Method of making a textile substrate with a continuous coating of a mixture of polyester polyurethane and polycarbonate polyurethane

A process for forming a coated textile comprising:

• a. forming an aqueous polycarbonate polyurethane dispersion, wherein the polycarbonate polyurethane dispersion comprises a plurality of polycarbonate polyurethane particles and aqueous solution, wherein the polycarbonate polyurethane particles have an average particle size of less than about 1 micron;
• b. forming an aqueous polyester polyurethane dispersion, wherein the polyester polyurethane dispersion comprises a plurality of polyester polyurethane particles and aqueous solution, wherein the polyester polyurethane particles have an average particle size less than 5 microns;
• c. mixing the polycarbonate polyurethane dispersion and the polyester polyurethane dispersion together forming a physical mixture, wherein the physical mixture contains between about 5 and 35% by weight polycarbonate polyurethane dispersion and between about 65 and 95% by weight polyester polyurethane dispersion;
• d. coating the physical mixture onto a textile substrate having an inner side and an outer side, wherein the coating at least covers one side of the textile;
• and,
• e. drying the coated textile using heat, wherein the heat dries of at least a portion of the aqueous component of the physical mixture and causes the polycarbonate polyurethane particles and polyester polyurethane particles to at least partially melt and bind to each other forming a continuous coating.