Title of Invention	"ELASTIC COMPOSITE STRUCTURE AND A METHOD FOR FABRICATING AN ELASTIC COMPOSITE STRUCTURE"
Abstract	An elastic composite structure, comprising: a surface layer comprising an elastomer system comprising at least one of a palyurethane resin, a polyurethane dispersion, or a silicone-based elastomer material; a mechanically durable re inforcer system layer comprising an elastic fabric, weave or knit structure including a flexible hybrid yarn and an elastic protecting matrix for the re inforcer system layer, the elastic protecting matrixcamprising an elastic and soft elastomer matrix at least partially coating/impregnating the fabric, weave or knit structure of the reinforcer system layer.

Title of Invention

"ELASTIC COMPOSITE STRUCTURE AND A METHOD FOR FABRICATING AN ELASTIC COMPOSITE STRUCTURE"

Abstract

An elastic composite structure, comprising: a surface layer comprising an elastomer system comprising at least one of a palyurethane resin, a polyurethane dispersion, or a silicone-based elastomer material; a mechanically durable re inforcer system layer comprising an elastic fabric, weave or knit structure including a flexible hybrid yarn and an elastic protecting matrix for the re inforcer system layer, the elastic protecting matrixcamprising an elastic and soft elastomer matrix at least partially coating/impregnating the fabric, weave or knit structure of the reinforcer system layer.

