments, the isocyanate is dicyclohexylmethane-2,4'-diisocyanate, dicyclohexylmethane-4,4'-diisocyanate, or liquid bis(4-isocyanatocyclohexyl)-methane.

Suitable polyols for preparing polyurethanes include monomers, oligomers, polymers, and mixtures thereof and include diols, triols, polyols having 4 or more hydroxyl groups, and mixtures thereof. Examples of polyols for use as reactants or as starting materials for oligomer or polymer polyols include ethylene glycol, propylene glycol, 1,3 -propanediol, glycerol, diethylene glycol, dipropylene glycol, triethylene glycol, trimethylolpropane, trimethylolethane, tripropyleneglycol, neopentyl glycol, pentaerythritol, 1,4-butanediol, hexyleneglycol, 1,6-hexanediol, cyclohexanedimethanol, a polyethylene or polypropylene glycol, isopropylidene bis(p-phenylene-oxypropanol-2), and mixtures thereof. Examples of suitable oligomer and/or polymer polyols include polyether polyols, polyester polyols, polyether-ester polyols, polyureapolyols, polyamide polyols, polycarbonate polyols, saturated or unsaturated polyolefin polyols, and combinations thereof. In some embodiments, the soft segments in the polyurethane of the continuous polymeric film layer include polyethers (e.g., polytetrahydrofuran, polypropylene oxide, polyethylene oxide, or combinations thereof). The polyether segments may be incorporated into the polyurethane by reaction of a polyoxyalkylene polymer having hydroxyl terminal groups as described below in any of the embodiments of the polyoxyalkylene polymer. In some embodiments, the polyether has number average molecular weight in a range from 600 to 6000 grams per mole (g/mol), for example.

In some embodiments, the polyurethane of the second polymeric layer is formed using polyols that provide high water vapor permeability. In some embodiments, the polyol contains ethylene glycol repeat units. Examples of polyols with ethylene glycol repeat units include polyethylene glycol, poly(ethylene glycol-block-propylene glycol, polyethylene glycol-random-propylene glycol), poly(diethylene glycol)adipate, bisphenol A ethoxylate, and combinations of these polyols. In some embodiments, the polyol is polyethylene glycol diol. In some embodiments, the number average molecular weight of the polyethylene glycol diol is at least 500 g/mol, 800 g/mol, or 1000 g/mol. In some embodiments, the molecular weight of the polyethylene glycol diol is not more than 4000 g/mol, 3000 g/mol, 2500 g/mol, or 1000 g/mol.

In some embodiments, the polyurethane is a reaction product of components comprising polyethylene glycol, a chain extender, and an aliphatic isocyanate. The polyethylene glycol and aliphatic isocyanate can be any of those described above in any of their embodiments. A chain extender is a diol having a molecular weight of not more than 250 g/mol and can be any of those described above.

In some embodiments, the polyurethane of the second polymeric layer is formed using at least one polyol having a functionality of greater than two, in some embodiments, a functionality of about three. Examples of polyols with a functionality of three include glycerol, polycaprolactone triol, polypropylene oxide triol, poly(ethylene-co-propylene oxide) triol, and trimethylol propane. In some embodiments, the hydroxyl groups from the triol comprise at least or more than 1 mole percent (mol %), 2 mol %, or 3 mol % of the total number of hydroxyl groups in the formulation to make the polyurethane. In some embodiments, the hydroxyl groups from the triol comprise not more than or less than 10 mol %, 6 mol %, or 4 mol % of the total number of hydroxyl groups in the formulation to make the polyurethane. Including at least one polyol having a functionality of greater than two in the preparation of the polyurethane can be useful, for example, to increase the melt viscosity of polyurethanes of the continuous polymeric fdm layer.

In some embodiments, the polyurethane is a TPU, composed of molecules that are substantially linear and have some physical crosslinking, usually through the interaction between urethane groups in the molecules. Commercially available polyurethanes that can be useful in the polymeric multilayer fdm and article of the present disclosure include those obtained from BASF Company, Ludwigshafen, Germany, under the trade designation “ELASTOLLAN”, from Covestro Company under the trade designation “DESMOPAN”, and under the trade designation “ESTANE” from Lubrizol, Wickliffe, OH.

In some embodiments, the second polymeric layer includes an acrylic block copolymer having hard segments and soft segments. In some embodiments, the acrylic block copolymer includes poly(methyl methacrylate) (PMMA) hard segments, and the soft segments of the acrylic block copolymer can be formed from monomers of an acrylate or methacrylate having a C4-C9 alkyl sidechain or mixtures thereof, for example. Examples of monomers useful for forming the second block include n-butyl acrylate, n-pentyl acrylate, n-hexyl acrylate, n-heptyl acrylate, 2-ethylhexyl acrylate, isooctyl acrylate, n- octyl acrylate, n-nonyl acrylate, methacrylates of the foregoing acrylates, and mixtures thereof. In some embodiments, monomers useful for forming soft segments include a C2-4 hydroxyalkyl acrylate or methacrylate such as 2-hydroxyethyl acrylate, 3 -hydroxypropyl acrylate, 2-hydroxyethyl methacrylate, and 3 -hydroxypropyl methacrylate. In some embodiments, the acrylic block copolymer is a poly(methyl methacrylate)-poly(n-butylacrylate)-poly(methyl methacrylate) triblock copolymer. In some embodiments, the block copolymer contains about 70% PMMA and 30% poly(n-butyl acrylate). The block copolymer may have a number average molecular weight of up to about 120,000 grams per mole. Suitable commercially available materials useful for the block copolymer include those obtained under the trade designation “ABC KURARITY” from Kuraray, Chiyoda City, Japan (e.g., grades LA2330 and LA 3320), and those obtained under the trade designation “NANOSTRENGTH” from Arkema, King of Prussia, PA.

In some embodiments, the second polymeric layer comprises a polyamide. In some embodiments, the polyamide is a thermoplastic polyamide elastomer, and the soft segment is a polyether polyol segment such as any of these described above. Certain useful thermoplastic polyamides are commercially available, for example, under the trade designation “PEBAX” from Arkema. In some embodiments, the second polymeric layer comprises an amorphous polyester. In some embodiments, the amorphous polyester has polyether polyol segments such as any of those described above. Useful amorphous polyesters include those obtained from BASF, Florham Park, NJ, under the trade designation “ARNITEL”. In some embodiments, the second polymeric layer comprises polylactic acid (PLA). PLA is typically prepared from renewable resources (e.g., com starch, tapioca, or sugarcane) and is commercially available, for example, from NatureWorks, LLC (Plymouth, MN).

The second polymeric layer can be made in the blown film apparatus described above, for example, by not including or injecting a foaming agent in the resin for the layer in the annular stacked die. Continuous layers can also be provided by techniques known in the art, such as hot melt extrusion of an extrudable composition comprising the components of the continuous layer composition. Examples of methods for making extrudable continuous layers are described, for example, in Progelhof, R. C., and Throne, J. L., “Polymer Engineering Principles,” Hanser/Gardner Publications, Inc., Cincinnati, OH, 1993. Alternatively, for example, at least one layer may be extruded as a separate sheet and laminated together with the first polymeric layer that comprises a porous random network of strands and connective regions.

Typically, and advantageously, the polymeric multilayer film can combine the best properties of different resins in the various layers while minimizing the use of the most expensive resins, leading to a higher value and lower cost vapor permeable film. In some embodiments, the polymeric film layer comprising the porous random network of strands and connective regions provides mechanical strength for specific applications while also being inherently inexpensive compared to traditional vapor permeable films. In some embodiments, the continuous layer can be made ultra-thin to save on cost and improve permeability. Desirable properties and cost can be balanced through the selection of first and second polymeric layers.

In some embodiments, there are at least 2, 3, 4, 5, 6, or 7 first polymeric layers comprising a porous random network of strands and connective regions and at least 2, 3, 4, 5, 6, or 7 continuous second polymeric layers. In some embodiments with more than one first polymeric layer comprising a porous random network of strands and connective regions, at least two such layers exhibit different random networks of strands and connective regions. In some embodiments with more than one continuous second polymeric layer, at least two such layers have a different polymeric composition. In some embodiments, the first polymeric layers comprising a porous random network of strands and connective regions at least partially alternate with the continuous second polymeric layers. In some embodiments only one first polymeric layer comprising a porous random network of strands and connective regions is in direct contact with a continuous second polymeric layer. In some embodiments, at least one first polymeric layer comprising a porous random network of strands and connective regions is disposed between two continuous second polymeric layers. In some embodiments, a continuous second polymeric layer is disposed between two first polymeric layers comprising a porous random network of strands and connective regions. In some embodiments, the first major surface of the polymeric multilayer film comprises the first polymeric layer comprising a porous random network of strands and connective regions. In some embodiments, the second major surface of the polymeric multilayer film comprises the continuous second polymeric layer.

In some embodiments, there is a tie layer between the first polymeric layer and the second polymeric layer. In some embodiments, the tie layer comprises an ethylene-containing copolymer, for example, including a polar comonomer, as described above in any of its embodiments. Examples of ethylene-containing copolymers including a polar comonomer include ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, and ethylene-methacrylic acid copolymer. In some embodiments, the ethylene-containing copolymer of the tie layer includes at least 70 wt.%, at least 75 wt.%, or at least 80 wt.%, of ethylene. In some embodiments, the ethylene -containing copolymer of the first polymeric layer includes up to 99 wt.%, up to 95 wt.%, up to 90 wt.%, or up to 85 wt.% of ethylene. The tie layer can comprise a porous random network of strands and connective regions as described above in any of its embodiments. In some embodiments, the tie layer is a continuous layer.

The polymeric multilayer film is water- vapor permeable. In some embodiments, the polymeric multilayer film has a moisture vapor transmission rate of at least 5 perms, at least 10 perms, at least 15 perms, or at least 20 perms. In some embodiments, polymeric multilayer films described herein have a thickness in a range from 1 micrometer to 1000 micrometers (in some embodiments, in a range from 25 micrometers to 500 micrometers, 50 micrometers to 250 micrometers, or even 2 micrometers to 10 micrometers). Both the number of open pores (e.g., in the first polymeric layer) and materials (e.g., in the first and second polymeric layers) influences the permeability. A person skilled in the art can select materials (e.g, in the first and second polymeric layers) and porosity (e.g, in the first polymeric layer) depending on the desired permeability.

