CA2103402A1 - Improved composite yarn with thermoplastic component - Google Patents

Abstract

IMPROVED COMPOSITE YARN
WITH THERMOPLASTIC COMPONENT

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 is comprised of a core which is covered in an adhesive layer of thermoplastic material which forms a containment barrier, combined with one or more and subsequent overlying layers of fibers wrapped or otherwise applied thereto in conventional yarn construction methods. The finished composite yarn is designed for knitting and weaving fabrics, or for otherwise forming cordage and non-woven products. The composite yarn also is utilized to produce end products such as cut-resistant apparel for environments where workers are exposed to possibly contaminated products or where core materials in the yarn can damage the end product of manufacture.

Description

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l~ACKGE~OUND ~ SUI~ARY C)F THE PRE~ENT INVE~
1 he present invention is relatcd to cut-r~sistane yams and associa~ed fab~ics, col~d~e, o~ non wo~en products whic~ mAy be produced with the yarn. It is als~
relntcd to static d;ssipathe materials, materials reinforced for ltrength, and abrasion-rcsistant mato~ial~. Most partlcularly the prcs~nt in~ ention h rel~ted t~

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the abo~e products when contalnment of a core maten~tl ls reqllir~d due to thq potential ~or ha~td to ehe cmployee, product, or en~rironment lf ~he core maeeria~

is exposed.
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,. There has been signl~cant sctlvity in recent years with reBard to the ~anufiacture of yarns ~nd fabri~s for cut-resi~tant pro~ectivc app~rel. Many of these acti~itlcs deal with the u~ ~f stainless steel wlre in con,~uJlctlon v~ith various 6be~ to B~t~lill an op~imal bal~nce of cut resist~nc~ and ile~dblli~, couplcd with co~t of production.
tJ.S. Patent No. 4,3~d"4~9 to Byrn~s te~he~ the use oE a 10ngitudinally po~itioned wi~ strand co~ered with nram~d, and the numerou~ resultin~ advantages ~; oE s~lch wrapped wiro. One ~dYanlage ~5 supenor cue resistance perfonnance, when compared to UJoves formed of pure ar~mid. Byrncs ~Iso descr~bes ~mproved knitabillty on ~ conventional ~love lulltt~n~ mnchine, and Impro~ed dcx~erity of a glove knitted ~om such a w~re yarn.
U.S. Patent 4,470,251 tO Bettcher extends the teachings of the above~
, mentloned Byrn~ patent by illustr~tlng hvo pr~m~y dlscoveries. Firs~, tha~ two or m~ro smalhr ~ire stran~s yiold grcater ae~iblli~ ~hnn ono s~r~n~l, whlle allowing a i) ~ :, -, ~

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2~3~Q2 larger quantity oE wirc to be usecl, an~ the u~e o~ a longitu~lnatly po~itioned hbrous strand Jncorporated wlth the wire strands hlrther ~mproves ~e~le mo~ement.
Sccond, Bet~chet demonstrates that an ~uter coverin~ f~rmed of a polyamlde such as nylon improves the ~omfort of the glove to thc wearer.
KolmcslPlemmons, in U.S. Patents nu~nbered 4,83$, 01~ and 4,7~7,78g, teach the wrappin~ of arlnealed stalnless steel wire about a core ~ber; wr~pp~n~ the stran~s of v.~ire in opposing ~irections ~nd hlrther increas~n~ fiexibili~r of the fabric whil~s malntninln~ cl~ proteetion. KotmeslPlemmons nl30 documented a bfoad range of fibe~s th~t ~an loe used In th~ cor~ and outer wraps of thc composite yarn.
The cbtabl~shed prlor ~rt referenced here offer~ teaehing!l that have improv~d thc state of prot~ctive npparel. While each Is repres~ntst~vc of Improvenl~nt, th~ present invention extends tar beyond these p~ior tea~hin~s a~d ., demonstrate3 a novel and un~que approach whlch soh~es a serious and horetofore unaddrcssed Issue related tO the manufaeture of protec~he appaFcl. One previously unrecognlzed pro~lem 1~ the Fnct that In the use of wir~ ~omposito yarns, the wlro strands frequently bre~k, puncturlng the skln of the wearer, contamlnating val~ious m~nu~cturing and production operations, and e~posing the wearer to ~he possib~lity of dlsease. Wire will invariably ~ncture aEter repeated flexure ~nd uill penetr~to .

~he surface of any kno~vn composite yarn.
Th~ pr~sent In~entor ha~ dis~vered thnt the Inven-lon taught h~ro~n pro~des n method o~ c~ntalnlng w~r~ and olhor materlals such as ~berglass wb~n thes~ ma~er~als arc uscd as thc 3rarn CDre. To date thor~ has been n~ serhuc ..

