Abstract: Protective articles that provide an unprecedented level of safety and comfort are made of a composite fabric in a continuous, one-step process. The composite fabric incorporates two or more dissimilar yarns or materials, such as thermoplastics, elastomers, metals and other materials not commonly viewed as textiles, each having dissimilar mechanical properties and characteristics that provide optimum protection against the threats of injury associated with a particular application. The continuous, one-step manufacturing process overcomes the disadvantages of the existing labor intensive, costly process of piecing together a protective article from a plurality of separate fabrics made of different materials. Thus, the invented process is both cost effective and minimizes the inefficient use of a heavy weight fabric in regions of the article where exceptional protection is not critical to avoid the accompanying loss of tactile sensitivity and increase in the stiffness and rigidity of the article.

Abstract: A composite yarn formed of melt-fusible thermoplastic fibers combined with selected other fibers and/or materials includes a containment barrier that encapsulates one or more core materials which may present a threat of contamination to workers and/or the environment. The composite yarn includes a core covered by an adhesive layer of thermoplastic material which forms a containment barrier, combined with one or more subsequent overlying layers of fibers wrapped or otherwise applied thereto using conventional yarn construction methods. In a preferred embodiment the core material is coated with a liquid adhesive, and preferably a polyester-based polyurethane which contains silicon grit, just prior to being wrapped with one or more layers of fibers which form the containment barrier. The cured and finished composite yarn is designed for knitting and weaving fabrics, or for otherwise forming cordage and non-woven products.

Abstract: The present invention is a composite layered protective fabric having an outer primary layer composed of an abrasive material and an inner primary layer composed of an inherently cut-resistant material positioned below the outer primary layer and when assembled into a garment is positioned proximate to the wearer's skin. In another preferred embodiment of the present invention, a secondary layer is added to the inner and outer layer framework. The secondary layer is composed of a material that provides additional protection against potential threats other than cuts, that increases comfort or that improves aesthetics. The invented composite fabric is continuously manufactured in a one-step process which plates the layers of yarn. Thus formed, the invented composite fabric can be formed into cut-resistant apparel and articles that provide a high level of protection against sharp objects.