In some embodiments, neither of the first polymeric layer comprising a porous random network of strands and connective regions nor the continuous second polymeric layer is a pressure-sensitive adhesive (PSA). In some embodiments, the polymeric multilayer film has a PSA disposed thereon to form an article of the present disclosure, which may be a tape. In these embodiments, the polymeric multilayer film can be referred to as a tape backing. Referring again to FIG. 1, the illustrated article includes PSA 105 on the polymeric multilayer film 100. It should be understood that the polymeric multilayer film 100 can include any number of first and second polymeric layers, as described above, and that the PSA may be disposed on the first polymeric layer 101 instead of or in addition to the second polymeric layer 102 as shown in FIG. 1.

In some of these embodiments, to retain a desired level of water vapor permeance in the article, the pressure sensitive adhesive layer is discontinuous in order to leave portions of a major surface of the polymeric multilayer film. For discontinuous layers, typically in the range of about 10% to 90%, more typically about 30% to 80%, most typically 40% to 70%, of the area of a major surface of the polymeric multilayer film is covered with adhesive. In other words, at least 10% to 90%, in some embodiments 20% to 70% or 30% to 60%, of the area of a major surface of the polymeric multilayer film is typically adhesive-free in order to maintain sufficient water vapor permeability of the article.

Discontinuous layers of pressure sensitive adhesive may be applied in a random fashion or in a specific pattern. Some examples of discontinuous coatings of adhesive are described, for example, in U.S. Pat. Nos. 3,039,893 (Banigan, Jr.), 3,426,754 (Bierenbaum), 5,374,477 (Lawless), 5,593,771 (Lawless), 5,895,301 (Porter), 6,495,229 (Carte), 6,901,712 (Lionel), and 10,704,254 (Seabaugh et al.) and U.S. Pat. Appl. Pub. No. US 2017/0072430 (Maier et al.).

To prevent the lateral movement of air between the article of the present disclosure and the substrate to which it is bonded and through lap joints of the article, the adhesive coated areas of the air and water barrier article can be made to intersect to isolate the uncoated areas, thereby eliminating channels through which air can laterally move. This can be achieved by any number of patterns, such as intersecting circles with adhesive free centers, intersecting squares or rectangles of adhesive, and intersecting strips in a checkered pattern.

A variety of PSAs may be useful in the article of the present disclosure. Examples of suitable PSAs include natural rubber-, acrylic-, block copolymer-, silicone-, polyisobutylene-, polyvinyl ether-, polybutadiene-, or and urea-based pressure sensitive adhesive and combinations thereof. These PSAs can be prepared, for example, as described in Adhesion and Adhesives Technology, Alphonsus V. Pocius, Hanser/Gardner Publications, Inc., Cincinnati, Ohio, 1997, pages 216 to 223, Handbook of Pressure Sensitive Adhesive Technology, Donatas Satas (Ed.), 2nd Edition, Van Nostrand Reinhold, New York, NY, 1989, Chapter 15, and U.S. Pat. No. Re 24,906 (Ulrich). Another example of a pressure sensitive adhesive useful in assembling architectural structures (e.g., buildings) is a rubber modified asphalt (bitumen) pressure sensitive adhesive or a synthetic rubber pressure sensitive adhesive.

Examples of PSAs include those available, for example, under the trade designations “OCA8171” and “OCA8172” from 3M Company, St. Paul, MN. Extrudable pressure sensitive adhesives are commercially available, for example, under the trade designations “LIR-290,” “LA2330,” “LA2250,” “LA2140E,” and “LAI 114” from Kuraray, Osaka, Japan; and “ESCORE” from Exxon Mobil, Irving, TX. The tackiness of pressure sensitive adhesives can be adjusted, for example, with tackifiers.

In some embodiments, PSAs can be coextruded with the polymeric multilayer film using the apparatus shown in FIGS. 3 and 3A. A foaming agent such as any of those described above can be included in or injected into the PSA composition. The PSA can be any of those described in U.S. Pat. No. 10,953,573 (Emslander et al.).

In some embodiments, the PSA is selected to be a solventless or hot melt-processable adhesive. In some embodiments, solvent-based adhesives or water-based adhesives may be used. Examples of suitable adhesives include radiation-cured adhesives (e.g., UV radiation or electron-beam cured (co)polymers resulting from polymerizable monomers or oligomers). Suitable hot melt-processable adhesives may contain (co)polymers such as butyl rubber, styrene-butadiene-styrene (SBS), styrene- isoprene-styrene (SIS), styrene butadiene (SB), styrene-ethylene-butadiene-styrene (SEBS), and ethylene/vinylacetate (EVA). Tackifying resins, which generally refer to materials that are compatible with the elastomer and have a number average molecular weight of up to 10,000 grams per mole, are typically added to these elastomers. Useful tackifying resins can have a softening point of at least 70 °C as determined using a ring and ball apparatus and a glass transition temperature of at least -30 °C as measured by differential scanning calorimetry. In some embodiments, the tackifying resin comprises at least one of rosin, a polyterpene (e.g., those based on a-pinene, -pinene, or limonene), an aliphatic hydrocarbon resin (e.g., those based on cis- or trans-piperylene, isoprene, 2-methyl-but-2-ene, cyclopentadiene, dicyclopentadiene, or combinations thereof), an aromatic resin (e.g. those based on styrene, a-methyl styrene, methyl indene, indene, coumarone, or combinations thereof), or a mixed aliphatic -aromatic hydrocarbon resin. Any of these tackifying resins may be hydrogenated (e.g., partially or completely). Natural and petroleum waxes, oil, and bitumen may be useful as additives to the PSA composition.

In some embodiments, PSAs compositions that are useful in the article of the present disclosure are acrylic PSAs. As used herein, the term "acrylic" or "acrylate" includes compounds having at least one of acrylic or methacrylic groups. Useful acrylic PSAs can be made, for example, by combining at least two different monomers. Examples of suitable first monomers include 2-methylbutyl acrylate, 2- ethylhexyl acrylate, isooctyl acrylate, lauryl acrylate, n-decyl acrylate, 4-methyl-2 -pentyl acrylate, isoamyl acrylate, sec-butyl acrylate, isononyl acrylate, and methacrylates of the foregoing acrylates. Suitable first monomers also include mixtures of at least two or at least three structural isomers of a secondary alkyl (meth)acrylate of Formula (I): wherein R¹ and R² are each independently a Ci to C30 saturated linear alkyl group, in which the sum of the number of carbons in R¹ and R² is 7 to 31, and R³ is H or CH3. The sum of the number of carbons in R¹ and R² can be, in some embodiments, 7 to 27, 7 to 25, 7 to 21, 7 to 17, 7 to 11, or 7. Methods for making and using such monomers and monomer mixtures are described in U.S. Pat. No. 9,102,774 (Clapper et al.).

Examples of suitable second monomers useful for preparing acrylic PSAs include a (meth)acrylic acid (e.g., acrylic acid, methacrylic acid, itaconic acid, maleic acid, and fumaric acid), a (meth)acrylamide (e.g., acrylamide, methacrylamide, N-ethyl acrylamide, N-hydroxy ethyl acrylamide, N-octyl acrylamide, N-t-butyl acrylamide, N,N-dimethyl acrylamide, N,N-diethyl acrylamide, N-ethyl-N-dihydroxyethyl acrylamide, and methacrylamides of the foregoing acrylamides), a (meth)acrylate (e.g., 2-hydroxyethyl acrylate or methacrylate, cyclohexyl acrylate, t-butyl acrylate, isobomyl acrylate, and methacrylates of the foregoing acrylates), N-vinyl pyrrolidone, N-vinyl caprolactam, an alpha-olefin, a vinyl ether, an allyl ether, a styrenic monomer, or a maleate. In some embodiments, the PSA in the article of the present disclosure includes a pendent carboxylic acid group incorporated into the PSA by including, for example, acrylic acid, methacrylic acid, itaconic acid, maleic acid, or fumaric acid in the preparation of the PSA.

Acrylic PSAs may also be made by including crosslinking agents in the formulation. Examples of crosslinking agents include copolymerizable polyfunctional ethylenically unsaturated monomers described below; ethylenically unsaturated compounds which in the excited state are capable of abstracting hydrogen (e.g., acrylated benzophenones such as described in U.S. Pat. No. 4,737,559 (Kellen et al.), p-acryloxy-benzophenone, which is available from Sartomer Company, Exton, PA, monomers described in U.S. Pat. No. 5,073,611 (Rehmer et al.) including p-N-(methacryloyl-4-oxapentamethylene)- carbamoyloxybenzophenone, N-(benzoyl-p-phenylene)-N’ -(methacryloxymethylene)-carbodiimide, and p-acryloxy-benzophenone); nonionic crosslinking agents which are essentially free of olefinic unsaturation and capable of reacting with carboxylic acid groups, for example, in the second monomer described above (e.g., l,4-bis(ethyleneiminocarbonylamino)benzene; 4,4- bis(ethyleneiminocarbonylamino)diphenylmethane; l,8-bis(ethyleneiminocarbonylamino)octane; 1,4- tolylene diisocyanate; 1,6-hexamethylene diisocyanate, N,N’-bis-l,2-propyleneisophthalamide, diepoxides, dianhydrides, bis(amides), and bis(imides)); and nonionic crosslinking agents which are essentially free of olefinic unsaturation, are noncopolymerizable with the first and second monomers, and, in the excited state, are capable of abstracting hydrogen (e.g., 2,4-bis(trichloromethyl)-6-(4- methoxy)phenyl)-s-triazine; 2,4-bis(trichloromethyl)-6-(3,4-dimethoxy)phenyl)-s-triazine; 2,4- bis(trichloromethyl)-6-(3,4,5-trimethoxy)phenyl)-s-triazine; 2,4-bis(trichloromethyl)-6-(2,4- dimethoxy )phenyl)-s-triazine; 2,4-bis(trichloromethyl)-6-(3-methoxy)phenyl)-s-triazine as described in U.S. Pat. No. 4,330,590 (Vesley); 2,4-bis(trichloromethyl)-6-naphthenyl-s-triazine and 2,4- bis(trichloromethyl)-6-(4-methoxy)naphthenyl-s-triazine as described in U.S. Pat. No. 4,329,384 (Vesley)). If a photocrosslinking agent is used, the coated adhesive can be exposed to UV radiation having a wavelength of about 250 nm to about 400 nm. The radiant energy in this range of wavelength required to crosslink the adhesive is about 100 millijoules/cm² to about 1,500 millijoules/cm², or in some embodiments, about 200 millijoules/cm² to about 800 millijoules/cm².