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2~03~2 altempt by the Food and 1: rug A~ministrat;on (F~) or the U.S. r)eyartment oF
A~riculture (USl:)A) to climinate the usa o~ such materials ~ a yarn coro, but the issuc is volstile and v~l1 eventually nced ~o be resolvcd. The resolution may not ~e one which Industry 6nds acc~ptable or even practic~l.
Wlro and SberglAss are known to pro-~id~ sdditlonAI cut resistan~e to composit~ yarns by microscoplcally altet~ng the ~dgo of ~he cuttin~ surface. 7~1is is due ~o e~ceptional high density snd abra~iveness which dulls the edBe of any cutting instrumen~ or de~ce that contacts the material. ~Ire and fi~e~l~s~ abo sdd strength to n yarn. l'he m~terials ~re prehrre~ bccause of thc many beneits tbey add to a comp~site relative to tho cost. However, lhese same ma~olials ~re contr~ersial bec~use ~hey cann~t be allow~d to escape ~r~m the compo~ite y~rn Into the work place for cnv~ronmental and/or health rea~ons. ~o present im~ention pr~rides a composlte yarn and f~bric whlch m~y ~elcctlv~1y ~ncarporat~ t~vire and/or ~bor~las~ ancVor othor nec059nr~r but potentially hnrm~u~ mate~ials Into the basic yaln corc, btJt ~vhlch o~ers pro~ect~on lo the worker firom exposure to the Inaterials.
which mat~rlals may h~gment or spllnter and threaten the he~1th o~ the worker ~nd - `~
also ~amage thc end product.
Thc pre~cnt ~nvention prc~ldcs a novel method of forming a cont4~nment barri~t alound ~ single cornponcnt or multf~omponcnt core of such controvers;al and pvtentlally cont~minatlng m~terW5, ~nd subst~ntlally d~ereases th~ ~sk o~ ~heso contamlnatu belng role~sed. The ~oundation of the presen~ ln~rcntion i5 a compwltc prn whlch USeJ mell~ lble thermoplnstlcs to enc~psulnt6 nnd thercby ~, ~, .

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21 ~3~2 i~olate one or more coro mater~ls which Inay prescnt a throat ~f contamination to workers or the environn~ent. Thi!~ novel ya~ is basically comprised o~ one or more core materlals ~hich ~re covered In ~hermoplastics and additional layers of matcrials which form onc or more ~uter Govels. The con~bination i9 then hcat set j:, to hrm a fle~ible fiber barrier whjcl~ surrounds and en~rap9 thc un~af~ core.
The b~ier which contains the selec~ed core l8 creatcd by melt hslng a ~he~moplast~c mnte~al v~jth o~he~ cU~felin~ fiber pro~uc~ In ~uch a way that thoso undesJrable matèrials are trapped between a shroud oE ~s~d ~ber~ ~nd a Sber core. In othcr embodim~n~s, ~ate~ials whi¢h ~re longitudinall~ posltioned to ~rm the core are encapsulated in n continuous ~brous sheath w~th no a~hesion between thc ~h~ath and aJI inner corc yarn.
It ;s prehrrcd to ~rap w~re In a Fused 6ber lByer having a smooth outer sl~rFace whlch 15 unllkely to bond with subseguent outer covcr Inyers. Because wire itself h~s a smoo~h sur~acc unllkely to bond with thermoplastic, il is lmportant ~hat the core bond ~o ~he lhermnpla~ic and isolate ~he wire therebetwe~n; The comblnatiol~ bccomes a hi~hly effective containment ~ehicle th~t retains a high l~vel o~ ~c~dbility. whn~ the end prot~uc~ ~ucll nic a glove mny becomo sll~htly more rl~id after heat trea~inl3 to t~italn shnpe, the composite y~rn Is hlgllly D~iblo and can thercfore ~e easil~r kni~tod, wovcn, bralded, or otheru~se ~ormcd In~o a ~love or other proeluc~. ~ero are many di~ferent materials and- processing methods available to torm the ~omposlte yarn, dep~ndin~ on ~he on.l use desired.
C:Qnven~hnsl eover~n~ or wlrc~wrappln~ cqulpmcnt is most ~uitnblc to m~nufacture ~` ' '.
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`` ~-- 2103~2 th~ composi~e yarn. Other eq!lipm~nt may bc used as needed to preprocess materials which can later ~ wrapp¢d or used as wraps. Examples ar~ c~mmingl~
machines, twisting cquipment, and ~xtrudin~ machines.
The cor¢ of shc composite yarn is selected Erom a group of hbers or types oE
, other materials whlch may be spun, continuous, mul~ifilamcnt, Ot m~noffl~ment.
The core Is selectively comprised o a sin~le s~r~nd or multiple ~trand$ of single er type or a mixtllre of fiber ~rpes. The core structure lc virtu~Jly unllmlted and mag Includ¢ 6berglass, wirc strands, thermo-plastic~, andlor olh~r su~h c~ntr~vorsial materl~ls ~r comblnations of ~uch mater~als. The core structure m~y bo of a plur~Uty of such fibers combined by blend spinning, tvnSting, cxkusion or any other -method dc~med appropriato lo aeeomplish the deslred corc and end produc~.
S~eral pre~ously unknown b~neEits of yarns Inanufactured In ~ceordancc uith those methods h~vo been disc~ered. It h~s been found th~t abrasive~ su~h as vire or fiberglass perfo~n thelr ~unc~lon be~er when locked firmly in place. lhe ~unction of abr~sivw in cut reslst~nt yarns has been oxplalne~ a~ d~lllin~ the culting edge and thereby in~re~slng ~he p~rformsnce of the other hl~h stre~th fibers.
'Vhen u~r~ ig used, lt tontls to move away from ~he CuttiD6 ~d~e exposing more ~ .
t'iber to the thr~t. Whsn wiro is fus~d in place ~s wlth the present inverltion, it engases the cdge more dircctl~ an~ ;B more abrasive. I~ effecti~ely shields ~ubseq~lent lay~rs until thc hll abrasiw ef~ec~ is used. T~ls j5 also true with fiberglass. Flbe~glass is n~t cffective onee lt is ~mented and Ulls occurs quickly upon con~ct-wlth ~he cuttlng ed~e nnd durln~ normal fle~ e. By bondlng the ~la .~

