Fibrous web impregnated with coagulated polyurethane and polyolefin admixture

Claim 3

The method of claim 1 wherein said fibrous web is a needled fibrous batt.

Claim 4

The method of claim 2 wherein said needled fibrous batt has a bulk density of less than 0.5 g/cm 3 .

Claim 5

The method of claim 3 wherein said needled fibrous batt has a bulk density of less than 0.25 g/cm 3 .

Claim 6

The method of claim 3 wherein said needled fibrous batt has a bulk density of between about 0.12 and 0.4 g/cm 3 .

Claim 7

The method of claim 1 wherein the compatible polymeric dispersion or emulsion is a neoprene latex.

Claim 8

The method of claim 1 wherein said fibrous web is fully impregnated when coagulated.

Claim 9

The method of claim 2 wherein said needled fibrous batt has a thickness of at least 30 mils.

Claim 10

The method of claim 2 wherein said needled fibrous batt is composed of substantially non-fusible fibers.

Claim 11

The method of claim 1 wherein the combined solids of said aqueous anionic polyurethane dispersion and the compatible polymeric dispersion or emulsion is about 5 to 60 percent by weight.

Claim 12

The method of claim 1 wherein said polyurethane is crosslinked.

Claim 13

The method of claim 1 wherein the polyurethane polymer and the other polymer are present in said web at a level of at least 70 percent by weight add-on based upon the weight of the fibrous batt.

Claim 14

The method of claim 12 wherein said polyurethane polymer and the other polymer are present at a level of less than about 400 percent by weight add-on based upon the weight of said fibers.

Claim 15

The method of claim 13 wherein said polyurethane polymer and the other polymer are present at a level of about 200 to 300 percent by weight add-on based upon the weight of said fibrous batt.

Claim 16

The method of claim 1 wherein said impregnated fibrous web has a density of up to about 0.75 g/cc.

Claim 17

The method of claim 15 wherein said impregnated fibrous web has a density of between about 0.4 about 0.75 g/cc.

Claim 18

An impregnated fibrous web comprised of a fibrous web having impregnated therein a coagulated homogeneous admixture of anionic dispersion of a polyurethane polymer and a compatible anionic, cationic or nonionic dispersion or emulsion of a polymer selected from the group consisting of neoprene, polyvinyl chloride, polyacrylate polymers, polyolefin polymers and polyfloroolefin polymers wherein said polymers are water soluble in their coagulated state; said coagulated polymers are present at a level of 30 to 65 percent by weight based on the total weight of polymer in the impregnated fibrous web and said impregnated fibrous web having a uniform density throughout.

Claim 19

An impregnated fibrous web comprised of a fibrous web having impregnated therein a coagulated homogeneous admixture of anionic dispersion of a polyurethane polymer and a compatible anionic, cationic or nonionic dispersion or emulsion of a polymer selected from the group consisting of neoprene, polyvinyl chloride, polyacrylate polymers, polyolefin polymers and polyfloroolefin polymers wherein said polymers are water soluble in their coagulated state; said coagulated polymers are present at a level of 30 to 65 percent by weight based on the total weight of polymer in the impregnated fibrous web and said impregnated fibrous web having a uniform density throughout.

Claim 20

The sheet material of claim 17 wherein the polymer other than the polyurethane polymer is neoprene.

Claim 21

The impregnated porous sheet material of claim 17 wherein said porous substrate is a needled fibrous batt.

Claim 22

The impregnated porous sheet material of claim 19 wherein: the homogeneous admixture of coagulated polyurethane anionic dispersion and a compatible polymeric dispersion or emulsion is distributed throughout the batt with the density of said impregnated porous sheet material uniform throughout; the bulk density of said sheet material being less than the actual density of said sheet material, whereby the sheet material is porous; and said impregnated web having filaments which are both coated and uncoated with polymeric resin, and concentrations of polymeric resin.

Claim 23

The impregnated porous sheet material of claim 20 wherein said polyurethane and other polymer are present at a level of at least 70 percent by weight add-on based upon the weight of the fibrous batt.

Claim 24

The impregnated porous sheet material of claim 21 wherein said polyurethane and other polymer are present at a level of less than 400 percent by weight add-on based upon the weight of the fibrous batt.

Claim 25

A simulated leather sheet material comprising a polymer impregnated fibrous mass with a grain layer forming one surface, the grain layer having an actual density equal to its bulk density and a split layer forming the opposing surface, the improvement comprising said polymer being comprised of a homogeneous admixture of a coagulated anionic polyurethane dispersion and a coagulated anionic, cationic or nonionic dispersion or emulsion of a polymer selected from the group consisting of neoprene, polyvinyl chloride, polyacrylate polymers, phenol-formaldehyde resins, polyolefin polymers and polyfloroolefin polymers wherein the polymer is water insoluble in its coagulated state; and wherein the polymer other than the polyurethane polymer is present at a level of 30 to 65 percent by weight based on the total weight of polymer in the simulated leather sheet material.

Claim 26

A simulated leather sheet material comprising a polymer impregnated fibrous mass with a grain layer forming one surface, the grain layer having an actual density equal to its bulk density and a split layer forming the opposing surface, the improvement comprising said polymer being comprised of a homogeneous admixture of a coagulated anionic polyurethane dispersion and a coagulated anionic, cationic or nonionic dispersion or emulsion of a polymer selected from the group consisting of neoprene, polyvinyl chloride, polyacrylate polymers, phenol-formaldehyde resins, polyolefin polymers and polyfloroolefin polymers wherein the polymer is water insoluble in its coagulated state; and wherein the polymer other than the polyurethane polymer is present at a level of 30 to 65 percent by weight based on the total weight of polymer in the simulated leather sheet material.

Claim 27

The simulated leather sheet material of claim 23 wherein the other polymer is neoprene.