Suitable copolymerizable polyfunctional ethylenically unsaturated monomers include diacrylate esters of diols, such as ethylene glycol diacrylate, diethylene glycol diacrylate, propanediol diacrylate, butanediol diacrylate, butane- 1,3-diyl diacrylate, pentanediol diacrylate, hexanediol diacrylate (including 1,6-hexanediol diacrylate), heptanediol diacrylate, octanediol diacrylate, nonanediol diacrylate, decanediol diacrylate, and dimethacrylates of any of the foregoing diacrylates. Further suitable polyfunctional monomers include polyacrylate esters of polyols, such as glycerol triacrylate, dipropylene glycol diacrylate, tripropylene glycol diacrylate, trimethylolpropane triacrylate, pentaerythritol tetraacrylate, neopentyl glycol diacrylate, dipentaerythritol pentaacrylate, methacrylates of the foregoing acrylates, and combinations thereof. Further suitable polyfunctional crosslinking monomers include divinyl benzene, allyl methacrylate, diallyl maleate, diallyl phthalate, and combinations thereof. Further suitable polyfunctional crosslinking monomers include polyfunctional acrylate oligomers comprising two or more acrylate groups. The polyfunctional acrylate oligomer may be a urethane acrylate oligomer, an epoxy acrylate oligomer, a polyester acrylate, a polyether acrylate, a polyacrylic acrylate, a methacrylate of any of the foregoing acrylates, or a combination thereof. Combinations of any of these crosslinking agents may be useful.

In some embodiments, the first monomer is used in an amount of 80 wt.% to 100 wt.% based on a total weight of an acrylic copolymer, and a second monomer as described above is used in an amount of 0 wt.% to 20 wt.% based on the total weight of an acrylic copolymer. The crosslinking agent can be used in an amount of 0.005 wt.% to 4 wt.% based on the combined weight of the monomers, for example from about 0.01 wt.% to about 2 wt.% or from about 0.05 wt.% to 1 wt.%. In some embodiments, the crosslinking agent is used in an amount of up to 4.0 wt.%, 3.0 wt.%, 2.0 wt.%, or 1.0 wt.% based on the total weight of monomer units in the acrylic copolymer. In some embodiments, the crosslinking agent is used in an amount of at least 0.10 wt.%, 0.15 wt.%, 0.20 wt.%, 0.25 wt.%, 0.30 wt.%, 0.40 wt.%, 0.50 wt.%, 0.60 wt.%, or 0.70 wt.%, based on the total weight of monomer units in the acrylic copolymer.

Acrylic copolymers useful for PSAs in the article the present disclosure can be prepared, for example, by any conventional free radical polymerization method, including solution, radiation, bulk, dispersion, emulsion, solventless, and suspension processes. In some embodiments, the acrylic copolymer is prepared in a solvent or by a solvent free, bulk, free-radical polymerization process (e.g., using heat, electron-beam radiation, or ultraviolet radiation). Such polymerizations are typically facilitated by a polymerization initiator (e.g., a photoinitiator or a thermal initiator). The polymerization initiator is used in an amount effective to facilitate polymerization of the monomers (e.g., 0.1 part to about 5.0 parts or 0.2 part to about 1.0 part by weight, based on 100 parts of the total monomer content) . The resulting copolymers may be random or block copolymers.

A typical solution polymerization method is carried out by adding the monomers, a suitable solvent, and an optional chain transfer agent to a reaction vessel, adding a free radical initiator, purging with nitrogen, and maintaining the reaction vessel at an elevated temperature, typically in the range of about 40 °C to 100 °C until the reaction is completed, typically in about 1 to 24 hours, depending upon the batch size and temperature. Examples of the solvent are methanol, tetrahydrofuran, ethanol, isopropanol, tert-butanol, acetone, methyl ethyl ketone, methyl acetate, ethyl acetate, toluene, xylene, and an ethylene glycol alkyl ether. Those solvents can be used alone or as mixtures thereof. In a typical thermal polymerization method, a monomer mixture may be subjected to thermal energy in the presence of a thermal polymerization initiator (i.e., thermal initiators). Examples of suitable thermal initiators are those available under the trade designations “VAZO” from DuPont.

A syrup polymer technique comprises partially polymerizing monomers to produce a syrup polymer comprising an acrylic copolymer and unpolymerized monomers. The syrup polymer composition is polymerized to a useful coating viscosity, which may be coated onto a substrate (such as a tape backing) and further polymerized. In some embodiments, the polymerization is conducted in the absence of a solvent such as ethyl acetate, toluene, or tetrahydrofuran which are unreactive with the functional groups of the components of the syrup polymer. Polymerization to achieve a coatable viscosity may be conducted such that the conversion of monomers to polymer is up to about 20%, 15%, or 10%. The syrup composition contains 1 to 20 wt.% of the acrylic copolymer and 80 to 99 wt.% monomers based on a total weight of the syrup composition, wherein the monomers comprise the linear or branched alkyl (meth)acrylate and (meth)acrylic acid. The composition is a solution of acrylic copolymer in the monomers and can be, for example, about 3 wt.% to 15 wt.% or 5 wt.% to 10 wt.% of the acrylic copolymer and 85 wt.% to 97 wt.% or 90 wt.% to 95 wt.% of the monomers. Polymerization can be accomplished by exposing the syrup polymer composition to light energy in the presence of a photoinitiator. Polymerization can be terminated when the desired conversion and viscosity have been achieved by removing the light source and by bubbling air (oxygen) into the solution to quench propagating free radicals. Energy activated initiators may be unnecessary where, for example, ionizing radiation is used to initiate polymerization.

In some embodiments, a free-radical photoinitiator is useful in the polymerization to make an acrylic copolymer. In some embodiments, the free radical photoinitiator is a type I (cleavage-type) photoinitiator. Cleavage-type photoinitiators include acetophenones, alpha-aminoalkylphenones, benzoin ethers, benzoyl oximes, acyl (e.g., benzoyl) phosphine oxides, acyl (e.g., benzoyl) phosphinates, and mixtures thereof. Examples of useful benzoin ethers include benzoin methyl ether and benzoin butyl ether. Examples of suitable acetophenone compounds include 4-diethylaminoacetophenone, 1- hydroxycyclohexyl phenyl ketone, 2-benzyl-2 dimethylamino-4'-morpholinobutyrophenone, 2-hydroxy- 2-methyl-l-phenylpropan-l one, 2,2-dimethoxyacetophenone, and 2,2-dimethoxy-l,2-diphenylethan-l- one. Example of suitable acyl phosphine oxide, acyl phosphinate, and acyl phosphonate compounds include bis(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentyl phosphine oxide, phenylbis(2,4,6- trimethylbenzoyl) phosphine oxide, ethyl phenyl(2,4,6-trimethylbenzoyl)phosphinate, (2,4,6- trimethylbenzoyl)diphenylphosphine oxide, dimethyl pivaloylphosphonate, and poly(oxy-l,2-ethanediyl), a,a',a"-l,2,3-propanetriyltris[co-[[phenyl(2,4,6-trimethylbenzoyl)phosphinyl]oxy]. Further suitable photoinitiators include substituted alpha-ketols such as 2- methyl-2-hydroxy propiophenone; aromatic sulfonyl chlorides such as 2-naphthalene-sulfonyl chloride; and photoactive oximes such as 1 -phenyl- 1,2- propanedione-2-(O-ethoxy-carbonyl)oxime. Many photoinitiators are available, for example, from IGM Resins, Waalwijk, Netherlands, under the trade designations “OMNIRAD” and “ESACURE”. Two or more of any of these photoinitiators may also be used together in any combination. Additional photoinitiator can be added to a mixture to be coated after the copolymer has been formed, (i.e., photoinitiator can be added to the syrup polymer mixture).

The degree of conversion (of monomers to copolymer) can be monitored during the irradiation by measuring the index of refraction of the polymerizing mixture.

If desired, a chain transfer agent may be added to the monomer mixture to prepare the acrylic copolymer useful for the PSA in the article of the present disclosure. Examples of useful chain transfer agents include carbon tetrabromide, alcohols, mercaptans, and mixtures thereof. In some embodiments, the chain transfer agent comprises at least one of isooctylthioglycolate or carbon tetrabromide.

A useful solvent-free polymerization method is disclosed in U.S. Pat. No. 4,379,201 (Heilmann et al.). Initially, a mixture of first and second monomers can be polymerized with a portion of a photoinitiator by exposing the mixture to UV radiation in an inert environment for a time sufficient to form a coatable base syrup, and subsequently a crosslinking agent and the remainder of the photoinitiator may be added. This final syrup containing a crosslinking agent (e.g., which may have a Brookfield viscosity of about 100 centipoise to about 6000 centipoise at 23 °C, as measured with a No. 4 LTV spindle, at 60 revolutions per minute) can then be coated onto a substrate, for example, a polymeric film substrate. Once the syrup is coated onto the substrate, for example, the polymeric film substrate, further polymerization and crosslinking can be carried out in an inert environment (e.g., nitrogen, carbon dioxide, helium, and argon, which exclude oxygen). A sufficiently inert atmosphere can be achieved by covering a layer of the photoactive syrup with a polymeric film, such as silicone-treated PET film, that is transparent to UV radiation or e-beam and irradiating through the film in air.

By selecting the composition, thickness, and coverage (e.g., continuous or discontinuous) of the pressure sensitive adhesive, the article of the present disclosure can advantageously have a moisture vapor transmission rate of at least 3 perms, at least 4 perms, at least 5 perms, at least 10 perms, or at least 15 perms. To prevent any water from moving from one longitudinal side edge of the article to the other, in some embodiments, a continuous pressure sensitive adhesive layer can be beneficial. In some embodiments, the PSA is water vapor permeable as defined herein. Methods and additives for making water vapor permeable adhesives are described, for example, in U.S. Pat. Nos. 5,198,064 (Tani et al.); 9,562,174 (Russell); and 10,899,107 (Bess).

