Porous polyurethanes and method of manufacture

Claim 2

evaporating solvent from said layer to cause the formation of a porous polyurethane film having a thickness of about 1 to 30 mils on said carrier member; and

Claim 4

a continuous, breathable polyurethane film having a thickness of about 1 to 30 mils adherently bonded to said fabric material; wherein said article is prepared by a method which comprises the steps of: a. applying a layer of film forming polyurethane solution to a carrier member; b. evaporating a portion of the solvent from said layer to form a polyurethane film on said carrier member; c. applying said fabric material to said polyurethane film; d. drying the resulting composite structure to cause the formation of a unitary breathable article; and e. stripping said carrier member from said breathable article.

Claim 5

a first film comprising a continuous, breathable polymer film adherently bonded to the fabric material, and

Claim 6

a second film comprising a continuous, breathable polyurethane film adherently bonded to said first film; wherein the total polymer film thickness is in the range from about 1 to 30 mils; said article prepared by a method which comprises the steps of: a. applying a first coating of a solution of a film-forming flexible polyurethane to a carrier member; b. evaporating at least a portion of the volatile constituents of said first coating whereby the remaining constituents form a solidified film which is strippably adherent to said carrier member; c. applying a second coating of a film-forming polymer to said first coating to form a permanent bond therewith; d. laying said fabric material on said second coating to interlock the fabric therewith; e. evaporating the volatile constituents of the resulting composite to cause the formation of a unitary breathable article; and f. stripping said carrier member from said breathable article.

Claim 7

The method according to claim 2 wherein the carrier member is stripped from the unitary article.

Claim 8

applying a fabric material to said polyurethane film; and

Claim 9

stripping said carrier member from the polyurethane film.

Claim 10

applying a second coating of a film-forming polymer to said first coating to form a permanent bond therewith;

Claim 11

laying a fabric material on said second coating to interlock the fabric therewith; and

Claim 12

drying the resulting composite structure to cause the formation of a unitary breathable article wherein the polyurethane coating thickness is in the range of about 1 to 30 mils.

Claim 14

evaporating the volatile constituents of the resulting composite to cause the formation of a unitary, breathable article having a total polymer coating thickness in the range of about 1 to 30 mils.

Claim 15

The method according to claim 4 wherein the carrier member is stripped from the unitary article.

Claim 16

The method of claim 4 wherein said second coating is a solution of a film-forming flexible polyurethane.

Claim 17

The method of claim 6 wherein said first and second coatings comprise a solution of a film-forming, flexible polyesterurethane dissolved in a mixture of dimethylformamide, toluene and methyl ethyl ketone.

Claim 18

A polyurethane film produced by the process of claim 1.

Claim 19

A polymer coated fabric article consisting essentially of:

Claim 20

A polymer coated fabric article consisting essentially of:

Claim 21

The article of claim 10 having a film of carrier material strippably bonded to said second film.

Claim 22

The article of claim 10 wherein said first film is a polyurethane film.

Claim 23

The article of claim 12 wherein said fabric material Is cotton.

Claim 24

The article of claim 12 wherein said fabric material is open-cell, foamed polyvinyl chloride.

Claim 25

The article of claim 12 wherein said first and second films are polyesterurethanes.