Full Text	Elastic composite structure The invention relates to an elastic composite structure, which is intended for use as a flexible, pliable and thin film structure in the manufacture of a 2- or 3-dimensional product, particularly for providing mechanical protection against cutting, puncturing and/or the like. The above type of elastic composite structures can be exploited e.g. in textile products for applications relating to health service and health care industry, as well as in a number of other con-texts. In reference to the prior art, e.g. Patent publications EP 0,318,415, US 5,230,937, US 3,974,320, US 5,447,5 94, US 4,338,370, and JP 6278247 disclose structures, which are based on fabric or non-woven constructed plies of material. All of the above are inadequate in terms of their functions, especially due to their lack of strain or stretching property, and hence inapplicable for the manufacture of products which particularly require elasticity. The reason for this is that the fabric or non-woven structures used in such products are only capable of providing pliable or flexible constructions, which are not, however, actually stretchable. The foregoing applies also largely to the solutions disclosed in Patent publications JP 62297333, JP 11172860, and JP 1096227, all of which are not necessarily provided with a so-called fabric or non-woven structure as a reinforcement but, for example, with carbon fiber systems or the like. Even these solutions cannot enable the manufacture of a 2- or 3-dimensional elastic product, since the discussed solutions are only capable of producing pliable structures. All the foregoing solutions may be able to produce even highly flexible structures, yet incapable of producing structures which would be uni-, 2 not to mention bi- or triaxially stretchable, as required by elasticity. The prior art further discloses the implementation of structures provided especially with a fabric-based reinforcement structure, e.g. as set forth in Patent publications WO 9200343 or JP 60259682. Even at its best, the strain provided by these solutions is less than 36%, which restricts significantly the usefulness of such solutions in the manufacture of products requiring special elasticity. The inadequate strain properties and high module of elasticity result from and are based on the fact that the fabric structures used in connection therewith are consistent with traditional technology. Thus, a sufficient elasticity is not provided thereby, since in practical applications, particularly with regard to the demands of health care industry, the minimum requirement for elasticity is easily about 100%. It is an object with an elastic composite structure of this invention to provide a decisive improvement: over the foregoing problems and, thus, to raise substantially the current state of the art. In order to carry out this objective, the elastic composite structure of the invention is principally characterized by what is set forth in the characterizing sections of the two independent claims directed thereto. The most important benefits gained by an elastic composite structure of the invention include the simplicity of its construction and manufacture, which enables the manufacturing of products with very high elasticity, yet provided with sufficiently good mechanical strength properties, particularly against puncturing, cutting and/or the like. The inventive elastic composite structure is optionally feasible with a wide variety of constructions, the reinforce- 3 ment system included therein being first of all constructible as a fabric, weave or knit structure made from a hybrid yarn, or else as an oriented flake reinforcement structure made from laminated flakes. In a preferred embodiment, the inventive fabric, weave or knit structure, shielded e.g. with a particularly elastic protective matrix, makes use of a hybrid yarn wound from rigid and elastic polymer fibers, thus effecting the maximization of an elasticity resource between friction points in a fabric, weave or knit structure. The inventive construction is also feasible by using one or more hard polymer layers, which is also integrally provided with an elastomer matrix for creating an elastic structure. It is further possible to exploit the invention as so-called combination structures by providing the same with both fabric-, weave- or knit-structured and laminate-structured reinforcement layers along with an elastomer matrix. Thus, the inventive elastic composite structure offers a solution, which differs essentially and favourably from traditional solutions and which is applicable even in highly demanding conditions, e.g. in garments worn in the context of hospital hygiene as such, without separate and multilayer solutions dressed on top of each other. The invention will now be described in detail with reference made to the accompanying drawings, in which figs, la and lb show a few preferred principles for an elastic composite structure of the invention, regarding particularly a knit-structured reinforcement system. 4 figs. 2a-2c show a few optional constructions for an elastic composite structure of the invention, regarding particularly a fabric-, weave- or knit-structured reinforcement system, figs. 3a-3c show further a few preferred optional solutions for an elastic composite structure of the invention, regarding particularly a reinforcing flake-structured reinforcement system, figs. 4a-4d show further preferred embodiments for an elastic composite structure of the invention in the way of so-called combination structures , and figs. 5a and 5b show further a few preferred constructions for an elastic composite structure of the invention, which have been produced by means of certain types of manufacturing techniques. The invention relates to an elastic composite structure, which is intended for use as a flexible, pliable and thin film structure in the manufacture of a 2- or 3-dimensional product, particularly for providing mechanical protection against cutting, puncturing and/or the like. The composite structure comprises firstly an elastomer system 1, which is constituted by one or more qualitatively different PUR- (polyurethane resin), PUD- (polyurethane dispersion), SI- (silico-ne)based elastomer materials and/or the like, and secondly by a mechanically durable reinforcer system 2, such as a fabric, weave or knit structure 2a made from one or more flexible hybrid yarns, an oriented 5 flake reinforcement structure 2c made from laminated flakes y, and/or the like. In a particularly preferred embodiment, a fabric structure, or the type of knit structure 2 depicted by way of example in figs, la and lb, included in the reinforcement system of a composite structure, is manufactured from a hybrid yarn L wound from rigid and elastic polymer fibers L1, L2, such as liquid crystal polymer (LCP) and elastane fibers, particularly for the maximization of an elasticity resource x between friction points fp present in the fabric, weave or knit structure 2; 2a. This way, it is even possible to achieve a strain of e.g. 500% between the friction points. The hybrid yarn L is also relaxable e.g. by the application of heat, whereby the threaded multifilament structure thereof retains its carriage more effectively and provides the knit stitch with a proportional specific elasticity which is better than that obtained with a non-relaxed yarn. The manufacture of a hybrid yarn can be effected by using various fiber materials and systems, such as organic and inorganic fibers, mono- or multifilaments, for a variety of ultimate properties. A knit structure constituted by the hybrid yarn L may be "overelastic" prior to coating, in spite of which, ¦ since the knitting loses some of its elasticity