In some embodiments, the PSA useful in the article of the present disclosure is water vapor permeable and includes an acrylic copolymer and a polyoxyalkylene polymer. In some embodiments, the acrylic copolymer comprises at least 60 wt.%, 65 wt.%, or 70 wt.% of linear or branched alkyl (meth)acrylate monomer units, based on the weight of the acrylic copolymer. In some embodiments, the acrylic copolymer comprises up to 95 wt.%, up to 90 wt.%, up to 87.5 wt.%, less than 85 wt.% or up to 84 wt.%, 83 wt.%, 82 wt.%, 81 wt.%, or 80 wt.% of linear or branched alkyl (meth)acrylate monomer units, based on the weight of the acrylic copolymer. The acrylic copolymer useful in the water vapor permeable PSA in the article of the present disclosure comprises from 5 wt.% to 40 wt.% of (meth)acrylic acid monomer units, based on the weight of the acrylic copolymer. In some embodiments, the acrylic copolymer comprises (meth)acrylic acid monomer units in an amount of at least 10 wt.%, greater than 10 wt.%, at least 12.5 wt.%, greater than 12.5 wt.%, at least 15 wt.%, greater than 15 wt.%, at least 16 wt.%, or at least 17 wt.%, based on the weight of the acrylic copolymer. In some embodiments, the acrylic copolymer comprises from 12.5 to 40 wt.%, 15.5 to 40 wt.%, from 16 to 35 wt.%, from 16 to 30 wt.%, from 16 to 25 wt.%, from 17 to 25 wt.%, from 17 to 23 wt.%, from 17 to 20 wt.%, or from 17 to 19.5 wt.% of (meth)acrylic acid monomer units, based on the weight of the acrylic copolymer.

In some embodiments, the linear or branched alkyl (meth)acrylate monomer units are C1-C32 (meth)acrylic acid ester monomer units, C1-C24 (meth)acrylic acid ester monomer units, or Ci-Cis (meth)acrylic acid ester monomer units. Examples of suitable alkyl (meth)acrylates useful for providing these monomer units include those represented by Formula CH2=C(R)COOR’, wherein R is hydrogen or a methyl group and R’ is an alkyl group having 1 to 30, 4 to 30, 6 to 30, 8 to 30, 6 to 24, 6 to 20, 6 to 18, 8 to 24, 8 to 20, or 8 to 20 carbon atoms and may be linear or branched. Examples of suitable monomers represented by this formula include methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl (meth)acrylate, n-pentyl (meth)acrylate, iso-pentyl (meth)acrylate, n-hexyl (meth)acrylate, iso-hexyl (meth)acrylate, octyl (meth)acrylate, iso-octyl (meth)acrylate, 2-octyl(meth)acrylate, 2-ethylhexyl (meth)acrylate, decyl (meth)acrylate, isodecyl acrylate, undecyl (meth)acrylate, n-dodecyl acrylate, lauryl (meth)acrylate, tridecyl (meth)acrylate, tetradecyl (meth)acrylate, pentadecyl (meth)acrylate, hexadecyl (meth)acrylate, heptadecyl (meth)acrylate, 2-propylheptyl (meth)acrylate, stearyl (meth)acrylate, n-nonyl (meth)acrylate, isononyl (meth)acrylate, isomyristyl (meth)acrylate, isostearyl (meth)acrylate, octadecyl (meth)acrylate, and behenyl (meth)acrylate. Suitable monomer units further include mixtures of at least two or at least three structural isomers of a secondary alkyl (meth)acrylate represented by Formula I as described above in any of its embodiments. In some embodiments, the linear or branched alkyl (meth)acrylate monomer units are low T_g monomer units. A low T_g monomer is one that provides a homopolymer with a glass transition temperature (T_g) no greater than 20 °C, as reported in Thermal Transitions of Homopolymers: Glass Transition & Melting Point (sigmaaldrich.com). Tables of glass transition temperatures for homopolymers are also available from various suppliers of monomer such as Polyscience and BASF. Examples of low T_g monomers include n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, isoamyl acrylate, n-hexyl acrylate, 2-methylbutyl acrylate, 4-methyl-2 -pentyl acrylate, 2-methylhexyl acrylate, n- octyl acrylate, 2-octyl acrylate, isooctyl acrylate, 2-ethylhexyl acrylate, nonyl acrylate, isononyl acrylate, n-decyl acrylate, isodecyl acrylate, undecyl acrylate, dodecyl acrylate, lauryl acrylate, isotridecyl acrylate, isostearyl acrylate, and octadecyl acrylate. In some embodiments, the linear or branched alkyl (meth)acrylate monomer units are units of n-butyl acrylate, n-octyl acrylate, 2-octyl acrylate, isooctyl acrylate, 2-ethylhexyl acrylate, 2-propylheptyl acrylate, or isononyl acrylate.

Examples of (meth)acrylic acid monomer units include acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, ethacrylic acid, crotonic acid, citraconic acid, cinnamic acid, beta-carboxy ethyl acrylate, and 2-methacrylolyloxyethyl succinate. In some embodiments, the (meth)acrylic acid monomer units are acrylic acid monomer units or methacrylic acid monomer units. (Meth)acrylic acid monomer units encompass salts of these acids, such as alkali metal salts and ammonium salts.

In some embodiments, the acrylic copolymer useful in the water vapor permeable PSA in the article of the present disclosure further comprises monomer units of a “high Tg” monomer that when polymerized provides a homopolymer having a glass transition temperature (Tg) of at least 50 °C, 60 °C, or 70 °C (i.e., a homopolymer formed from the monomer has a Tg at least 50 °C, 60 °C, or 70 °C). In some embodiments, the acrylic copolymer further comprises at least 5 wt.% (in some embodiments, at least 7.5 wt.%, 10 wt.%, 12.5 wt.% or 15 wt.%) monomer units of a “high Tg” monomer. The Tg of many homopolymers are reported in Thermal Transitions of Homopolymers: Glass Transition & Melting Point (sigmaaldrich.com). Tables of glass transition temperatures for homopolymers are also available from various suppliers of monomer such as Polyscience and BASF. Some suitable high Tg monomers include methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, tert-butyl (meth)acrylate, cyclohexyl methacrylate, isobomyl (meth)acrylate, stearyl (meth)acrylate, phenyl acrylate, benzyl methacrylate, 3,3,5 trimethylcyclohexyl (meth)acrylate, tert-butyl cyclohexyl methacrylate, 2-phenoxyethyl methacrylate, N- octyl (meth)acrylamide, tetrahydrofurfuryl methacrylate, and mixtures thereof. Other suitable high Tg monomers have a single vinyl group that is not a (meth)acryloyl group such as various vinyl ethers (e.g., vinyl methyl ether), vinyl esters (e.g., vinyl acetate and vinyl propionate), styrene, substituted styrene (e.g., alpha-methyl styrene), vinyl halide, and mixtures thereof.

In some embodiments, the acrylic copolymer useful in the water vapor permeable PSA in the article of the present disclosure is crosslinked, for example, with any of the crosslinking agents described above for acrylic PSAs. In some embodiments, the acrylic copolymer is crosslinked with a triazine as described above in any of its embodiments.

The acrylic copolymer useful in the water vapor permeable PSA in the article of the present disclosure can be made by any of the methods described above, for example. An acrylic polymer can be analyzed by nuclear magnetic resonance spectroscopy ( ¹ H or ¹³C NMR) to identify the monomer units in the polymer. Solid state or solution NMR may be useful depending on the level of crosslinking in the polymer. For solid state NMR the acrylic polymer can be swelled in an appropriate solvent for analysis.

In some embodiments of the water vapor permeable PSA in the article of the present disclosure, the acrylic copolymer has a Tg in a range from 2°C and 100°C, between 2°C and 80°C, between 2°C and 60°C, between 2°C and 50°C, between 2°C and 45°C, between 5°C and 45°C, between 5°C and 40°C, between 5°C and 35°C, or between 10°C and 30°C.

Mixtures of acrylic copolymers can be useful in the water vapor permeable PSA of the present disclosure. However, in some embodiments, the water vapor permeable PSA in the article of the present disclosure comprises not more than 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, 1 wt.%, or 0 wt.% of a further acrylic copolymer having from 0.1 wt.% to 15 wt.% (in some embodiments, 0.1 to 14.5 wt.%, 0.1 to 12 wt.%, 0. 1 to 11 wt.%, from 0. 1 to 10 wt.%, from 0.2 to 10 wt.%, from 0.2 to 9 wt.%, from 0.2 to 8 wt.%, from 0.3 to 8 wt.%, from 0.5 to 8 wt.%, from 0.5 to 6 wt.%, from 1 to 6 wt.%, or from 1 to 5 wt.%) of (meth)acrylic acid monomer units, based on the weight of the further (meth)acrylate copolymer. Such a further (meth)acrylate copolymer in the PSA described herein would tend to lower the Tg, cohesive strength, and/or the storage modulus of the PSA.

In some embodiments, the water vapor permeable PSA useful in the article of the present disclosure comprises a tackifying resin, including any of those described above. In some embodiments, the water vapor permeable PSA includes at least about one percent by weight and up to about 50 wt.% of the tackifying resin, based on the total weight of the PSA. In some embodiments, the tackifying resin is present in a range from 1 to 25, 2 to 20, 2 to 15, 1 to 10, or 3 to 10 wt.%, based on the total weight of the PSA. In some embodiments, the water vapor permeable PSA does not include a tackifying resin or includes less than 1, 0.5, 0.1, or 0.05 wt.% of a tackifying resin, based on the total weight of the PSA.

