Synthetic film with a paper-like surface and method of forming same

Claim 2

An oriented polymeric film structure comprising: at least one layer of a thermoplastic polymeric matrix material, within which is located a strata of voids, positioned at least substantially within at least a substantial number of said voids at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix, the void space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximately a corresponding cross-sectional dimension of said void, at least one surface of said layer being of a paper-like, non-even, micro-rough, microcrater-containing lamellae-like, random textured, ink-acceptable configuration.

Claim 3

An oriented polymeric film structure comprising: at least one layer of a thermoplastic polymeric matrix material, within which is located a strata of voids, positioned at least substantially within at least a substantial number of said voids is at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix, the void space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void, a first surface of said layer being of a paper-like, non-even microcrater-containing, lamellae-like, ink-acceptable configuration; and a second layer in intimate contact with the second surface of said at least one layer comprising a void-free thermoplastic layer, said layer being of a thickness or strength at least greater than that of the thickness or strength of the delaminatable strata regions of said matrix material.

Claim 4

An oriented polymeric film structure comprising: at least one layer of a thermoplastic polymeric matrix material, within which is located a strata of voids, positioned at least substantially within at least a substantial number of said voids is at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix, the void space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void, a first surface of said layer being of a paper-like, non-even microcrater-containing, lamellae-like, ink-acceptable configuration; and a second layer in intimate contact with the second surface of said at least one layer comprising a void-free thermoplastic layer, said layer being of a thickness or strength at least greater than that of the thickness or strength of the delaminatable strata regions of said matrix material.

Claim 5

The film structure of claim 2 wherein said second layer is in intimate contact with two layers of said thermoplastic polymeric matrix material so as to provide a structure having a printable or writable surface on both sides thereof.

Claim 6

The film structure resulting from the splitting lengthwise and breadthwise through the core matrix layer of the following three layer structure; an opaque biaxially oriented polymeric film structure comprising: a core thermoplastic polymeric matrix material within which is located a strata of voids, positioned at least substantially within at least a substantial number of each of said voids, is at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix material, the void-space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void; void-free, thermoplastic skin layers adhering to the surfaces of said core layer, said skin layers being of a thickness or a strength at least sufficient to withstand without breaking, the force necessary to cause lengthwise and breadthwise splitting or delamination of said core matrix material.

Claim 7

The film structure resulting from the splitting lengthwise and breadthwise through the core matrix layer of the following three layer structure; an opaque biaxially oriented polymeric film structure comprising: a core thermoplastic polymeric matrix material within which is located a strata of voids, positioned at least substantially within at least a substantial number of each of said voids, is at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix material, the void-space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void; void-free, thermoplastic skin layers adhering to the surfaces of said core layer, said skin layers being of a thickness or a strength at least sufficient to withstand without breaking, the force necessary to cause lengthwise and breadthwise splitting or delamination of said core matrix material.

Claim 8

The structure of claim 4 wherein said particle is spherical.

Claim 9

The structure of claim 4 wherein said particle is inorganic.

Claim 10

The film structure of claim 4 wherein said particle is an organic material.

Claim 11

The film structure of claim 4 wherein said organic material is a polymer.

Claim 12

The structure of claim 4 wherein said structure is a co-extruded structure.

Claim 13

The structure of claim 4 wherein said structure is a laminated structure.

Claim 14

The structure of claim 4 wherein the core thickness is from about 2 to about 70 percent of said structure.

Claim 15

The structure of claim 4 wherein said skin layers are of the same polymeric material as said matrix material.

Claim 16

The structure of claim 4 wherein said skin layers are of a different polymeric material from said matrix material.

Claim 17

The structure of claim 4 wherein said voids have a dimension of X, Y and Z, wherein dimensions X and Y are major dimensions and dimension Z is a minor dimension at least generally corresponding to the diameter of said particle.

Claim 18

The structure of claim 14 wherein said splitting or delamination occurs at least generally in an X Y plane of said core layer.

Claim 19

The structure of claim 4 wherein the particles have an average diameter of about 0.1 to about 10 microns.

Claim 20

The structure of claim 4 wherein said core and skin polymer is a polyolefin.

Claim 21

The structure of claim 17 wherein said polyolefin is polypropylene.

Claim 22

The structure of claim 18 wherein said particles are of a nylon.

Claim 23

The structure of claim 19 wherein said nylon is nylon-6.

Claim 24

A process for preparing a film structure having at least one ink-acceptable surface comprising providing a structure defined as follows: a thermoplastic polymeric matrix material within which is located a strata of voids, positioned at least substantially within at least a substantial number of each of said voids, it at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix material, the void-space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void; drawing regions of said layer apart with sufficient force to cause splitting or delamination of said layer and thereby expose a film surface which is paper-like, non-even, micro-roughed, microcrater-containing, lamellae-like, random textured and ink-acceptable.

Claim 25

A process for preparing a film structure having at least one ink-acceptable surface comprising providing a structure defined as follows: a thermoplastic polymeric matrix material within which is located a strata of voids, positioned at least substantially within at least a substantial number of each of said voids, it at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix material, the void-space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void; drawing regions of said layer apart with sufficient force to cause splitting or delamination of said layer and thereby expose a film surface which is paper-like, non-even, micro-roughed, microcrater-containing, lamellae-like, random textured and ink-acceptable.

Claim 26

A process for preparing a film structure having at least one ink-acceptable surface comprising providing a three layered structure defined as follows: a core thermoplastic polymeric matrix material within which is located a strata of voids, positioned at least substantially within at least a substantial number of each of said voids, is at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix material, the void-space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void; void-free, thermoplastic skin layers adhering to the surface of said core layer said skin layers being of a thickness or a strength at least sufficient to withstand without breaking the force necessary to cause lengthwise and breadthwise splitting or delamination of said core matrix material, drawing said skin layers apart with sufficient force to cause splitting or delamination of said core layer to thereby expose a film surface which is non-even, micro-roughed, microcrater containing, lamellae-like, randomly textured and ink-acceptable.

Claim 27

A process for preparing a film structure having at least one ink-acceptable surface comprising providing a three layered structure defined as follows: a core thermoplastic polymeric matrix material within which is located a strata of voids, positioned at least substantially within at least a substantial number of each of said voids, is at least one void-initiating solid particle which is phase-distinct and incompatible with said matrix material, the void-space occupied by said particle being substantially less than the volume of said void, with one generally cross-sectional dimension of said particle at least approximating a corresponding cross-sectional dimension of said void; void-free, thermoplastic skin layers adhering to the surface of said core layer said skin layers being of a thickness or a strength at least sufficient to withstand without breaking the force necessary to cause lengthwise and breadthwise splitting or delamination of said core matrix material, drawing said skin layers apart with sufficient force to cause splitting or delamination of said core layer to thereby expose a film surface which is non-even, micro-roughed, microcrater containing, lamellae-like, randomly textured and ink-acceptable.

Claim 28

The process of claim 22 further including placing two of the split structures in face to face bonded relationship with said void-free thermoplastic layers as the core layer thereof.