in the coating process, it is preferable that the hybrid yarn and the knitting be provided with as much of elasticity resource as possible in the above-described fashion . Naturally, a hybrid yarn can also be used for producing fabrics, weaves or the like. In a preferred application, especially in reference to the embodiments depicted in figs. 2a-2c, a fabric 2; 2a' or knit structure 2a included in the reinforcement system of a composite structure is precoated/-impreg- 6 nated partially or entirely with an elastic and soft elastomer matrix 2b, which, at a strain of 100%, has a modulus of elasticity of 1.0 Mpa or less, particularly for protecting the hybrid yarn L and the friction points fp of the fabric, weave or knit structure 2; 2a, or for retaining the optimal elasticity feature of the fabric, weave or knit structure by forming the composite structure's actual surface layer 1 on top of the soft elastomer matrix 2; 2b. In a further preferred embodiment, the elastomer matrix 2; 2b of the fabric 2a; 2a' , weave or knit structure 2a is fabricated on a multicomponent principle by firstly pretreating the fabric, weave or knit structure locally or entirely with a first component, the fabric, weave or knit structure being secondly further coated with a blend of components, such as by dipping, spraying and/or in a like manner, by using a blend of components containing a second and third component, whereby, during the coating process, the second component has reacted with the first component so as to produce a soft and elastic matrix 2; 2b around/on top of the fabric, weave or knit structure 2; 2a, and the third component has produced a mechanically more durable surface layer 1 on top. of the soft elastomer matrix. In this context, the first component may comprise e.g. a prepolymer, the second component may be a cross-linker or a chain extender/former, and, furthermore, the third component can be a neutralized, inert poly-/elastomer. Naturally, the above type of composite structure can also be prepared from a fabric, a weave or the like by coating as described above. The composite structure has a reinforcer content in the matrix preferably within the range of 5-95% by volume. With an optimized 7 structure, it is possible to attain similar elasticity properties both in lengthwise and crosswise directions of the structure. This way, it is possible to vary the elasticity feature of a structure even over the range of 100%-1500%. On the other hand, the invention relates to an elastic composite structure, which is intended for use as a flexible, pliable and thin film structure in the manufacture of a 2- or 3-dimensional product and which comprises a reinforcement system 2 for mechanically ¦reinforcing the same against cutting, puncturing and/or the like. The reinforcement system 2 for a composite structure of the invention is prepared as a flake reinforcement system 2c, consisting of hard organic and/or inorganic materials and having its flakes y arranged as one or more hard polymer layers . and, which contain an elastomer matrix 2; 2b adapted to provide the elastic structure with an integral composition. In this context, reference is made especially to figures 3a-3c, all of which nevertheless include also the actual surface structure 1. In a further preferred embodiment, the flake reinforcement for a composite structure of the invention is manufactured from a hard organic and/or inorganic material, having a surface area which is preferably > 2 mm2 and a thickness which is within the range of 0,02-1 mm, preferably by laminating from one or more hard polymer layers and by providing the laminated structure preferably also with extra reinforcements, such as an extremely thin and dense non-woven or fabric reinforcer or the like. Preferred applications for this type of arrangement include e.g. the following solutions, wherein the flake reinforcement system 2; 2c is designed as an integral and comprehensive mechanical protective 8 layer, in which one or more structural layers of the flake reinforcement system are established: - by applying the flakes y with mechanical and/or manual orientation to the surface of an elastomer coating 1; - by applying the flakes y to the surface of an elastomer coating 1 electrostatically by spraying along with the soft elastomer coating 2; 2b; - by applying the flakes y with free orientation to the surface of an elastomer 1; or by applying the flakes y electrostatically or pneumatically so as to locate the same as desired to constitute a desired type of orientation layer 2c; 2c" prior to a subsequent elastomer coating 1, this application being depicted especially in figure 5a. Referring especially to what is described above,, orientation of the flakes y is most preferably carried out electrostatically in such a way that the flakes y have been polarified for a desired orientation by using, as an orientation pattern, a so-called imbricate structure or the like as shown e.g. in figures 3a or 3b, or else a free orientation 2c; 2c' as shown e.g. in figure 3c. In the preferred embodiments shown especially in figures 4a-4d, the reinforcement system 2 included in a composite structure has been prepared from a combination of reinforcements, comprising the fabric, weave and knit structure 2a and the flake reinforcement layers 2c. As a further preferred application, the flake reinforcement composition 2c is attached in this type of embodiment to the fabric, weave or knit structure 2a by means of an anchoring technique, the flake reinforcement being treated with a first component and the fabric, weave or knit structure, respectively, either 9 comprehensively or locally, with a second component for providing a desired adhesion between the fabric, weave or knit structure and the flake reinforcement at a desired location. In particular reference to the construction shown in figure 5b, a flake reinforcement system 2c; 2c' is provided on top of a fabric, weaved or knitted structural layer 2a, coupled with an elastomer coating l, so as not to restrain the elasticity of the fabric, weaved or knitted structural layer, by the application of a multicomponent principle or the like, the flake reinforcement being treated with a third component, which does not provide an adhesion with the fabric, weave or knit structure 2a, or with a yarn L used therein. It is obvious that the invention is not limited to the applications described or depicted above but, as disclosed in the following examples, it can be applied in most diverse variations. Thus, particularly cutting proof structures as shown especially in figures 2a-2c, as well as puncture-proof structures as shown especially in figures 3a-3c, or else both cutting- and puncture-proof structures as shown in figures 4a-4c may of course be prepared by the application of most diverse manufacturing techniques, e.g. in such a way that such structures are pre-designed with a certain type of surface texture, such as groove patterns, nodule patterns or the like. In addition, the use of suitable manufacturing techniques, such as electrostatic coating, also enables the preparation of perfectly three-dimensional products, such as gloves or the like, which additionally provide a so-called perfect fit in such a way that, instead of tubular forms, the manufacturing process is set to produce structures having cross-sections which vary in the longitudinal direction thereof. Furthermore, the type 10 of elasticity principles depicted particularly in figures 2a and 2b will be fulfilled also in the case of fabric-, weave or web-structured texture structure by using a twisted hybrid yarn. 11 WE CLAIM: An elastic composite structure, comprisings a surface layer comprising an elastomer system comprising at least one of a polyurethane resin, a polyurethane dispersion, or a silicone-based elastomer material; a mechanically durable reinforcer system layer comprising an elastic fabric, weave or knit structure comprising a flexible hybrid yarn and an elastic protecting matrix for the reinforcer system layer, the elastic protecting matrix comprising an elastic and soft elastomer matrix at least partially coating/impregnating the fabric, weave or knit structure of the reinforcer system layer, 2. The composite structure as claimed in claim 1, wherein the structure is a flexible, pliable thin structure. 