Process of making synthetic suede

Claim 1

A method of continuously and simultaneously producing two separate rolls of a synthetic suede product which comprises the following sequential step: (a) continuously feeding two polyurethane films onto two separate preheated, endless silicone rubber molding bands, the outer surfaces of which are provided with a multiplicity of cavities, and forcing a major portion of each of said polyurethane films into said molding band cavities; (b) continuously feeding the thus treated polyurethane films into a nip formed by two rotating cylinders, while simultaneously feeding two separate webs of fibrous material into said nip in between the polyurethane films to provide substrates; (c) continuously compressing the resulting assembly in said nip at a temperature of from about 385° to 410° F. and at a pressure of from about 65 to 100 psi whereby the remaining portion of the polyurethane films become affixed to adjacent substrate material; (d) continuously passing the assembly compressed between molding bands into a cold water bath maintained at a temperature sufficiently cold to solidity any molten polyurethane feed material; (e) continuously stripping the assembly composed of two separate layers, each layer comprising a substrate and outward extending polyurethane fibers affixed thereto, from the molding band by passing the molding bands over a pair of rotating cylinders provided with an internal vacuum and gripping the separate layers with a pair of rotating cylinders covered with card clothing; and (f) continuously winding up two rolls of the stirpped layers having outwardly extending fibers affixed to the outer surfaces of the substrates and constituting said synthetic suede product.

Claim 2

A method of continuously and simultaneously producing two separate rolls of a synthetic suede product which comprises the following sequential step: (a) continuously feeding two polyurethane films onto two separate preheated, endless silicone rubber molding bands, the outer surfaces of which are provided with a multiplicity of cavities, and forcing a major portion of each of said polyurethane films into said molding band cavities; (b) continuously feeding the thus treated polyurethane films into a nip formed by two rotating cylinders, while simultaneously feeding two separate webs of fibrous material into said nip in between the polyurethane films to provide substrates; (c) continuously compressing the resulting assembly in said nip at a temperature of from about 385° to 410° F. and at a pressure of from about 65 to 100 psi whereby the remaining portion of the polyurethane films become affixed to adjacent substrate material; (d) continuously passing the assembly compressed between molding bands into a cold water bath maintained at a temperature sufficiently cold to solidity any molten polyurethane feed material; (e) continuously stripping the assembly composed of two separate layers, each layer comprising a substrate and outward extending polyurethane fibers affixed thereto, from the molding band by passing the molding bands over a pair of rotating cylinders provided with an internal vacuum and gripping the separate layers with a pair of rotating cylinders covered with card clothing; and (f) continuously winding up two rolls of the stirpped layers having outwardly extending fibers affixed to the outer surfaces of the substrates and constituting said synthetic suede product.