Method for manufacturing a synthetic leather base

Claim 1

METHOD OF MANUFACTURING A SYNTHETIC LEATHER BASE EXHIBITING A HOMOGENEOUS CROSS-SECTION, COMPRISING PREPARING A THICK, HOMOGENEOUS SHEET OF HIGH DENSITY FROM SYNTHETIC FIBERS, SAID FIBERS HAVING A DENIER LESS THAN 3, CURL FREQUENCY OVER 6, A CURL RATIO OVER 10 AND A CURL PERMANENCE OVER 50 PERCENT, SAID METHOD BEING A CONTINUOUS METHOD AND INCLUDING FOUR SUCCESSIVE PHASES, THE FIRST PHASE CONSISTINFG OF PREPAR ING TWO CONTINUOUS NON-WOVEN PRIMARY SHEETS FROM SAID FIBERS, THE SECOND PHASE CONSISTING OF NEEDLING THE TWO THUS NEESHEETS SEPARATELY FROM ONE SIDE ONLY WITH NEEDLES STRIKING IN THE SAME DIRECTION, THE THIRD PHASE CONSISITNG OF TURINING OVER ONE OF SAID PRIMARY SHEETS AND SUPERPOSING THE TWO THUS NEEDLED PRIMARY SHEETS SUCH THAT THE SURFACES WHICH HAVE BEEN INITIALLY CONTACT WITH THE NEEDLES ARE ON THE OUTSIDE OF THE SHEET FORMED BY THEIR SUPERPOSITION, AND THE FOURTH PHASE CONSISTING OF SUBJECTING THE SHEET THUS FORMED TO INTENSE NEEDLING FROM BOTH SIDES, APPLYING A SURABLE BINDER THROUGH THE RESULTING SHEET, CURING SAID BINDER SO AS TO BIND TOGETHER THE FIBERS TO FORM A BOUND SHEET AND SUBJECTING THE BOUND SHEET TO SPLITTING OPERATIONS DIVIDING IT INTO LAYERS OF THE DESIRED. THICKNESS.