3. The composite structure as claimed in claim 1, wherein the structure is operative in the manufacture of a 2—or 3-dimensional product. 4. The structure as claimed in claim 1, wherein the structure provides mechanical protection against cutting and puncturing. 12 5. The composite structure as claimed in claim 1, wherein the soft elastomer matrix protects the hybrid yarn and the friction points of the fabric, weave or knit structure. 6. The composite structure as claimed in claim l, wherein the soft elastomer matrix retains a maximum elasticity feature of the fabric, weave or knit structure. 7. The structure as claimed in claim 1, wherein the reinforcer system comprises an oriented flake reinforcement structure com prising laminated flakes. 8. The composite structure as claimed in claim 7, wherein the flakes comprise at least one of hard organic or inorganic materials, and wherein the flakes are arranged as one or more hard polymer layers comprising an elastomer matrix adapted to provide the elastic structure with an integral composition. 9. The composite structure as claimed in claim 8, wherein the flakes are polarified for a desired orientation by using, as an orientation pattern, an imbricate structure, or a free orienta tion . 10. The composite structure as claimed in claim 7, wherein the flake reinforcement is treated with a first component and the 13 fabric weave or knit structure, is treated comprehensively or locally with a second component for providing a desired adhesion between the fabric, weave or knit structure and the flake reinforcement at a desired location. 11 . The composite structure as claimed in claim 10, wherein the flake reinforcement system is provided on top of the fabric? weave or knitted structural layer. 12. The composite structure as claimed in claim 11, wherein the flake reinforcement system does not block the elasticity of the fabric, weave or knitted structural layer. 13. The composite structure as claimed in claim 11, wherein the flake reinforcement system is provided by application of a multicomponent principle, and wherein the flake reinforcement is treated with a third component that does not adhere to the fabric, weave or knit structure, or with a yarn used therein. 14. The composite structure as claimed in claim 1, wherein the hybrid yarn comprises rigid fibers and elastic fibers. 15. The composite structure as claimed in claim 14, wherein the elastic polymer fibers comprise elastane fibers. 14 16. The composite structure as claimed in claim 15, wherein the rigid polymer fibers comprise liquid crystal polymer. 17. The composite structure as claimed in claim 1, wherein the elastic polymer fibers maximize an elasticity resource between friction points present in the fabric , weave or knit structure. 18. The composite structure as claimed in claim 7. wherein the flake reinforcement system comprises an integral and comprehensive mechanical protective layer, and wherein the flakes are applied with mechanical and/or manual orientation to the surface of an elastomer coating, applied to the surface of an elastomer coating electrostatically along with the soft elastomer coating, applied with free orientation to the surface of an elastomer, or applied electrostatically or pneumatically so as to locate the flakes as desired such that the flakes, constitute a desired type or orientation layer prior to a subsequent elastomer coating. 19. A method of fabricating an elastic composite structure, comprising! at least locally pretreating a fabric, weave or knit structure with a first component comprising a prepolymer; and coating the fabric, weave or knit structure with a blend of a second component comprising a cross-linker and a third compo- 15 nent comprising a neutralized, inert poly/elastomer, whereby during the coating process the second component reacts with the first component so as to produce a soft and elastic matrix around/on top of the fabrics weave or knit structure, and whereby the third component produces a mechanically durable surface layer on top of the soft elastomer matrix. 20. The method as claimed in claim 19, wherein the coating is carried out by dipping or spraying. 21. The method as claimed in claim 19, wherein the reinforcer system comprises an oriented flake reinforcement structure comprising laminated flakes, and wherein the flakes are arranged as one or more hard polymer layers having an elastomer matrix adapted to provide the elastic structure with an integral composition. 22. The method as claimed in claim 19, wherein the reinforcer system comprises an oriented flake reinforcement structure comprising laminated flakes, the method additionally comprising: designing a flake reinforcement system as an integral and comprehensive mechanical protective layer comprising one or more structural layers of flake reinforcement system: applying the flakes with mechanical and/or manual orientation to the surface of an elastomer coating; applying the flakes to the surface of an elastomer coating electrostatically by spraying along with the soft elastomer coating; applying the flakes with free orientation to the surface of an elastomer; or applying the flakes electrostatically or pneumatically so as to locate the flakes as desired to constitute a desired type of orientation layer prior to a subsequent elastomer coating. 23. The method as claimed in claim 19, wherein the reinforcer system comprises an oriented flake reinforcement structure com prising laminated flakes, and wherein orientation of the flakes is carried out electrostatically such that the flakes are polari- fied for a desired orientation by using, as an orientation pat tern, an ambricate structure, or a free orientation. 24. The method as claimed in claim 19, wherein the rein- forcer system comprises an oriented flake reinforcement structure comprising laminated flakes, wherein a flake reinforcement compo sition is attached to the fabric, weave or knit structure by means of an anchoring technique and wherein the flake reinforce- 17 ment is treated with the first component and the fabric, weave or knit structure, is treated comprehensively or locally with the second component for providing a desired adhesion between the fabric, weave or knit structure and the flake reinforcement at a desired location. 25. The method as claimed in claim 24, wherein the flake reinforcement system is provided by application of a multicomponent principle and wherein the flake reinforcement is treated with a third component that does not adhere to the fabric, weave or knit structure, or with a yarn used therein. An elastic composite structure, comprising: a surface layer comprising an elastomer system comprising at least one of a palyurethane resin, a polyurethane dispersion, or a silicone-based elastomer material; a mechanically durable re inforcer system layer comprising an elastic fabric, weave or knit structure including a flexible hybrid yarn and an elastic protecting matrix for the re inforcer system layer, the elastic protecting matrixcamprising an elastic and soft elastomer matrix at least partially coating/impregnating the fabric, weave or knit structure of the reinforcer system layer.

