Breathable multilayer films with breakable skin layers

Abstract

A breathable multilayer film including a breathable core layer and one or two skin layers is prepared by providing a core layer mixture of a thermoplastic polymer and a particulate filler, providing a skin layer mixture of at least two incompatible polymers, coextruding the core and skin layer mixtures to form a multilayer film, and stretching the multilayer film to cause void formation in the core layer and crack formation in the one or two skin layers. By forming cracks in the skin layers during stretching, the skin layers can perform dual functions of alleviating die build-up of filler from the core layer during coextrusion, and bonding the film to a substrate subsequent to coextrusion, without unduly hindering the moisture vapor transmission rate of the film or laminate product. The breathable film, and laminates including the film, are useful in a wide variety of personal care absorbent articles, medical garments, and other products.