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filingDate 1969-06-06-04:00^^<http://www.w3.org/2001/XMLSchema#date>
publicationDate 1972-06-14-04:00^^<http://www.w3.org/2001/XMLSchema#date>
publicationNumber GB-1277438-A
titleOfInvention Preparation of leather replacement products
abstract 1277438 Porous coated sheet materials TENNECO CHEMICALS Inc 6 June 1969 [6 June 1968] 56295/71 Divided out of 1277436 Heading B2E A breathable, supple, fibrous sheet comprising a vapour-permeable substrate and a grain layer comprising a microporous elastomeric composition containing intercommunicating cells is produced by (a) wetting a substrate containing randomly oriented fibres entangled and interlocked with each other with an aqueous liquid in which the elastomer of the composition is insoluble to produce a wet substrate in which the surface is substantially free of a surface film of the aqueous liquid, b) coating the resulting wetted substrate with a solution containing 2-45 % by weight of the elastomeric composition, based on the weight of the solution, in a solvent which is miscible with the aqueous liquid, and (c) exposing the resulting coated, wetted substrate to additional aqueous liquid to deposit the elastomeric composition as a grain layer extending above the surface of the substrate and into the upper strata thereof. The elastomer may be a polyurethane or a mixture thereof with polyvinyl chloride. Preferably the miscible solvent also contains 30-120 parts by weight of intert particles per 100 parts by weight of dry elastomer in the size range 200 angstroms-150 microns, e.g. charcoal, aluminium dust, leather dust, nylon, oxides of silicon, silicates, barytes, talc, and preferably microporous, microcrystalline, resilient, cellulosic particles such as may be prepared by acid hydrolysis of cellulose, followed by mechanical sheering in a water slurry and drying. The elastomeric composition may be deposited by exposing the coated wetted substrate to vapours of the aqueous liquid or by dipping in a bath of the aqueous liquid. The process may be repeated to produce grain layers of varying thicknesses. Substrates exemplified are (1) a nylon staple fleece needled into a polyurethane foam, the nylon side being further needled to a nylon/polyester staple fleece, the whole having been hot-pressed at 5 psi and 315‹F to cause partial bonding of the nylon/ polyester and being impregnated finally with a polyurethane, (2) a similar product wherein the second fleece contains only nylon staple, and (3) a nylon staple fleece needled into a polyurethane foam, hot-pressed at 300 psi and 300‹F. and impregnated with a polyurethane.
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