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-- 21(~02 with l11e me~hods dcscnbed, ~t is less easily shattered. ~he ma~dmum abr~si~o ability is obt~ined by pJesen~ing the gia~ss as a uni~ied and ~Inmo~ng abrasive su~ce that is not easl~ shattered. By making these abrasi~es moro o~cct~ve, it is now po~sible to at~ain equ~l ~ut protection with a lower abrasive content o~ ~o ~ncrcas~ protecdon with ec~iual cont~nts.
When the cutt~n~ threat 1~ ~om a chopping blow as opposed to a slash~ng ~ovement, 1h~ presont In~ention 81so exhibits uniquo abilltie3. Tho fu~d Sb~rs of the ;nvention ar~ pulled in ~he directlt)n of the cutting edge thus Increasing the concentration of protecti~e fiber and abrasivcs in t}~0 threat ara. Tb~ lncrea~e~
the level of protect~on to this type of threat.
It ha~ also been found th~t this ITlethod of mamlf~cturing creates a yarn wlth Improved abDities lo ab~orb impacts and ~ribration of all types. ~s is due to th~
rcsU~ent properties prescnt in the compounds used for h~sin~ composito to~ether. Thi8 charactoristlc ls u~cful to dalnpen vibration and pro~ido a meusur~
of protection ~ono blunttrauma. ~ ;
l~e core conta~nment barrier has been foun~ more uso~ul In containing wire th~n orlgJnally bl!lieved. It wa~ bc1ievcd thnt lon~itundinnlly positioned stran~3 o~
~re should not exceed ,W2 ~nches diameter tluc ~n an increa~ed l~kelihoo~ o~
punctutlng thc cont2inment bartiet. Success wa~ found with longi~udin~l wire rands of .W6 in~h dlamc~cr without increasin~ ~he overall dlamotor to the ~nl~hed yarn. Thb ~IIOWS th~ uso o~ hoavler wlre strands with mllllm~l r1~k of barr~er . . - .
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Finally, it ha~ bcen obsesvcd ~hat ~mbodi~ents ha~nng c~res fotmed la~ely of m~lt Eusible thermoplastic~ become hollow af~r heat trefltn~¢nt. ~hese etnbodiments ~re very unique and exhibit improved ductility. ~his is in1ponant in apparel applic~tions wher~ w~arer com~ort Is Important.
In some embodim~nts, ralher than bond the core t~ the thermopl~tie, it is desirnble that the selected core i~ ne~t covered ~ith a layer oE ma~cri~l which creatu an inner core containment bnrrier separa~ing the core Erom tho ~urroundine ~1t~h~s1bl~ the~noplastics. Thl~ Is necess~ly t~ prcvent the eoro structu~e f~ombondin~ ur~th ~he thermoplastic~ and the~eby restricting ilex~ r. Core materialsthat ar~ particularly brlttl~ wlll dcterioratn qulckly 1~ not allowcd to move ~e~ly within such A shroud. Tnl~ inner core conlAlnment barri~r layer ma~ be o~ any materinl ~vhich h~s a highcr melt point than ~he lhennoplastics whlch surround it.
Using the heat~set method rather than li~uid internal coatin~, a pre~erred embodlment Includes a baslc core, arl~ around the circum~erence of the baslc corc, the ~rst layer of one or m~re strands o~ wire may ~e wrapp~d t~ provide a s~condcomponent to the ba~c core. The wi~e m~y be wrapped in ono direc~ion with onG
or more strands applled parallel to each other, or the ~nre mny bo twisted or comb~ne~ ~n ~ny oth~r known way. The wire may nlso be wrapped In oppo~ine directions relative ~o each other, with one stran~l bell~ clockwlse, and the othcr counterclockw~sc The pref~rred w~re is an annealed stainless steel 304 v~th a range of ,00~" diamet~r or smaller. T}le most pre~e~re~ ~s .004S" f~r a ~ingle ~p, or .003" for ~ double wr~p. Flner ~trnnds may be us~d when ~here i5 ~ ~omblned ~ .

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plu~ality of w~rG strands. In such embodiments, usin~ ~rire o~ .00~" clfamGtcr or mnre, wrapping is preferr~d. rhe wir~ wrapp~d about ~he ba~c core may bc wrapped ~t a pit¢h oE one to 10~ turns per inch as the embodiment r¢quires. It has been observed thnt the helic~l shape ~hich is thus formcd directs the u ~re's angle more to the center of ~he composite yarn ttructure. Thls becomes important when a wire strand fractures. Lon~itudinally positioned w~re strands tend to pr~ect a rfdd polnt when broken. Thls ri~id pn~nt is then 50 orien~d as to punctur~ the surfac~ whcn th~ yarn i8 ~e~ed and ls dimcult to wntaln.
Followlng applleation of the ~ire component and/or Ihe eontainment barrlcr, an ~dditlonal la~er to be added to the con~posite is selected ~om the ~oup of melt~
hlsi~le thermoplA~it~cs. These may be polypropylene; low, hlgh, or ultrn~high~del1sl~y polyethylen~; low-melt nylon polyam~d; or polyamid blends; or low-melt polyettets, A nut~lber of hlgher melt t~mpetature thermoplastics e~d5t whlch h~ve not bc~n ...
tested, but are believed to be ~pplicable for hiE~her tempelatu~e appllcations and embodlment~. Thi5 In~rer may be ~ppJled In several different ~4ays, Includlng wrapping, t~stlng, ~pinn~ng al~c~ut th~ core and ~he containnlent barr1cr; may bç ~ ~
longitudin~lly positioned with the core, extruded ove~ ~he cole, or blende~ with the i~-corc, commingle~ h thc ~orc, or any combination oE Ihese mcth~ds. The thermopl~tic~ also rn~y be ~pplie~ to the wire s~rands prior to wrapping the strands ar~und th~ b~sic core. ~he ~elected lne~hod of combinlng the thermoptaslic~
with tho w~rc Is depentlent upon the number and size ~f the wire s~rands beln~
utillzed. ThG wlro strand~ may ~e wrapped, twtstedl pa~ led, pnr~lleled and ' :