Full Text

Elastic composite structure
The invention relates to an elastic composite structure, which is intended for use as a flexible, pliable and thin film structure in the manufacture of a 2- or 3-dimensional product, particularly for providing mechanical protection against cutting, puncturing and/or the like. The above type of elastic composite structures can be exploited e.g. in textile products for applications relating to health service and health care industry, as well as in a number of other con-texts.
In reference to the prior art, e.g. Patent publications EP 0,318,415, US 5,230,937, US 3,974,320, US 5,447,5 94, US 4,338,370, and JP 6278247 disclose structures, which are based on fabric or non-woven constructed plies of material. All of the above are inadequate in terms of their functions, especially due to their lack of strain or stretching property, and hence inapplicable for the manufacture of products which particularly require elasticity. The reason for this is that the fabric or non-woven structures used in such products are only capable of providing pliable or flexible constructions, which are not, however, actually stretchable. The foregoing applies also largely to the solutions disclosed in Patent publications JP 62297333, JP 11172860, and JP 1096227, all of which are not necessarily provided with a so-called fabric or non-woven structure as a reinforcement but, for example, with carbon fiber systems or the like. Even these solutions cannot enable the manufacture of a 2- or 3-dimensional elastic product, since the discussed solutions are only capable of producing pliable structures. All the foregoing solutions may be able to produce even highly flexible structures, yet incapable of producing structures which would be uni-,

2
not to mention bi- or triaxially stretchable, as required by elasticity.
The prior art further discloses the implementation of structures provided especially with a fabric-based reinforcement structure, e.g. as set forth in Patent publications WO 9200343 or JP 60259682. Even at its best, the strain provided by these solutions is less than 36%, which restricts significantly the usefulness of such solutions in the manufacture of products requiring special elasticity. The inadequate strain properties and high module of elasticity result from and are based on the fact that the fabric structures used in connection therewith are consistent with traditional technology. Thus, a sufficient elasticity is not provided thereby, since in practical applications, particularly with regard to the demands of health care industry, the minimum requirement for elasticity is easily about 100%.
It is an object with an elastic composite structure of this invention to provide a decisive improvement: over the foregoing problems and, thus, to raise substantially the current state of the art. In order to carry out this objective, the elastic composite structure of the invention is principally characterized by what is set forth in the characterizing sections of the two independent claims directed thereto.
The most important benefits gained by an elastic composite structure of the invention include the simplicity of its construction and manufacture, which enables the manufacturing of products with very high elasticity, yet provided with sufficiently good mechanical strength properties, particularly against puncturing, cutting and/or the like. The inventive elastic composite structure is optionally feasible with a wide variety of constructions, the reinforce-

3
ment system included therein being first of all constructible as a fabric, weave or knit structure made from a hybrid yarn, or else as an oriented flake reinforcement structure made from laminated flakes. In a preferred embodiment, the inventive fabric, weave or knit structure, shielded e.g. with a particularly elastic protective matrix, makes use of a hybrid yarn wound from rigid and elastic polymer fibers, thus effecting the maximization of an elasticity resource between friction points in a fabric, weave or knit structure. The inventive construction is also feasible by using one or more hard polymer layers, which is also integrally provided with an elastomer matrix for creating an elastic structure. It is further possible to exploit the invention as so-called combination structures by providing the same with both fabric-, weave- or knit-structured and laminate-structured reinforcement layers along with an elastomer matrix.
Thus, the inventive elastic composite structure offers a solution, which differs essentially and favourably from traditional solutions and which is applicable even in highly demanding conditions, e.g. in garments worn in the context of hospital hygiene as such, without separate and multilayer solutions dressed on top of each other.
The invention will now be described in detail with reference made to the accompanying drawings, in which
figs, la and lb
show a few preferred principles for an elastic composite structure of the invention, regarding particularly a knit-structured reinforcement system.

4
figs. 2a-2c
show a few optional constructions for an elastic composite structure of the invention, regarding particularly a fabric-, weave- or knit-structured reinforcement system,
figs. 3a-3c
show further a few preferred optional solutions for an elastic composite structure of the invention, regarding particularly a reinforcing flake-structured reinforcement system,
figs. 4a-4d
show further preferred embodiments for an elastic composite structure of the invention in the way of so-called combination structures , and
figs. 5a and 5b
show further a few preferred constructions for an elastic composite structure of the invention, which have been produced by means of certain types of manufacturing techniques.
The invention relates to an elastic composite structure, which is intended for use as a flexible, pliable and thin film structure in the manufacture of a 2- or 3-dimensional product, particularly for providing mechanical protection against cutting, puncturing and/or the like. The composite structure comprises firstly an elastomer system 1, which is constituted by one or more qualitatively different PUR- (polyurethane resin), PUD- (polyurethane dispersion), SI- (silico-ne)based elastomer materials and/or the like, and secondly by a mechanically durable reinforcer system 2, such as a fabric, weave or knit structure 2a made from one or more flexible hybrid yarns, an oriented