In some embodiments, the water vapor permeable PSA useful in the article of the present disclosure includes a polyoxyalkylene polymer. It should be understood that the polyoxyalkylene polymer is a separate polymer from the acrylic copolymer in the water vapor permeable PSA. In other words, the acrylic copolymer and the polyoxyalkylene polymer are not covalently attached. In some embodiments, suitable polyoxylalkylene polymers include ethyleneoxy (e.g., -CH2CH2O-), propyleneoxy (e.g., -CH(CH₃)CH2O-, -CH2CH2CH2O-, -CH2CH(CHS)O-), or butyleneoxy (e g., -CH2CH2CH2CH2O-, -CH(CH₂CH₃)CH₂O-, -CH₂CH(CH₂CH₃)O-, and -CH₂C(CH₃)₂O-) groups or combinations of any of these. The poly oxyalkylene polymer may have a wide variety of terminal groups including alkyl (e.g., having up to 30 carbon atoms), hydroxyl (i.e., -OH), amino (i.e., -N(R⁴)₂). and silane (i.e., -Si(Y)_3.x(R⁵)_x) terminal groups. Each R⁴ is independently hydrogen, an alkyl group having up to 8 carbon atoms (e.g., methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl, n-hexyl, n-heptyl, or n-octyl), or a phenyl group. In some embodiments, each R⁴ is hydrogen. R⁵ is an alkyl group having up to 8 carbon atoms (e.g., methyl, ethyl, n-propyl, isopropyl, n-butyl, secbutyl, tert-butyl, n-pentyl, isopentyl, neopentyl, n-hexyl, n-heptyl, or n-octyl) or a phenyl group. In some embodiments, R⁵ is an alkyl group having up to 4 carbon atoms. In some embodiments, R⁵ is methyl or ethyl. Each Y is independently a hydrolyzable group, e.g., halogen (i.e., fluoride, chloride, bromide, or iodide), alkoxy (i.e., -O-alkyl), acyloxy (i.e., -OC(O)alkyl), or aryloxy (i.e., -O-aryl), and x is 0, 1, or 2. The Y groups are generally capable of hydrolyzing, for example, in the presence of water under acidic conditions to produce groups capable of undergoing a condensation reaction, for example silanol groups. In these embodiments, alkyl (e.g., in alkoxy and acyloxy) is optionally substituted with one or more halogen atoms. In some embodiments, alkoxy and acyloxy have up to 8, 6, 4, 3, or 2 carbon atoms. In some embodiments, aryloxy has 6 to 12 (or 6 to 10) carbon atoms which may be unsubstituted or substituted by halogen, alkyl (e.g., having up to 4 carbon atoms), and haloalkyl. The polyoxyalkylene polymer can also include functional groups other than ethers in the backbone, for example, secondary and tertiary amines, esters, amides, ureas, and carbamates.

In some embodiments, the polyoxyalkylene polymer comprises at least one of an alkoxylated alcohol, diol, or polyol, an alkoxyated amine, diamine, or polyamine, an alkoxylate ester, an alkoxylated amide, or an alkoxylated urethane. Mono- or multi-functional alcohols and amines can be alkoxylated using methods known in the art. Carboxylic acids and amides can be alkoxylated to provide alkoxylate esters and amides using methods known in the art. Polyalkylene alcohols can be reacted with isocyanates to provide urethanes using known methods.

In some embodiments, the polyoxyalkylene polymer is a polyether represented by formula R⁷O-(EO)p-(R⁶O)q-(EO)_p-R⁷ or R⁷O-(R⁶O)_q-(EO)_p-(R⁶O)_q-R⁷. In these formulas, R⁷ is hydrogen or alkyl having up to 4 carbon atoms (e.g., methyl, ethyl, n-propyl, isopropyl, butyl, isobutyl, or t-butyl), wherein alkyl is unsubstituted or substituted by hydroxyl (i.e., -OH), amino (i.e., -N(R⁴)2), or silane (i.e., -Si(Y)3-_x(R⁵)x), wherein R⁴, R⁵, and x are as described above in any of their embodiments. In some embodiments, each R⁷ is hydrogen. In some embodiments, each R⁷ is methyl. EO represents -CH2CH2O-. Each R⁶O is independently -CH(CH₃)CH₂O-, -CH2CH2CH2O-, -CH₂CH(CH₃)O- -CH2CH2CH2CH2O-, -CH(CH₂CH₃)CH₂O-, -CH₂CH(CH₂CH₃)O-, or -CH₂C(CH₃)₂O-. In some embodiments, each R⁶O independently represents -CH(CH₃)CH2O-, -CH2CH(CH₃)O-, -CH2CH2CH2CH2O-. Each p is independently a value from 0 to 150 (in some embodiments, from 7 to about 130, or from 14 to about 130); and each q is independently a value from 0 to 150 (in some embodiments, from about 20 to about 100, 1 to 55, or from about 9 to about 25). The sum p + q is at least 3 (in some embodiments, at least 5, 10, 15, 20, or at least 25.) In some embodiments, the ratio p/q has a value from at least 0.5, 0.75, 1 or 1.5 to 2.5, 2.7, 3, 4, 5, or more. For example, the percentage of the repeating EO groups in the polyoxyalkylene polymer can be in a range from 10 to 90, 10 to 75, or 20 to 50, based on the total number of EO and R⁶O groups in the polyoxyalkylene polymer. Useful polyoxyalkylene polymers include those available from Dow Chemical Company, Midland, MI, under the trade designations "CARBOWAX" and “UCON” and block copolymers of ethylene oxide and propylene oxide having a molecular weight of about 500 to 15000 g/mol (e.g., those available from BASF Corporation, Ludwigshafen, Germany, under the trade designation "PLURONIC"). In some embodiments, the polyoxyalkylene polymer has a number average molecular weight in a range from 200 to 15,000, 1000 to 15,000, 1000 to 10,000, or 1000 to 5000 g/mol. In some embodiments, the polyoxyalkylene polymer contains ethylene glycol repeating units and hydroxyl terminal groups and can be any of those described above in connection with water-vapor-permeable polyurethanes.

In some embodiments, the polyoxyalkylene polymer is a monoamine, diamine, or triamine having one, two, or three primary amino groups, respectively. Polyether amines typically have a number average molecular weight of at least 200 g/mol and can have a molecular weight up to 2500, 2000, 1500, 1000, or 500 g/mol. Useful polyether amines are commercially available, for example, under the trade designation “JEFF AMINE” from Huntsman Chemical, The Woodlands, Texas, and from BASF, Florham Park, New Jersey.

In some embodiments, the polyoxyalkylene polymer is a fatty acid ester or a fatty amine ethoxylate. In some embodiments, the poly oxyalkylene polymer is a tallowalkyl amine ethoxylate. In some embodiments, the polyoxyalkylene polymer is tris polyoxyethylene (15)-N-tallowalkyl-l,3- diaminopropane. Some fatty amines are commercially available, for example, under the trade designations “ETHOMEEN T/25” and “ETHODUOMEEN T/25” from Nouryon, Amsterdam, The Netherlands. Fatty acid esters can be made, for example, by ethoxylating fatty acids.

Useful commercially available polyoxyalkylenes having silane terminal groups can be obtained, for example, from Kaneka under the trade designation “MS” and “SILYL” in various grades, for example, "MS S203", "MS S303", "SILYL SAT10", and "SILYL SAT30". In some embodiments, the main chain of the polyoxyalkylene polymer may contain other functional groups such as a group represented by formula -NR⁸-C(O)-W-, wherein W is -O-, -S-, or -NR⁸-, and wherein R⁸ represents a hydrogen atom or a monovalent organic group, such as a substituted or unsubstituted monovalent C1-20 hydrocarbon group or a substituted or unsubstituted monovalent Cus hydrocarbon group. Poly oxyalkylene polymers having -NR⁸-C(O)-W- groups may be produced, for example, by reaction of an isocyanato group and a hydroxy group; by reaction of an isocyanato group and an amino group; or by reaction of an isocyanato group and a mercapto group. Examples of methods for producing a polyoxyalkylene polymer having a group represented by formula -NR⁸-C(O)-W- and groups represented by formula -Si(Y)3-_x(R⁵)_x include those described in U.S. Pat. Nos. 3,632,557 (Brode); 3,711,445 (Chu); 4,067,844 (Barron); 4,345,053 (Rizk); 4,374,237 (Berger); 4,645,816 (Pohl); 5,068,304 (Higuchi); 5,364,955 (Zwiener); 5,756,751 (Schmalstieg); 5,990,257 (Johnston); 6,001,946 (Waldman); 6,046,270 (Roesler); 6,197,912 (Huang); and 7,060,750 (Jansen) and European Patent Publication EP 0676403, published October 11, 1995. Examples of suitable commercially available polymers having silane terminal groups include the “GENIOSIL STP- E” series products from Wacker Chemical such as “GENIOSIL STP-E10”, “GENIOSIL STP-E 35” trimethoxysilylpropyl-carbamate-terminated polyether, and “GENIOSIL STP-E 30” silane-terminated polyether with dimethoxy(methyl)silylmethylcarbamate terminal groups.

In some embodiments of the water vapor permeable PSA in the article of the present disclosure, the PSA comprises from 55 to 80 wt.%, from 55 to 75 wt.%, from 55 to 70 wt.%, from 60 to 75 wt.%, or from 60 to 70 wt.%, of the acrylic copolymer, wherein the weight percentages are based on the total weight of the water vapor permeable PSA. In some embodiments, the water vapor permeable PSA comprises from 20 to 45 wt.%, from 25 to 45 wt.%, from 30 to 45 wt.%, from 25 to 40 wt.%, or from 30 to 40 wt.% of the poly oxyalkylene polymer, wherein the weight percentages are based on the total weight of the water vapor permeable PSA. Further information about water vapor permeable PSAs useful in the article of the present disclosure can be found in co-pending U.S. Pat. Appl. Serial No. 63/635,815, which is incorporated by reference in its entirety herein.

Other additives can be added to the PSA in the article of the present disclosure, in any of its embodiments described above, if desired. For example, leveling agents, ultraviolet light absorbers, hindered amine light stabilizers (HALS), oxygen inhibitors, wetting agents, rheology modifiers, defoamers, biocides, flame retardants, dyes, and particulate fillers can be included.

In some embodiments, the PSA useful in the article of the present disclosure takes the form of a foam. A foam comprises voids, which may be open or closed cells. In some embodiments, the voids are present in the foam in an amount of at least 5% by volume, from 10% to 55% by volume, from 10% to 45% by volume, from 15% to 45% by volume, or from 20% to 45% by volume. The voids or cells in the foam can be created in any of the known manners described in the art and include the use of a gas or blowing agent and/or including hollow particles into the composition for the foam. For example, according to one method to create a foam described in US 4,415,615 (Esmay et al.), an acrylic foam can be obtained by frothing a composition containing acrylate monomers and optional comonomers, coating the froth on a backing, and polymerizing the frothed composition. It is also possible to coat the unfrothed composition of the acrylate monomers and optional comonomers to the backing and to then simultaneously foam and polymerize that composition. Frothing of the composition may be accomplished by whipping a gas into the polymerizable composition optionally in the presence of a surfactant (e.g., hydrocarbon or fluorochemical surfactant) or surface-modified nanoparticles to stabilize the foam. Inert gases such as nitrogen, argon, and carbon dioxide may be useful, particularly if the polymerization is photoinitiated. In some embodiments, the PSA useful in the article of the present disclosure is not frothed or foamed. In some embodiments, the PSA is free of a fluorinated surfactant.