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wrapped with more the~moplastic, paralieled and ~4rappeci ~ntl~ v¢ry fine denlernon-thennoplastic, or the wire may be coated by means of any of the more comcntional co~in~ mcthods.
Sel~cted thennoplastics for this layer may be mono61amellt, multifilament, SpUIl or blended with other materials. rhe percentage of thelmoplastic conten~ In this layer 15 limited only to thsî which is necessary to propet~ly qont~ln and stabilize the un~erly;ng materials. When comblnlng w1lh the wir~ prior to wrapping lhe wirc ~round thc basic core, two bene~ts are attalned. Flrst, prior combining ~llow~ a,~ ~tcp to bc climinated in processing by not requirlng a ~epara~e wrapping oE
thcrmoplast~'c. Secondly, tho lhermoplasti~ is concentrated only in tho ~roa whlch surrQund th~ wlr~, leavln~ some un~us~d areas to Incrcss~ tho ~c~dbllity ~f the composlte. Some o~ ~he more effe tivc Ine~hods will be detailcd bolow.
., The next lager is the primary core cOnlainn~ent bRrri~r and is selocted h-om a broad group o synthetic or org~nlc maten'als Includi~g but not llmited to~
pobegter, nylon, aramid, high dcn~lty polyethylene, ultra hlgh molec~la~ wcight ex~ended chain polyothylene, such as ~lied's Spectra~, colton, wool, polycoteon,rayorl, ~oechsl C:elanese's P~IlM, Dupont's Tc~onTM, and blends. Tho e~ceptions - are thosc matcrlals which aro the same as thos~ to be contained, and matefials having melt points which are lower than the selected thcrmoplaslic. This layer s ~ serves ~e~etul funclions: -1~ It ~orms the layer oi. fiber ~vhlch 15 ~used with lhe underlyine adh~sivc l~y~r lo hrm a ~hroud. In cert~ln ombo~lments wrappod wlre is tho material to bo . .

21~4~)2 :` 11 contain~d and ~hls l~yer l~ utili~cd to ~use wi~h thc b~sic corc matcrisl around which the wire is wrapped. Thi~ results In ~ sandwich efhct that th~rou~hly traps the uAre in a ~e~ble cspsule or ~used fibrous material whic~ is almost impenet~abte.
~ ) In embodiments ~sing wrapped wirc, this shtoud ~unct~ons to prevent the uire ~o~n movlng a~ tl1o composite is heated. Th~ ~clectod ~ber must therefore be nf rcasona~ly hig~ lenacl~ d not gcnerally susc~ptible tn loss of ~trength atthe ~ushn temperature of the underh,ring then~oplastic.

3) Tbls la~r adds cut reslstance to the ~inished cnmposite yarn.

4) Thls layer se~v~s as a shroud whl~h ha~ ~ufficient thlckness to ab~tb the underlying m~lt~hu1blo polymcr and prevent the polymeF ~rom passi~g to the ~-~
outer wraps. This is o~ parti~ular importance when subs~qucnt outer covers must i~ .
be ~ble to function Independentiy of ~he c~re and ba1rier yarns. Indcpond~nt movement is sometilne~ necessnry primarny for ~exlbilit~, but also ~110~4s the perfonnance charactoristlcs of th~ yarn not to be impeded by en~rapment. It has ;~ been observed that yarns ~re more cut and/or abrasion resistant when Ule yarns arc nllowed to move ~eely wllh the cuttln~ or abr~dinu surface. Th}~ is ~mply lllustrated by obsennn~ tho rela~ive ease ~th ~vhioh a yarn m~y be cut u~d¢r ~enslon, VeFSUS one that i~ cu~ under less ~ension.
In a~dition t~ thc above hrlcti~n~, whton used in ~h~ wrapped wire embodtmenls, it is proferred that thi~ third l~yor b~ wrapped at the number of turns pcr Inch whkh provldel nn nngle ~g closo to 90 del~rces reJetlv~ ta tho wire ~5 foasible. Ne~r perp~ndhulnr anglos Qro opt~nlel to ~ w th~ 18h~d eompo~ite .~
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2l03~a2 ~ra~n to perfornl. Pres~nt en~bodiments havc attainod 70 deiqree ~n~ie at eight (~) tums per ~nch uslng 840 denier nylon. In other embodiments It is neco~i3i~ry to apply a tighter denier at a very high ran~c o~ turns per inch. This ;s par~icularly true where multiple ends of ~ire are wrapped in opposin~ directions. l'he turns p6r lnch must bo a comb~nation of optimal angle~, total encapsulation, densi~ ofthe layer and the ~ber's abillty to prcvcnt movement o~ the ~rç durln~ the heat cycl~. It sbould be noted that ~he type 304 alloy o~ st~tnl~s~ has a coefficient of t thennal expiansion cqual to 10.1 ~ p~r de~re~ rise In temp¢rature Fahrenhel~.
1~ th~ composfte is processed a~ 295 degrees Fahrenholt then a o~o-inch sectIon would normally e%pand to 1.00~26846". Whlle t~ amount o~ mcntement n~ny ~ppear smAII, It does have thc ablllty to deform the ~abrlc If not controllod. Tostlng has 3h~um that wire can push through the tbermopl~stlc l~yer as the w~r~ expandst dur;ng the heat cycle, and thls mol~enlent pre~ents a proper bond i~oln ~rming because thc thermopla6ti~s t~nd to cool more qulckly than wire, Tbi~ l~yer Ici¢ally shouid be wrapped with a comparable ran~e oF turns per inch as the underlying core using i~ yarn oir suf~c~ent weight or dian~e~e to provld~ complete coverage and denii3ity. H~wev~r, yal`ll5 ~rom 20 to 4800 denier m~y be used and may b~ applled f~om threo to 200 ~UJ'115 p~r Inch as the cmbodiment requires. This shr~ud layerma~r be on~ or more wraps In slnlilar or opposin~ ~irections relatlve to one another.
As with the baslc core, thl~ laver can be mal~é up of a multipllclty of ya~ns, depondin~ o~ the deslred ond cf~¢ct or product.

