| abstract |
A composite synthetic leather sheet material and method of manufacture thereof is disclosed. The composite sheet material comprises outer thermoplastic polymeric layers bonded to opposite faces of a reinforcing textile fabric, preferably a porous woven fabric of high strength material, by an intermediate polymeric layer which fills the interstices of the fabric and has opposite surfaces disposed adjacent the fabric surfaces to engage and firmly secure the outer thermoplastic polymeric layers in the composite sheet. One of the outer thermoplastic layers is foamed to a relatively high degree and the outer surface of the foam is mechanically abraded or buffed to provide a suede-like leather appearance thereto. The other outer thermoplastic layer may be foamed and provided with an embossed leather-like surface appearance. The sheet material product is reversible in use, completely heat-sealable, flow-moldable, and printable on both sides for subsequent manufacture of synthetic leather good articles. The polymeric layers of the composite sheet are preferably applied to the reinforcing fabric in plastisol form, and all of the layers may be foamed in varying degrees, if desired. The sheet material is produced by applying a first thermoplastic polymeric layer to an embossed release paper, heating the first layer to a tacky state, applying a reinforcing fabric to the surface of the tacky layer, and impregnating the fabric with a second polymeric composition to fill the interstices and contact the lower polymeric layer on the release paper. The sheet is heated to gel the two polymeric layers and a third foamed or foamable thermoplastic polymeric layer is applied to the exposed surface of the sheet. The resultant composite is heated to foam, cure and fusion bond the polymeric layers, and the unembossed foamed polymeric layer is thereafter mechanically abraded to impart a suede-like leather appearance thereto. |