5
flake reinforcement structure 2c made from laminated flakes y, and/or the like.
In a particularly preferred embodiment, a fabric structure, or the type of knit structure 2 depicted by way of example in figs, la and lb, included in the reinforcement system of a composite structure, is manufactured from a hybrid yarn L wound from rigid and elastic polymer fibers L1, L2, such as liquid crystal polymer (LCP) and elastane fibers, particularly for the maximization of an elasticity resource x between friction points fp present in the fabric, weave or knit structure 2; 2a. This way, it is even possible to achieve a strain of e.g. 500% between the friction points. The hybrid yarn L is also relaxable e.g. by the application of heat, whereby the threaded multifilament structure thereof retains its carriage more effectively and provides the knit stitch with a proportional specific elasticity which is better than that obtained with a non-relaxed yarn. The manufacture of a hybrid yarn can be effected by using various fiber materials and systems, such as organic and inorganic fibers, mono- or multifilaments, for a variety of ultimate properties.
A knit structure constituted by the hybrid yarn L may be "overelastic" prior to coating, in spite of which, ¦ since the knitting loses some of its elasticity in the coating process, it is preferable that the hybrid yarn and the knitting be provided with as much of elasticity resource as possible in the above-described fashion . Naturally, a hybrid yarn can also be used for producing fabrics, weaves or the like.
In a preferred application, especially in reference to the embodiments depicted in figs. 2a-2c, a fabric 2; 2a' or knit structure 2a included in the reinforcement system of a composite structure is precoated/-impreg-

6
nated partially or entirely with an elastic and soft elastomer matrix 2b, which, at a strain of 100%, has a modulus of elasticity of 1.0 Mpa or less, particularly for protecting the hybrid yarn L and the friction points fp of the fabric, weave or knit structure 2; 2a, or for retaining the optimal elasticity feature of the fabric, weave or knit structure by forming the composite structure's actual surface layer 1 on top of the soft elastomer matrix 2; 2b.
In a further preferred embodiment, the elastomer matrix 2; 2b of the fabric 2a; 2a' , weave or knit structure 2a is fabricated on a multicomponent principle by firstly pretreating the fabric, weave or knit structure locally or entirely with a first component, the fabric, weave or knit structure being secondly further coated with a blend of components, such as by dipping, spraying and/or in a like manner, by using a blend of components containing a second and third component, whereby, during the coating process, the second component has reacted with the first component so as to produce a soft and elastic matrix 2; 2b around/on top of the fabric, weave or knit structure 2; 2a, and the third component has produced a mechanically more durable surface layer 1 on top. of the soft elastomer matrix.
In this context, the first component may comprise e.g. a prepolymer, the second component may be a cross-linker or a chain extender/former, and, furthermore, the third component can be a neutralized, inert poly-/elastomer.
Naturally, the above type of composite structure can also be prepared from a fabric, a weave or the like by coating as described above. The composite structure has a reinforcer content in the matrix preferably within the range of 5-95% by volume. With an optimized

7
structure, it is possible to attain similar elasticity properties both in lengthwise and crosswise directions of the structure. This way, it is possible to vary the elasticity feature of a structure even over the range of 100%-1500%.
On the other hand, the invention relates to an elastic composite structure, which is intended for use as a flexible, pliable and thin film structure in the manufacture of a 2- or 3-dimensional product and which comprises a reinforcement system 2 for mechanically ¦reinforcing the same against cutting, puncturing and/or the like. The reinforcement system 2 for a composite structure of the invention is prepared as a flake reinforcement system 2c, consisting of hard organic and/or inorganic materials and having its flakes y arranged as one or more hard polymer layers . and, which contain an elastomer matrix 2; 2b adapted to provide the elastic structure with an integral composition. In this context, reference is made especially to figures 3a-3c, all of which nevertheless include also the actual surface structure 1.
In a further preferred embodiment, the flake reinforcement for a composite structure of the invention is manufactured from a hard organic and/or inorganic material, having a surface area which is preferably > 2 mm2 and a thickness which is within the range of 0,02-1 mm, preferably by laminating from one or more hard polymer layers and by providing the laminated structure preferably also with extra reinforcements, such as an extremely thin and dense non-woven or fabric reinforcer or the like.
Preferred applications for this type of arrangement include e.g. the following solutions, wherein the flake reinforcement system 2; 2c is designed as an integral and comprehensive mechanical protective