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`` 13 In the p~eferred em~odimcnts descll~ed bel~w, it will be sb~rious that the ~1 simpler methods and ysrn comblna~ions achieve the best rGsulls.
A ~nal, or ollter layer may be added. This oute~ l~er i~ of pa~ticular ', importance when ~ho undorlying layer is not capable o~ ~bsorbln~ the molten thermoplastic nnd preventin~ it ~om risin~ to the surface of th~ Snish product ~ .
~kno~4n as ~wet ou~"). The ~ber content of thls outcr layer may bo sol¢c~ed frDmthe sanle gtoup B5 the wiro.contairlment wrap. Therc may bo ono or more of thescoutcr wrap layer~ and cach may bc slmilar or ~issim~ar. The selected mat~rial wrap .~ may be of a slngle str~nd, multiple strands oE a single yarn or a multipliciey ~f d~f~ring yarn ~ib¢rc or typcs. This outer layer mny also be spun over thc ~i~ underlylng layers as with ~Ict~on spinnin~3 cqulpment.
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Wlth use of such overlying multiple layers lt Is pre~rred, but not requircd, that each o~ tho layers be wrapped In opposin~ dircctlons~ l'his method oE
wr~pl~lng In opposlnu dlrcctlc)ns 15 known ns counterbalarlclng and has the e~fect of maklng the yarn balanced, stralght, and with separate coverlns layers that tend to lock ~o~ether and do not easily ~ay.
The com~ined selectiotl o~yarn ~b~rs and type5 ~5 ~a~ed primarfly on tbc end u~e o~ the yarn, the fabric ol~ tho pro~lu~:t. Some of the m~rc common m~t~r~nl~ nrc nylon, p~lye.~ter, nrnmld. extcn~led'chnin polyethylene, rayon. cotton, or wool. Ho~cv~r, th~ f3~crst~pe~ may bc scl~c~d ~rom any of tlle ~ynthcti~ or n~turnl mat~rlals group. As~y onc o~ the lay~rs or wraps m~y sen/e any o~ the functlons of enh~nc~d cut tcslstanc~, abras~n sesl~tance, lmproved com~ort to tho ~ ~.

2:l~3~92 wearer, increased thermal pcr~o~mance, enhanced texture ~r handling ~pecial materials, impr~ved knltabili~, or other s~lch characteristics.
The hnished novel cumposite yarn is applica~le to knittin~, wcavit~g, ~raiding, h~Asting, ~r otherwise ~rmin8 into a ~esir~d fabric or product. Oncc the en~ product is prov~ded, ~he ~nal step o~ ~hermoplas~ic fusion generally takes plac~.
Treattnent tempera~ure~ and e~rposure times ~ill v~ry according t~ the characteristiu of lh~ thennoplastic" density oE the composite and th;ckness of t~e article manufactured. With glovesl ~or ex~mple, a ~ypical heat treating method s wouid m~ke us~ of a glovo doning machine whlch is dcsigned ~or preci~e tempcr~ture and e,np~suro time con~ol. Yarns may also be heat treated on the packa~e in a dry or ~vot yarn condition;n~ oven.

DESCRI~TIONS C)F 1~ l;)RAWl~GS
il~ Figures lA and lB, 2A, 2B and 2C, ~, ~1, and 6 are schçma~ic rcpresen~atiolls o~ var~ous cmbo~iments of the composite yarn; and ::
Figures 5 and 7 are ~ tive views of a glove made fron the com~
posite yarn.
~ Figures 8 and 9 illustrate further entodinents of a cc~posite yarn.
`~ DESCRIPTlC)~ OF PE~l~FERR~O ~MBO~IMENl`S
These de6ni~ions will be help~ul in identi~ing ~he various designations and functions oE tho dcscri~ood layers.

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(1) Basi~ Co~e: ~a~ be one or more longitu~inal mateT~als including all ~, thermopl~stic ~bcr~, and carbon fibers or olher po5~(ble~ colltam~nnte ~roups.
~as~c core may hAve thes,~t selected matcrials spun, wrappcd, twl~ted or coated over one or more longitudinal members.
(2) Inner Cote l ontainmen~ B~r~er This is an optional layer for us~ in those embodiments that req~lire separa~ion of ~h~ coro andadhesive layers. ~t may bG ~pun or wrnpp~d over the basie core. Selected matarials only exclude those contamlna~es of the bnslc core or msterinls with n~elt te~aperatures equAI to or lowor th~n thc thcrmaplas~lcs oE the heat processed embodimen~s.
(3) Adhesive layer: This layer may be ~sed as the only ~ourco of ~dhesive~ in t conJunctiorl ~itb adhesi~es in the basic eore, or not us~d at all whcn sufficient adhesi~n is avnilable from materials in the baslc coro. l`h~ layer mny ~c wr~pped, splln, coated, h~s~e~ or iiosit~oned longitudinally to th~
basi~ core or conta~nmcnt b~rrier layers.
(4) Primary C~ore C:ontainment Barrier: Prom the same yroup oEmaterial~ ;
selecled for the Inner core conta;nment bar~ier; may be wr~pped or spun over the Inner l~yen and ~e slngulnr of a plur~ r of yarns comblned in any S way, t5) C)uter Layers: Prom the same ~roup of contnlnment barr~er fi~ers: thi~ luyer -or 1uyerJ Is optlonnl to enllanco perhrnlanc¢ a~ nc~d~d.