In some embodiments, the PSA useful in the article of the present disclosure incorporates hollow fillers, such as hollow polymeric particles, hollow glass microspheres, and hollow ceramic microspheres. Hollow polymeric microspheres include elastomeric particles available, for example, from Akzo Nobel, Amsterdam, The Netherlands, under the trade designation "EXPANCEE". Examples of hollow ceramic microspheres include alumina/silica microspheres having particle sizes in the range of 5 to 300 microns and a specific gravity of 0.7 (“FILLITE”, Pluess-Stauffer International), aluminum silicate microspheres having a specific gravity of from about 0.45 to about 0.7 (“Z -LIGHT”), calcium carbonate-coated polyvinylidene copolymer microspheres having a specific gravity of 0.13 (“DUALITE 6001AE”, Pierce & Stevens Corp.), and glass bubbles marketed by 3M Company, Saint Paul, Minnesota, as “3M GLASS BUBBLES” in grades KI, K15, K20, K25, K37, K46, S15, S22, S32, S35, S38, S38HS, S38XHS, S42HS, S42XHS, S60, S60HS, iM30K, iM16K, XLD3000, XLD6000, and G-65, and any of the HGS series of “3M GLASS BUBBLES”. Foams that include hollow microspheres are referred to as syntactic foams. In some embodiments, the PSA is free of hollow microspheres or includes not more than 1, 0.5, 0.1, 0.05, or 0.01 wt.% hollow microspheres.

The PSA useful in article of the present disclosure may be prepared by simple blending of the acrylic copolymer, in some embodiments, the polyoxyalkylene polymer, and in some embodiments, the optional ingredients such as the fdler material and the tackifying resin. The components can be blended using several conventional methods, such as melt blending, solvent blending, or any suitable physical blending device.

The PSA useful in the article of the present disclosure can have a variety of thicknesses depending on the desired application. In some embodiments, the PSA has a thickness in a range from 50 to 6000 micrometers, from 100 to 4000 micrometers, from 100 to 2000 micrometers, or from 100 to 1500 micrometers. In some embodiments, the PSA has a thickness of at least 100 micrometers.

In some embodiments, the article of the present disclosure includes a liner. Referring again to FIG. 1, the illustrated article includes PSA 105 on the polymeric multilayer fdm 100. It should be understood that the polymeric multilayer fdm 100 can include any number of first and second polymeric layers, as described above, and that the PSA may be disposed on the first polymeric layer 101 instead of or in addition to the second polymeric layer 102 as shown in FIG. 1. PSA 105 is attached to a liner 106. The liner can be useful, for example, when the article is wound into a roll. In some embodiments, the liner 106 is coated on at least one of the major surfaces with a release coating. In some embodiments both major surfaces of the liner 106 are coated with a release coating. In this case, the release coating may the same or different on each of the major surfaces of the liner 106. Examples of materials useful as release coatings for the liners disclosed herein include acrylics, silicones, siloxanes, fluoropolymers, and urethanes. In some embodiments, a silicone coating is useful for facilitating release of the PSA.

Various liners may be useful. In some embodiments, the liner comprises at least one of a polyester film, polyethylene film, polypropylene film, polyolefin coated polymer film, polyolefin coated paper, acrylic coated polymer film, and polymer coated kraft paper. The polyolefin coated film or paper may be polyethylene coated film or paper. Examples of suitable commercially available liners include those available under the trade designations “2.0 CL PET U4162/U4162”, “48# CL PET H/H UE 1095/000”, and “4 BU DHP UE1094B/000” from Loparex, Hammond, Wisconsin, a red pigmented, multilayer, thermoplastic olefin film containing a proprietary blend of high density polyethylene and low density polyethylene, having a thickness of about 63 micrometers (0.0025 inches), commercially available from Iso Poly Films, Incorporated, Gray Court, South Carolina, and a clear, polyester release liner available under the designation “2PAKN” from Mitsubishi Polyester Film, Inc., Greer, SC.

The liner may be produced using a variety of processing techniques. For example, liner processing techniques such as those disclosed in U.S. Pat. Appl. No. 2013/0059105 (Wright et al.) may be useful to produce a liner suitable for practicing the present disclosure. A suitable liner processing technique may include applying a layer comprising a (meth)acrylate-functional siloxane to a major surface of a substrate and irradiating that layer in a substantially inert atmosphere comprising no greater than 500 ppm oxygen with a short wavelength polychromatic ultraviolet light source having at least one peak intensity at a wavelength of from about 160 nanometers to about 240 nanometers. Irradiating can at least partially cure the layer. In some embodiments, the layer is cured at a curing temperature greater than 25 °C. The layer may be at a temperature of at least 50 °C, 60 °C 70 °C, 80 °C, 90 °C, 100 °C, 125 °C, or at least 150 °C, in some embodiments, no more than 250 °C, 225 °C, 200 °C, 190 °C, 180 °C, 170 °C, 160 °C, or 155 °C.

Alternatively, the exposed surface of the first polymeric layer 101 may include an overlaid or overcoated low surface energy release layer or low adhesion backsize (LAB), which may be useful for making a linerless article.

In some embodiments, at least one layer of polymeric multilayer film described herein comprises a release agent. Examples of suitable release agents include at least one of an alkyl dimethicone, a polyvinyl octadecyl carbamate, or an ethylene bis-stearamide. Alkyl dimethicones, are described, for example, in U.S. Pat. No. 9,187,678 (Boardman et al.). A polyvinyl octadecyl carbamate is commercially available, for example, under the trade designation “ESCOAT P-77” (a polyvinyl octadecyl carbamate in a linear, low density carrier resin) from Mayzo, Inc., Suwanee, GA. An ethylene bis-stearamide is available, for example, under the trade designation “AMPACET 100666” from Ampacet Corporation, Tarrytown, NY. The layer comprising the release agent may exhibit a random network of strands and connective regions, or it may be a continuous film.

In some embodiments, at least one layer of a polymeric multilayer film described herein comprises at least one of a dye or pigment (e.g., imparting a color such as white, yellow, green, blue, red, orange, brown, black, etc.). Examples of suitable dyes include those commercially available, for example, under the trade designation “CLARIANT REMAFIN PE63421213-ZN” (a green dye masterbatch) from Clariant International AG, Muttenz, Switzerland. Examples of suitable pigments include titanium dioxide, zinc oxide, and zirconium dioxide. In some embodiments, polymeric multilayer film described herein comprises a layer that is separable from the first polymeric layer and the second polymeric layer.

In some embodiments, the article of the present disclosure and/or made by the methods disclosed herein is applied to a substrate. The substrate can be made from a variety of materials such as wood, vinyl, metal, or concrete. In some embodiments, the article of the present disclosure may be simultaneously adhered to two different substrates (e.g., side-by-side substrates). Useful substrates can include at least one of an air and water barrier film, a subfloor, a window frame, a door frame, and wall sheathing materials (e.g., oriented strand board (OSB), foam insulation sheathing, exterior grade gypsum sheathing board, concrete, concrete masonry units (CMUs)). The substrate, in some cases, can be compacted soil or gravel. The substrate may be horizontal or vertical. In some embodiments, the article of the present disclosure and/or made by the methods disclosed herein is at least a portion of an interior wall, an exterior wall, a floor, a ceiling, or a roof.

A method of the present disclosure includes applying the article disclosed herein to the substrate using the PSA layer. The substrates can be any of those described above. The article of the present disclosure may be in the form of a tape, for example, useful as seaming tape or flashing tape.

The present disclosure also provides a method of installing a window or door. FIG. 5 is a perspective, exploded view of an embodiment of an article of the present disclosure, in the form of a tape, applied to a window frame. FIG. 5 illustrates a window opening 434 in wall sheathing 432 that is optionally covered with building wrap 436. Suitable materials for wall sheathing include plywood, oriented strand board (OSB), foam insulation sheathing, exterior grade gypsum sheathing board, concrete, concrete masonry units (CMUs), and other conventional sheathing materials commonly used in the construction industry. As shown in FIG. 5, tape 405, which is an article as described in any of the above embodiments, is applied on building wrap 436 or wall sheathing 432 level with the bottom edge of the rough opening frame 434 to form a sill flashing. Windowsill pans may be installed in the opening and the first layer 405 can overlap the sill pan. Window 446 is inserted into opening 434. Typically, the window frame fits within the opening and flanges extend from the window frame and over the wall sheathing. The window flanges are secured to the wall. Tape 415 and 425 of the present disclosure can also be applied on the window jambs extending from the window flange and onto the building wrap 436 or wall sheathing 432. Tape 435 of the present disclosure can also be applied at the top flange on the window and the sheathing. Cutting a flap of building wrap 436 to expose the wall sheathing 432 can allow clearance for the tape 435 at the top of the window.

In some embodiments, the article of the present disclosure and/or made according to the method of the present disclosure is an air and water barrier film. The air and water barrier film can be, for example, a building wrap as described above or a membrane used under a concrete floor or on an interior wall. An air and water barrier film can be useful, for example, for preventing external liquid water from infiltrating through the sheet yet venting water in vapor form. In some embodiments in which the article of the present disclosure is a tape, the tape of the present disclosure can be useful as seaming tape or flashing tape, for example, in connection with an air and water barrier film. The air and water barrier film can be an article according to the present disclosure.

Another example of an air and water barrier film useful, for example, as a substrate to which the article of the present disclosure and/or made by the methods disclosed herein is applied is commercially available under the trade designation “TYVEK” from E. I. Du Pont de Nemours and Company, Wilmington, Delaware USA, which is obtained by thermo-compressing a three -dimensionally-meshed fiber of high-density polyethylene. Further examples of air and water barrier films suitable as substrates to which the article of the present disclosure and/or made by the methods disclosed herein is applied include a water vapor permeable polymeric layer disposed on a first major surface of a porous layer. The polymeric layer may at least one of completely cover or impregnate the porous layer. In some of these embodiments, the polymeric layer is crosslinked. In some embodiments, the polymeric layer comprises a poly oxyalkylene polymer having at least one crosslink site derived from an alkoxy silane. In some embodiments, the water vapor permeable air and water barrier film is as described in U.S. Pat. Nos. 10,704,254 (Seabaugh et al.), 11,105,089 (Widenbrant et al.), 11,365,328 (Seabaugh et al.), 11,512,463 (Widenbrant et al.), and 11,731,394 (Seabaugh et al.), and U.S. Pat. Appl. Pub. Nos. 2017/0173916 (Widenbrant et al.), 2021/0207005 (Seabaugh et al.), and 2022/0282476 (Widenbrant et al.).