8
layer, in which one or more structural layers of the flake reinforcement system are established:
- by applying the flakes y with mechanical and/or
manual orientation to the surface of an elastomer
coating 1;
- by applying the flakes y to the surface of an
elastomer coating 1 electrostatically by spraying
along with the soft elastomer coating 2; 2b;
- by applying the flakes y with free orientation to
the surface of an elastomer 1; or
by applying the flakes y electrostatically or pneumatically so as to locate the same as desired to constitute a desired type of orientation layer 2c; 2c" prior to a subsequent elastomer coating 1, this application being depicted especially in figure 5a.
Referring especially to what is described above,, orientation of the flakes y is most preferably carried out electrostatically in such a way that the flakes y have been polarified for a desired orientation by using, as an orientation pattern, a so-called imbricate structure or the like as shown e.g. in figures 3a or 3b, or else a free orientation 2c; 2c' as shown e.g. in figure 3c.
In the preferred embodiments shown especially in figures 4a-4d, the reinforcement system 2 included in a composite structure has been prepared from a combination of reinforcements, comprising the fabric, weave and knit structure 2a and the flake reinforcement layers 2c.
As a further preferred application, the flake reinforcement composition 2c is attached in this type of embodiment to the fabric, weave or knit structure 2a by means of an anchoring technique, the flake reinforcement being treated with a first component and the fabric, weave or knit structure, respectively, either

9
comprehensively or locally, with a second component for providing a desired adhesion between the fabric, weave or knit structure and the flake reinforcement at a desired location.
In particular reference to the construction shown in figure 5b, a flake reinforcement system 2c; 2c' is provided on top of a fabric, weaved or knitted structural layer 2a, coupled with an elastomer coating l, so as not to restrain the elasticity of the fabric, weaved or knitted structural layer, by the application of a multicomponent principle or the like, the flake reinforcement being treated with a third component, which does not provide an adhesion with the fabric, weave or knit structure 2a, or with a yarn L used therein.
It is obvious that the invention is not limited to the applications described or depicted above but, as disclosed in the following examples, it can be applied in most diverse variations. Thus, particularly cutting proof structures as shown especially in figures 2a-2c, as well as puncture-proof structures as shown especially in figures 3a-3c, or else both cutting- and puncture-proof structures as shown in figures 4a-4c may of course be prepared by the application of most diverse manufacturing techniques, e.g. in such a way that such structures are pre-designed with a certain type of surface texture, such as groove patterns, nodule patterns or the like. In addition, the use of suitable manufacturing techniques, such as electrostatic coating, also enables the preparation of perfectly three-dimensional products, such as gloves or the like, which additionally provide a so-called perfect fit in such a way that, instead of tubular forms, the manufacturing process is set to produce structures having cross-sections which vary in the longitudinal direction thereof. Furthermore, the type

10
of elasticity principles depicted particularly in figures 2a and 2b will be fulfilled also in the case of fabric-, weave or web-structured texture structure by using a twisted hybrid yarn.

11
WE CLAIM:
An elastic composite structure, comprisings
a surface layer comprising an elastomer system comprising at least one of a polyurethane resin, a polyurethane dispersion, or a silicone-based elastomer material;
a mechanically durable reinforcer system layer comprising an elastic fabric, weave or knit structure comprising a flexible hybrid yarn and
an elastic protecting matrix for the reinforcer system layer, the elastic protecting matrix
comprising an elastic and soft elastomer matrix at least partially coating/impregnating the fabric, weave or knit structure of the reinforcer system layer,
2. The composite structure as claimed in claim 1, wherein the
structure is a flexible, pliable thin structure.
3. The composite structure as claimed in claim 1, wherein the
structure is operative in the manufacture of a 2—or 3-dimensional
product.
4. The structure as claimed in claim 1, wherein the structure provides mechanical protection against cutting and puncturing.

12
5. The composite structure as claimed in claim 1, wherein the soft elastomer matrix protects the hybrid yarn and the friction points of the fabric, weave or knit structure.
6. The composite structure as claimed in claim l, wherein the soft elastomer matrix retains a maximum elasticity feature of the fabric, weave or knit structure.
7. The structure as claimed in claim 1, wherein the reinforcer
system comprises an oriented flake reinforcement structure com
prising laminated flakes.
8. The composite structure as claimed in claim 7, wherein the
flakes comprise at least one of hard organic or inorganic
materials, and wherein the flakes are arranged as one or more
hard polymer layers comprising an elastomer matrix adapted to
provide the elastic structure with an integral composition.
9. The composite structure as claimed in claim 8, wherein the
flakes are polarified for a desired orientation by using, as an
orientation pattern, an imbricate structure, or a free orienta
tion .
10. The composite structure as claimed in claim 7, wherein the flake reinforcement is treated with a first component and the

13
fabric weave or knit structure, is treated comprehensively or locally with a second component for providing a desired adhesion between the fabric, weave or knit structure and the flake reinforcement at a desired location.
11 . The composite structure as claimed in claim 10, wherein the flake reinforcement system is provided on top of the fabric? weave or knitted structural layer.
12. The composite structure as claimed in claim 11, wherein the flake reinforcement system does not block the elasticity of the fabric, weave or knitted structural layer.
13. The composite structure as claimed in claim 11, wherein
the flake reinforcement system is provided by application of a
multicomponent principle, and wherein the flake reinforcement is
treated with a third component that does not adhere to the
fabric, weave or knit structure, or with a yarn used therein.
14. The composite structure as claimed in claim 1, wherein the
hybrid yarn comprises rigid fibers and elastic fibers.
15. The composite structure as claimed in claim 14, wherein the elastic polymer fibers comprise elastane fibers.