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Looking ~rst ut Pigure lA, ~ first embodirnent is detailed ns baving ~ basic c~re 2~ i'ormed o~ 840 denier industrial gr~de ~ylon. A single wrap 2S o'. .0045"
diameter ~nne~led stainless wire is nppl~ed over core 20, npplied At approx~ma~ely ei~ht turns per in~h of c~ro length. ~rapped about this sl~lc w~re wrap 25 Is a loq~melt-tempcrature the~moplastic adhesive layer 30 oE a ~pc such as .OU6"
Shakespeare mono~lament ~1C 101~ ~erpolyamide Eorming a wire/thetmoplastic layer 3~. The thcrmoplastic 'aarr~er layer 30 is appliod over wire 2S at appro~rimateb 100 turn5 per tnch of w~re core 1en8th. A prtmary core co~alnment b~rrier, 3~ i5 ~pplicd in tho oppos~te diroctlon ~relative to the wlre/th~rmopla~tic Isy~r 32) an~ is prefer~bly formed o~ 84~ denle~ industrial grade nylon; again ~
wr~pped at approximately ~ht turns per inch of core or yarn length. A final outer a layer ~0 is cump~.ised o~ one strand, ~ pped in a direction opposite to the ~! und~rlyln~ laycr 35, or ~pproximatcly ei~ht wrap~ per Inch oE coro ~r yarn, formcd ~:~ of 840 den~er industr~al grade nylon.
While thls embodiment in Figure lA is one oE ~he b~sic approae~es, it -i c~mbincs ~he the~noplastic Eiber with the wire wrElp prlor ~o wrapping ~he wir~

around ~ho core. Thus th~ ~dhesi~e action o~,the thermoplastic is concentrated in the c~ilical area~. B~ wrapping lhe u~ire wl~h 840 denier nylon, tb~ wire and nylon inters~ct ~t nn optimal angle to ~ont~in the thermal expnnsioll of the wire while stUI
` I malntainin~ t~l~l covcr~g~ of the wire. T~st rcsulls of this cmbodtn~ent Indlcate that tb~ composite yarn is equally ~u~resistant to any ~ther kn~wn wire y~r~
product~, ~nd exhl~its n~ dotrlmental tigidi~ resultinF ~om thc unlq~ e , ~ . :
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2~ ~3'~2 en~apsula~ion of the wire.
Usin~ the samo b~sic st~uctu~e of Inyers shown in Figure i~, snother embociiment shown in Fi~ure lB fe~tures a core ma~er~al 20' o~ 120() denier extended chain poly¢~hylene wrappcd with a strand ~5' of .0045" diameter anne~led stalnless ste~ approximately iive turns per inch. ~he .004S" diamet~r steel wire2S' is itse'f wrapp~d with comrentional mul~iiil~mcnt or m~noillament polyethyleno 3 30' o~ appro~dmately 200 denier before lhe wjr~ Is wrapped ~round the core 20'. A
subs~quont wr~p 3S~ i9, In thls embodiment, formed of ~50 cienlor extended chainpolyethylene at a ra~8e of iive or six wraps or turns per Inch to complotely covor the wire l~yer. The ~nal outer wrapping 40' is formecl of 840 denier i`ndustrialrade nyloll wrapped at approximA~ely ~ ht lurns pi~t inch of core or g~
It ~hould be not~d tba~ this second basic embodiment described with rc~eren~c tO th~ lay~r~d stmcture of Fiber lB utilizes an e~ended ch~in ? palyethyl~no having n melt po~nt of approximately 297 de~ree~ Pahrenheit to form layer 3S', to wrap or covcr the wire whlch has been pre~iously wrapped w~th a conventiona1 polyethylene 30' havlng a melt poin~ of approximately ~00 degrees Fahrenhoit, to ~nsure f~rm~tion oE an adhesive bond between the encaps~llating prima~y corc contairlment barrier 35 and the core. Such a structure is preferredbecau~e ~he con~entional po~o~hy1ene helps compcnsate ~or the poor adhe~ive per~ormanc~ of u~tend~d chain polyethylene. This structùre also offers an exceptionally hlgh level o~ cut resis~nce and an equal1y gwd ability ~o cncapsul~te the wlre becl~u~e o~ exLended chLlln pobclhylene'c un~urpnsted ~uen~LLh ~ind CL~