The article of the present disclosure can have a wide variety of widths. Useful widths for a flashing tape or a sealing tape can include between 2 inches (5.1 cm) and 18 inches (45.7 cm) in width. In some embodiments, the width of the tape is at least 1 inch (2.5 cm). In some embodiments, the width of the tape is at least 5 cm. In some embodiments, the width of the article (in some embodiments, the tape) is at most 75 cm (29.5 inches), 45 cm (17.7 inches), 30.5 cm (12 inches), or 10 cm (3.9 inches). In some embodiments, the width of the article is up to 75 cm (29.5 inches), up to 150 cm (59. 1 inches), or up to 160 cm (63.0 inches).

In a first embodiment the present disclosure provides a polymeric multilayer film comprising a first polymeric layer and a second polymeric layer, wherein the first polymeric layer comprises a porous random network of strands and connective regions, wherein the second polymeric layer is a continuous polymeric film layer, and wherein the polymeric multilayer film is water vapor permeable. In a second embodiment the present disclosure provides the polymeric multilayer film of the first embodiment, wherein the first polymeric layer is not fibrous. In a third embodiment, the present disclosure provides the polymeric multilayer film of the first or second embodiment, wherein the random network of strands has a first optical density, and the connective regions have a second optical density, wherein the first optical density is greater than the second optical density. In a fourth embodiment, the present disclosure provides the polymeric multilayer film of any one of the first to third embodiments, wherein a portion of the connective regions includes through holes, and portion of the connective regions does not include through holes.

In a fifth embodiment, the present disclosure provides a process for making a polymeric multilayer film, the process comprising coextruding a first polymeric layer and a second polymeric layer, wherein the first polymeric layer comprises a porous random network of strands and connective regions, wherein the second polymeric layer is a continuous polymeric film layer, and wherein the polymeric multilayer film is water vapor permeable. In a sixth embodiment, the present disclosure provides the process of the fifth embodiment, wherein coextruding comprises blown film coextruding. In a seventh embodiment, the present disclosure provides the process of the sixth embodiment, wherein blown film coextruding comprises coextruding from an annular die. In an eighth embodiment, the present disclosure provides the process of any one of the fifth to seventh embodiments, wherein a foaming agent is added during the coextruding to make the first polymeric layer.

In a ninth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to eighth embodiments, wherein the first polymeric layer comprises a polyolefin. In a tenth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to ninth embodiments, wherein the second polymeric layer comprises at least one of a polyurethane, a polyamide, polylactic acid, an acrylic block copolymer, or an amorphous polyester. In an eleventh embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to tenth embodiments, wherein the second polymeric layer does not comprise a polyoxyalkylene polymer crosslinked with siloxane bonds. In a twelfth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to eleventh embodiments, wherein second polymeric layer comprises a polyurethane, and wherein the polyurethane is a reaction product of components comprising polyethylene glycol, a chain extender, and an aliphatic isocyanate. In a thirteenth embodiment, the present disclosure provides the multilayer film or process of the twelfth embodiment, wherein the polyethylene glycol has a number average molecular weight in a range from 500 grams per mole and 2500 grams per mole, and wherein the aliphatic isocyanate comprises dicyclohexylmethane-4,4'-diisocyanate. In a fourteenth embodiment, the present disclosure provides the polymeric multilayer film or process of the twelfth or thirteenth embodiment, wherein the components further comprise a triol, and wherein the triol contributes hydroxyl groups in a range from 2 mole percent to 10 mole percent, based on the total moles of hydroxyl groups in the polyethylene glycol, the chain extender, and the triol. In a fifteenth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to fourteenth embodiments having a first major surface and a second major surface, wherein the second polymeric layer comprises the second major surface. In a sixteenth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to fifteenth embodiments having a first major surface and a second major surface, wherein the first polymeric layer comprises the first major surface. In a seventeenth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to sixteenth embodiments, wherein the polymeric multilayer film has a water vapor permeability of at least 5 US Perms. In an eighteenth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to seventeenth embodiments, further comprising a tie layer between the first polymeric layer and the second polymeric layer. In a nineteenth embodiment, the present disclosure provides the polymeric multilayer film or process of the eighteenth embodiment, wherein the tie layer comprises an ethylene-containing copolymer. In a twentieth embodiment, the present disclosure provides the polymeric multilayer film or process of any one of the first to nineteenth embodiments, wherein the first polymeric layer is one of a plurality of layers comprising a porous random network of strands and connective regions, and wherein the second polymeric layer is one of a plurality of continuous polymeric film layers.

In a twenty-first embodiment, the present disclosure provides an article comprising the polymeric multilayer film of any one of the first to twentieth embodiments or made by the process of any one of the fifth to twentieth embodiments and a pressure-sensitive adhesive disposed on at least one of a first major surface or a second major surface of the polymeric multilayer film. In a twenty-second embodiment, the present disclosure provides the article of the twenty-first embodiment, wherein the pressure -sensitive adhesive is present in a discontinuous pattern. In a twenty-third embodiment, the present disclosure provides the article of the twenty-first embodiment, wherein the pressure -sensitive adhesive is present in a continuous layer. In a twenty-fourth embodiment, the present disclosure provides the article of any one of the twenty-first to twenty-third embodiments, wherein the pressure-sensitive adhesive comprises an acrylic copolymer and a poly oxyalkylene polymer, the acrylic copolymer comprising: at least 60 weight percent of linear or branched alkyl (meth)acrylate monomer units, based on the weight of the acrylic copolymer; and from 10 weight percent to 40 weight percent of (meth)acrylic acid monomer units, based on the weight of the acrylic copolymer. In a twenty-fifth embodiment, the present disclosure provides the article of the twenty-fourth embodiment, wherein the polyoxyalkylene polymer is present in an amount of 20 weight percent to 45 weight percent, based on the total weight of the pressuresensitive adhesive. In a twenty-sixth embodiment, the present disclosure provides the article of the twenty-fourth or twenty-fifth embodiment, wherein the acrylic copolymer is crosslinked. In a twentyseventh embodiment, the present disclosure provides the article of any one of the twenty-fourth to twentysixth embodiments, wherein the acrylic copolymer is crosslinked with a triazine. In a twenty-eighth embodiment, the present disclosure provides the article of any one of the twenty-first to twenty-seventh embodiments, wherein the pressure -sensitive adhesive is free of a fluorinated surfactant. In a twentyninth embodiment, the present disclosure provides the article of any one of the twenty-first to twentyeighth embodiments, wherein the pressure -sensitive adhesive is not frothed. In a thirtieth embodiment, the present disclosure provides the article of any one of the twenty-first to twenty-ninth embodiments, wherein the article has a water vapor permeability of at least 5 US Perms. In a thirty-first embodiment, the present disclosure provides the article of any one of the twenty-first to twenty-ninth embodiments, wherein a release liner is disposed on the pressure-sensitive adhesive opposite the first major surface or the second major surface of the polymeric multilayer film.

EXAMPLES

Advantages and embodiments of this invention are further illustrated by the following examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this invention. All parts and percentages are by weight unless otherwise indicated. Table 1. Materials Vapor Permeable Pressure Sensitive Adhesive- 1

A pressure sensitive adhesive precursor composition was prepared by mixing 84 parts by weight (pbw) isooctyl acrylate (IOA), 16 pbw acrylic acid (AA), and 0.04 pbw of 2,2-dimethoxy-l,2- diphenylethan-l-one. This mixture was partially polymerized under a nitrogen atmosphere by exposure to low intensity ultraviolet radiation to provide a coatable syrup. An additional 0.272 pbw of 2,2- dimethoxy-l,2-diphenylethan-l-one, 0.467 pbw of 2,4-bis-trichoromethyl-6-(4-methoxyphenyl)-s- triazine, and 56 pbw of a monobutyl ether of a linear polymer of ethylene oxide: propylene oxide (1: 1) polyglycol were added to the syrup and mixed until all the components had completely dissolved to give a pressure sensitive adhesive precursor composition.

The adhesive precursor composition was then coated onto a siliconized polyethylene coated Kraft paper liner using a notch bar with a 0.130-millimeter (mm) (0.005 inches) gap setting greater than the thickness of the liner. The adhesive precursor was then exposed to a total energy of 850 milliJoules/square centimeter from an ultraviolet radiation source having a maximum at 351 nanometers in a nitrogen-rich environment. The result was a pressure sensitive adhesive coated release liner.

Example 1

A seven-layer film was produced using a seven-layer annular stack die (obtained under the trade designation “COEX 7-LAYER” (Type LF-400) from Labtech Engineering, Samut Prakan, Thailand) except there were only seven stacked die plates. Airflow to the die was manually controlled to achieve a blow-up ratio of about 2: 1. The bubble was subsequently collapsed about 3 meters (10 feet) above the die and rolled up. The feed materials were supplied by 7 independent 20-mm diameter extruders with about a 30: 1 length to diameter ratio.

A first extruder was used to melt and feed a blend containing 91.0 weight percent (wt.%) of Polyurethane 1 and 9 wt.% of the anti-blocking agent into an inside channel of the annular stack die at a rate of 15 revolutions per minute (rpm). The extrusion temperature was maintained at 180°C. Second, third, fourth, and fifth extruders were used to melt and feed Polyurethane 1 on subsequent outer layers of the first resin at a rate of 15 rpm. A sixth extruder was used to feed a blend containing 46.5 wt.% of the Thermoplastic Polyolefin, 46.5 wt.% of EMA, 5 wt.% of CBA, and 2 wt.% of carbon black at a rate of 60 rpm. An extrusion temperature of 215°C was maintained in layer 6. A seventh extruder was used to feed a blend containing 93.0 wt.% of the Thermoplastic Polyolefin, 5 wt.% of CBA, and 2 wt.% of carbon black at a rate of 60 rpm. The 7-layer coextruded blown film bubble was collected at a 3.7 feet per minute (fpm) line speed and was slit producing a single film. Vapor Permeable Pressure Sensitive Adhesive- 1 on release liner was hand laminated to the first extruder feed side of the film resulting in an overall vapor permeable construction with a removable release liner. Example 2

Example 2 was carried out using the method of Example 1 with the following modifications. The sixth and seventh extruders were both fed at a rate of 90 rpm, and the blown film bubble was collected at a line speed of 4. 1 fpm.