14
16. The composite structure as claimed in claim 15, wherein the
rigid polymer fibers comprise liquid crystal polymer.
17. The composite structure as claimed in claim 1, wherein the
elastic polymer fibers maximize an elasticity resource between
friction points present in the fabric , weave or knit structure.
18. The composite structure as claimed in claim 7. wherein the flake reinforcement system comprises an integral and comprehensive mechanical protective layer, and wherein the flakes are applied with mechanical and/or manual orientation to the surface of an elastomer coating, applied to the surface of an elastomer coating electrostatically along with the soft elastomer coating, applied with free orientation to the surface of an elastomer, or applied electrostatically or pneumatically so as to locate the flakes as desired such that the flakes, constitute a desired type or orientation layer prior to a subsequent elastomer coating. 19. A method of fabricating an elastic composite structure, comprising!
at least locally pretreating a fabric, weave or knit structure with a first component comprising a prepolymer; and
coating the fabric, weave or knit structure with a blend of a second component comprising a cross-linker and a third compo-

15
nent comprising a neutralized, inert poly/elastomer, whereby during the coating process the second component reacts with the first component so as to produce a soft and elastic matrix around/on top of the fabrics weave or knit structure, and whereby the third component produces a mechanically durable surface layer on top of the soft elastomer matrix.
20. The method as claimed in claim 19, wherein the coating is carried out by dipping or spraying.
21. The method as claimed in claim 19, wherein the reinforcer system comprises an oriented flake reinforcement structure comprising laminated flakes, and wherein the flakes are arranged as one or more hard polymer layers having an elastomer matrix adapted to provide the elastic structure with an integral composition.
22. The method as claimed in claim 19, wherein the reinforcer system comprises an oriented flake reinforcement structure comprising laminated flakes, the method additionally comprising:
designing a flake reinforcement system as an integral and comprehensive mechanical protective layer comprising one or more structural layers of flake reinforcement system:

applying the flakes with mechanical and/or manual orientation to the surface of an elastomer coating;
applying the flakes to the surface of an elastomer coating electrostatically by spraying along with the soft elastomer coating;
applying the flakes with free orientation to the surface of an elastomer; or
applying the flakes electrostatically or pneumatically so as to locate the flakes as desired to constitute a desired type of orientation layer prior to a subsequent elastomer coating.
23. The method as claimed in claim 19, wherein the reinforcer
system comprises an oriented flake reinforcement structure com
prising laminated flakes, and wherein orientation of the flakes
is carried out electrostatically such that the flakes are polari-
fied for a desired orientation by using, as an orientation pat
tern, an ambricate structure, or a free orientation.
24. The method as claimed in claim 19, wherein the rein-
forcer system comprises an oriented flake reinforcement structure
comprising laminated flakes, wherein a flake reinforcement compo
sition is attached to the fabric, weave or knit structure by
means of an anchoring technique and wherein the flake reinforce-

17
ment is treated with the first component and the fabric, weave or knit structure, is treated comprehensively or locally with the second component for providing a desired adhesion between the fabric, weave or knit structure and the flake reinforcement at a desired location.
25. The method as claimed in claim 24, wherein the flake reinforcement system is provided by application of a multicomponent principle and wherein the flake reinforcement is treated with a third component that does not adhere to the fabric, weave or knit structure, or with a yarn used therein.
An elastic composite structure, comprising: a surface layer comprising an elastomer system comprising at least one of a palyurethane resin, a polyurethane dispersion, or a silicone-based elastomer material; a mechanically durable re inforcer system layer comprising an elastic fabric, weave or knit structure including a flexible hybrid yarn and an elastic protecting matrix for the re inforcer system layer, the elastic protecting matrixcamprising an elastic and soft elastomer matrix at least partially coating/impregnating the fabric, weave or knit structure of the reinforcer system layer.

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Patent Number

201227

Indian Patent Application Number

IN/PCT/2002/00618/KOL

PG Journal Number

08/2007

Publication Date

23-Feb-2007

Grant Date

23-Feb-2007

Date of Filing

07-May-2002

Name of Patentee

OY OMS OPTOMEDICAL SYSTEMS LTD

Applicant Address

MATALASALMENKUJA 1, FIN -00150 HELSINKI A CO.ORG.AND EXIT.

Inventors:

#	Inventor's Name	Inventor's Address
1	HATJASALO LEO	SARKINIEMENTIE 11 A 6 ,FIN-00170
2	RINKO,KARI	VIRONKATU 3C ,FIN-00170 HELSINKI

PCT International Classification Number

B 32 B 25/10

PCT International Application Number

PCT/FI00/00952

PCT International Filing date

2000-11-01

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	19992367	1999-11-03	Finland