2~3~2 1~
~csistance. Nylon is used as ~l~e outer wrap 40' becQuso of it~ dissimilan~ ~rom the core. 1~ the he~t applicat~on Is not precisely corltrollod the cxt~ndcd chain polyethylene nlaterlal can re~ch Ihe soRenln~ polnt and bond ~th the outer cover5, thus increa~jng ~ lik~lihood of l~igidlty In the cnd product.
I ookin~ next at Figure 2, nnd cross-sectional vfews 2A, ~B, ~ third embodimellt h~ a core SO ~ormed o~ a sfn~le strand of 900 denlor ~erglass.
Posltioned longitudinalty of thi~ co~e SQ is an adhcslve lay~r S2 o~ three ~paccd apart ~t~ands of .006" Shakespear~ ~ 101~, strand~ S2n, 52b, and ~2~, having melt polnt oE 2'7S degree~ Fah~enheit. A single oncapsul~ti~n8 shroud or coro contalnmant bA~er 54 i~ ~ormed of $40 denie~ high ~enacl~ nyl~n wrapped ~ve~
the underly;ng materla~s at ~pproxfm~tely eiuht turns pcr Inch of core o- yarn. A
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s subs~qu~nt outer cov~r 5~ o~m~d o~ thc same 840 denler nylon wrapped in the opposftc direction (relativo to ~4) at ~pproxlma~ely cight turn~ pe~ inch. In thls e~ample the ~erpolyamlde (mclt h~ible nylon~ doe~ not conlphtety contain the core prlor to appl~catfon of he~t. Howe~er, dur~n~ ~he hcAt cycle the soanposite has a ~utflclent quan~ft~r o~ thls melt fuslblc matet~al to flc)w around thc cntfrc ;~3, circlJmferenco o~ tho cor~ ~Fl~ure 2C). Becau~ the 840 deni~r nylon enc~psulallon ~. shroud Sd, 1~ h polyamid~, ~n ~ ellent b~nd i~ formed wlth the melt hsible ~ .
eerolyam~de 52~,b.e. Residual pol~ner will aclhere ~o th~ ~bergl~ss core. The outer ~: wrap 5~ Is no~ Pused to the zncapsul~tion shroud S4 beeause there is su~ficicnt la~er - .
~ oE the Inner urrap to absor~ th¢ melt fusible m~tetial. ~ ~

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$ 19 ~ igure 3 illustrat~s a ourth embodiment which utili~es f~urte~in strands of 3 micron st~inI~Yss st~el type 304 to form a lon~l~udln~lly oriented bs~ic core 70. The core 70 i5 wrapped with 6S0 d~nier extended chain polyethylene at ~ve turn~ per inch to form an inner core containment barr1er 72. TheTI rnultiple ~trands ~.005"
Iow den~l~y poiyeth)~lei~e n~no~l~ment iR~e ~dded to lon~itudin~ sutround the wrapped core, parallel ~o th¢ ~ur~een strands of steel which ll~n e~ro 70, thus ~ormlng ~dheslv~ l~yer 74. A final outer layer o~ 200 d~nier TF~ nurocarbon (such as that made by I:)upont C:orporRtion ~nd sold under the tradem~rk TefionlM) Is wrapped in the nppos~te dl~ecdon (relatlve to wtap 72) at appro~m~tely twelve .
~j turn~ per Inch, to form the outer ccver or pri~ary cotc c~nt~inmont bnrrier 16. In `. thls cxnmplc, unusually ~ne strand~ of wire arc used ~o create a hlgbly aox~ble ba~ic core 70 which has a ~esulting denier eqlJivalent to 1000 denior; yct e~cb of the Indhridusl strsnds Is ~n4bh t~ puncture the relati~ely ~nc barrior layer 72. Thecontain~ncnt barr~er of extended chain polyethylene which Eorms the inner core : :
contalnlllcnt ~arrier 7~ is preferably ~Ulied Signal's product 301d under the ~; ~rademarkSpectr~ 1000~
Thls fi~ure 3 cmbodlment Js ~omewhat unique when compared to the ~ther .!
mbodiments taught herein, in that the final wrap 76 Is in dlrect cont~ with the `~ adhes~te l~yer 74 ~nd l~ therefore ~sed to the other materials. It ha~ been ~ound ~hat due to Te~on's~M lubricity It must be Fu~d in ~rder lo prevent the Te~onlM
lay~r ~orn movln~ and e~po~lng the m~ter~als beneath. Furthe~mare, Teaor~'M
doos no~ neod to hnc~lol~ Indop~ndently in ord~r to adequately per~orm ~n this .

2 1 ~ 2 ~U
embodiment. The unusually heavy la~er prevcnts the therm~pla8tic 74 ~om ~owing to the isudac~. Thi~ cmbodim~nt ~s particularly sllited to use in productior~ of ~ cut rcsistant surgeon's ~lo~o which wou1d ~e worn so as to underlic tho conventionalsterile late~ glove used in most surgical facilitie~.
Figure 4 Illuiq~rates a ~ft~ ernbodirnent wherein a core gO is formed o~ 1000 denler K~lar ~gTM (~ramid) made by l:)upont Co~poratioa. Po~itfoned lon~ftudlnall~ to this oore 90, are conta~ne~ by a layer 94 formed of ~upont Corporathn'J type ~8 pol~ei~ter of approxim~tely 1000 deni~r .~vhich has bcen r modi6ed to Incorpoîate hv~ pnr~llel strands ~Sa ~ncl OSb ~nd 160 denl~r polyethylene. This laycr 94 is ~rapped at approxlmatel)~ 6~e tur~s p~r irlch In the opposlto directfon to the wrap of the outGr wire la~rer 92b. A ~nsJ ~ut~r covcrlng i' ~6 Is formed ~ the same polyester and Is wruppe~ at spprox~lnately five turns por inch In a dircctlon oppo8ite thnt ~ th~ contained layer 94. This composito yarn is suitable for produc~lon of gloves ~hich nre knlt~e~ ~nd then heat treated ~r appro~dmately ~ mlnu~es at 340 dc~rccs Fahrenheit in a convontional g~ove dotling machinc. ~:
In thls embod~ment of P'lgure ~, thc ~dhesive layers 91,a,b,c are boneath tho qirc layers. Additional thormoplastlc ls comn~in~led wlth the prlmn~y cor~
containln~nt barrler 94 ~or ease of processln~. Becau~e h~o ~tr~nds of ~vire 9~a and 92b are used in opposin~ directions, the prim~ry ool~e containment b~rrier Y4 isapplicd outslde ta the outcr ~Ivlre wrap g2b. Since the ffrst, or lnnor wire ~trand is J wrnppod w~th tho snrnc numbor of turns and In tho same directl~n u tho ban~er 94, : .