Example 3

Example 3 was carried out using the method of Example 1 with the following modifications. The blown film bubble was collected at a line speed of 4.1 fpm.

Example 4

Example 4 was carried out using the method of Example 1 with the following modifications. The blown film bubble was collected at a line speed of 4.1 fpm. The fourth and fifth extruders were both fed at a rate of 20 rpm.

Example 5

The seven-layer annular stack die described for Example 1 was used. First and second extruders were used to melt and feed LDPE into the inside channels of the annular stack die at a rate of 60 rpm. Third, fourth, and fifth extruders were used to melt and extrude Polyurethane 1 on subsequent outer layers of the first resin at a rate of 15 rpm. A sixth extruder was used to feed a blend containing 46.5 wt.% of the Thermoplastic Polyolefin, 46.5 wt.% of EMA, 5 wt.% of CBA, and 2 wt.% of carbon black at a rate of 60 rpm. An extrusion temperature of 215°C was maintained in layer 6. A seventh extruder was used to feed a blend containing 93.0 wt.% of the Thermoplastic Polyolefin, 5 wt.% of CBA, and 2 wt.% of carbon black at a rate of 60 rpm. The 7-layer coextruded blown film bubble was collected at a line speed of 4. 1 fpm and was slit producing a single film. The inner two LDPE layers were stripped from the film creating an overall 5-layer coextruded blown film. Vapor Permeable Pressure Sensitive Adhesive-1 on release liner was hand laminated to the polyurethane side of the film creating an overall vapor permeable construction with a removable release liner.

Example 6

Example 6 was carried out using the method of Example 5 with the following modifications. The sixth and seventh extruders were both fed at a rate of 90 rpm.

Water Vapor Transmission Evaluation

The water vapor transmission rates of Examples 1 to 6 were evaluated generally as described in ASTM E96/E96M: “Standard Test Methods for Water Vapor Transmission of Materials” using Paragraph 11: Dessicant Method at (23 °C (73 °F)) and 50% relative humidity, with the following modifications. Six data points were obtained and used to calculate a permeance value. The six individual values were used to determine an average permeance value which was reported in units of Perms. Two samples were evaluated for permeance per condition and are both reported. The results are shown in Table 2, below.

Tensile Strength

The tensile strength of samples was evaluated according to ASTM D412, Method A, Die C, using an elongation rate of 508 mm/minute (20 inches/minute). Tensile strength was measured in both the machine direction (MD) and cross machine direction (CD). Three measurements were taken per condition and the average tensile strength was reported in pounds per square inch (lb/in²).

Peel Adhesion

Peel adhesion measurements were evaluated at a 90-degree angle according to ASTM D3330, Method F, on stainless steel after a 24-hour dwell time. Two measurements were taken per condition and the average peel adhesive was reported in pounds per inch (lb/in).

Table 2. Evaluations of Examples 1 to 6

Preparation of Aliphatic Thermoplastic Polyurethane

Pellets of an aliphatic thermoplastic polyurethane were prepared through a reactive extrusion process using a twin-screw extruder, Model ZSK25, available from Coperion Corp., Stuttgart Germany, having 12 barrel sections with each barrel having a length of 100 mm. The first barrel was closest to the extruder drive mechanism and twelfth barrel was nearest the exit of the extruder. Polyethylene glycol diol (addition rate of 75 grams per minute (g/min)) was added to the first barrel section via a heated ZENITH B-9000 gear pump, available from Circor International, Inc., Burlington, MA. 1,4-Butanediol (addition rate of 15.4 g/min) was added to the second barrel section by a Flow Meter Controlled Pump, sold as from the Mini-Cori series from Bronkhorst (Ruurlo, The Netherlands). Dibutyltin dilaurate (addition rate of 0. 15 g/min) was added to the second barrel section via a syringe pump, available from Harvard Apparatus, Holliston, MA. Polycaprolactone triol (addition rate of 1.2 g/min) was added to the second barrel section via a syringe pump. A blend of 3 parts-by-weight UV Absorber and 2 parts-by- weight HALS was added to the fourth barrel section via syringe pump (addition rate of 2.25 g/min). H12MDI (addition rate of 59.6 g/min) was added to the third barrel section via a second ZENITH B-9000 gear pump. The molten polyurethane was discharged from the extruder into a ZENITH PEP II gear pump, available from Circor International, Inc. The polyurethane was pumped into an underwater pelletizer, model number EUP10, available from ECON Inc., Monroe, MI.

Example 7

The seven-layer annular stack die described for Example 1 was used. First, second, and third extruders were used to melt and feed LDPE into the inside channels of the annular stack die at a rate of 40 rpm. The fourth extruder was used to melt and extrude the Aliphatic Thermoplastic Polyurethane described above on subsequent outer layers of the first resin at a rate of 20 rpm. A fifth extruder was used to melt and feed a blend containing 70.0 wt.% of EVA 1, 23.0 wt% of EVA 2, 5.0 wt.% CBA, and 2 wt.% of TiO₂ at a rate of 20 rpm. A sixth and seventh extruder were used to melt and feed a blend containing 70.0 wt.% of the Thermoplastic Polyolefin, 23.0 wt.% of EMA, 5 wt.% of CBA, and 2 wt.% of TiO₂ at a rate of 20 and 60 rpm, respectively. The 7-layer coextruded blown film bubble was collected at a line speed of 4. 1 fpm and was slit producing a single film. The inner three LDPE layers were stripped from the film creating an overall 4-layer coextruded blown film. Vapor Permeable Pressure Sensitive Adhesive- 1 on the release liner was hand laminated to the layer 4, polyurethane, side of the film creating an overall vapor permeable construction with a removable release liner. The Water Vapor Transmission Evaluation was carried out as described above, and the results were 5.50 US Perms and 5.58 US Perms.

Vapor Permeable Pressure Sensitive Adhesive-2 to 4

A pressure sensitive adhesive precursor composition was prepared by mixing 90 pbw IO A, 10 pbw AA, 0.19 pbw of 2,2-dimethoxy-l,2-diphenylethan-l-one, and 0.1 pbw 2,4-bis-trichoromethyl-6-(4- methoxyphenyl)-s-triazine. This mixture was partially polymerized under a nitrogen atmosphere by exposure to low intensity ultraviolet radiation to provide a coatable syrup. An additional 6.8 pbw AA, 0.13 pbw of 2,2-dimethoxy-l,2-diphenylethan-l-one, and the amounts of 2,4-bis-trichoromethyl-6-(4- methoxyphenyl)-s-triazine, isooctyl thioglycolate (IOTG), tallow amine ethoxylate, and tris (15- hydroxyethyl)-N-tallowalkyl-l,3-diaminopropane shown in Table 3, below, were added to the syrup and mixed until all the components had completely dissolved to give a pressure sensitive adhesive precursor composition. The adhesive precursor composition was then coated onto a release liner and cured as described in Vapor Permeable Pressure Sensitive Adhesive- 1.

The pressure sensitive adhesive was transferred to a paper towel for the measurement of Water Vapor Transmission as described above. Also, Peel Adhesion was measured according to the test method described above using a 50.8-micrometer (2 -mil) aluminum foil backing. The results are shown in Table 3, below. Table 3. Vapor Permeable Pressure Sensitive Adhesive-2 to 4

Foreseeable modifications and alterations of this disclosure will be apparent to those skilled in the art without departing from the scope and spirit of this invention. This invention should not be restricted to the embodiments that are set forth in this application for illustrative purposes.

Claims

What is claimed is:

1. A polymeric multilayer film comprising a first polymeric layer and a second polymeric layer, wherein the first polymeric layer comprises a porous random network of strands and connective regions, wherein the second polymeric layer is a continuous polymeric film layer, and wherein the polymeric multilayer film is water vapor permeable.

2. The polymeric multilayer film of claim 1, wherein the first polymeric layer comprises a polyolefin.

3. The polymeric multilayer film of claim 1 or 2, wherein the second polymeric layer comprises at least one of a polyurethane, a polyamide, polylactic acid, an acrylic block copolymer, or an amorphous polyester.

4. The polymeric multilayer film of any one of claims 1 to 3, wherein the second polymeric layer comprises a polyurethane, and wherein the polyurethane is a reaction product of polyethylene glycol, and chain extender, and an aliphatic isocyanate.

5. The polymeric multilayer film of any one of claims 1 to 4 having a first major surface and a second major surface, wherein the first polymeric layer comprises the first major surface, and wherein the second polymeric layer comprises the second major surface.

6. The polymeric multilayer film of any one of claims 1 to 5, wherein the polymeric multilayer film has a water vapor permeability of at least 5 US Perms.

7. The polymeric multilayer film of any one of claims 1 to 6, further comprising a tie layer between the first polymeric layer and the second polymeric layer.

8. The polymeric multilayer film of any one of claims 1 to 7, wherein the first polymeric layer is one of a plurality of layers comprising a porous random network of strands and connective regions, and wherein the second polymeric layer is one of a plurality of continuous polymeric film layers.

9. An article comprising: the polymeric multilayer film of any one of claims 1 to 8; and a pressure-sensitive adhesive disposed on at least one of a first major surface or a second major surface of the polymeric multilayer film.

10. The article of claim 9, wherein the pressure-sensitive adhesive is present in a discontinuous pattern.

11. The article of claim 9, wherein the pressure -sensitive adhesive is present in a continuous layer.

12. The article of any one of claims 9 to 11, wherein the pressure-sensitive adhesive comprises an acrylic copolymer and a poly oxyalkylene polymer, the acrylic copolymer comprising: at least 60 weight percent of linear or branched alkyl (meth)acrylate monomer units, based on the weight of the acrylic copolymer; and from 10 weight percent to 40 weight percent of (meth)acrylic acid monomer units, based on the weight of the acrylic copolymer.

13. The article of claim 12, wherein at least one of the following limitations is met: the polyoxyalkylene polymer is present in an amount of 20 weight percent to 45 weight percent, based on the total weight of the pressure-sensitive adhesive; or the polyoxyalkylene polymer is divalent or multivalent and comprises: a plurality of at least one of ethoxy, propoxy, or butoxy groups; and terminal groups comprising at least one of alkyl, hydroxyl, amino, or silane.

14. The article of any one of claims 9 to 13, wherein a release liner is disposed on the pressuresensitive adhesive opposite the first major surface or the second major surface of the polymeric multilayer film.

15. The article of any one of claims 9 to 13, wherein the article has a water vapor permeability of at least 5 US Perms.