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-` 21~3~2 i it w~uld normally pu~h Ulrou~h the commonly orientcd filamonts o~ polycste~ ~
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during the heat cycle. ~3y wrapping opp~site the oute~ wire str~n~, and thc~e~y controlllng its expanslon, the inner u lre strand is thus al~o controlled. Poly¢ster i~
usePul as an erlcapsulatin~ s~lroud and as a tlnal wrap du~ to ~ts shr~nk~ge o~
~3 appro~dmately fourteon p~rcent of tho hent-set tempcrature oF 340 degrecs Fahre~heit. Shrinknge causcs the polyester to c~ntr~c~ A6ainst thc e~psnding wirc and Eo~rn more closely with the cole ma~erial, cstablishing a st~ong adhe~ive bond.
. Thc embodimcnt ~n Figure 6 d~mon~tratcs there aro a ~arlety of yarn .
constnlctlon~ ~hat fall wilhin the teachings ot ~his di~closure ~n~ claim3, nnd can bo 1~ usod ~o crc~te the ~mo or c~milar products; Thlo embodimont 15 c~mpr;oed of a .~ core 110 ~ormed of Appr~ tely ~ourteen strands of 35 mlcron ~pe 304 s~ainloos r~ such ~s that n~nnuhctured b~ ~eckert Company. Wrapped abou~ tbis core 110 ~ Is a Inyer ~1S f~r~ned by comblning a wrnp~ing 115a o~ ~00 denior indu~tnal gr~lde -~ multi~ilamcnt nylon, wrnpped a~ sppro~nm~tely ~hir~r turns per inch of eore, nth a p~r~llcled strand 115b of .006" ~rand of melt hsible tcspolyam~do mono61amcnt.
'~ Th~ profemd te~polyamide monofilament is Shakespearo ~X 1012 which has a ~. mel~ point of 27S de8rees Fnhrenheit. Posilioned parallol to the coro 110 and ...,~
overlyin~ 11S i~ a ~ingle strand 11~ of 12W denier TFE ~urocarbon such as eDonsM~ The Te~nT~I is carefully fed lhrou~h ~ devic~ ~hlch ~irst ~ares the w~dth oE the multifila~nent, then ~apers around ~he core so as to surround tho inner .;, . ~ .
~1 surf~cc of ~hc coro 110 al~d 115 ~th Tc~on~ nen~. A ~nal outor wrap llfi of `~ 20 d~n~er nylon ~ wrApp~d at A ran~e of ~v~ to eight lurn~ p~r inch ~n tho opposito ':1 .

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` - 21~3~2 direct~on relative to the intler layer 115. l'his Einal wrap 116 holds the l'e~lonlM in plac6 un~ e compo~itc yarn ls he~t treated.
Fi~ure ~ illustrates a ynm constnl~tio~ wherein tha cor~ formed of an in~ust~ial grade polyestor tS00 denier) 202 combined w~th a sin~lo strand o~.0~3", type 304, stalnl~s~ s~eel wire 205. The adhcsive layer 21~ i9 helically wrapped about tho b~slc core 200 at ~pprox~mat~ly ~even lurll5 p~r inch, prcferably folmed of 3S~
den~er, '1~ ~lament, lo~lv den~ity polyethylene. Over this adhesivo l~y~r 15 a primary core contalnment barr~e~ 21S f~rmed of ~00 d~ni~r )ndustrial ~radl~ polyester which is helically wrapped ~t app~o~dlnat~ly nln~ turns pet Inch. A final outer layer 220 o~ -1000 donier Industrial ~ade polyegt~r is wrapped In the oppositc ~irec~ion at a pitch o~ appro~mately ~Ight tUltl5 per inch. The ~inished ynrn Is then heAt ~t ~or appro~dmately two and one~hal~ to ~o and lh~e-quar~r hours, at 280 degrees P`.
In a stc~m conditlaning uni~ e y~rn of this embodimer~t is hlghly suited for usc ~n construction ~t Indwtrl~l gloves ~nd olher cut-re~lstant fabrics.
Fig~lre g Illus~rates a ba~lc core 300 of 1sn denler textile grade polye~ter 302 and 100 den~er, 70 filament low-density polyethylene 305. Wrspp¢d about thJ~ basic core is a single strand 310 oE.00Z", type 304, stninless steel wirc which is wrapped :~
at a pitch of twen~-~our turns per Inch. The prilnn~y core con~ainment bartier 31S
(the ~inul layer) is 300 denler textile ~rade poly~ster w~apped in ~ direiction oppo~it0 that of the w~r~, at a pftch of appro~imately terr turns per ~nch. The - :
6nished yarn Is ~hen heat set for onc and lhree~quarter hours a~ 280 ~ee~ in a steam condltl~nlng unift. ll~is embodlment Is b~st sulted for finer cut-resi~tant . ,i .
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- ` 2~0~2 Eabrics and most p~nicularly for cut-resistant surgical glovcs.
Figures 5 and 7 i~ ctrates a cut-resistant glovesnade from any one of the embodiments oE the composite y~n~ descrlbcd above. It dem~ns~rates improvcd cut rcsistance, nexibility e,nd comfort. Olher end products are anticipated to be msde Erom thc novel y~rn described hereln, other embodiments of the yarn are anticlpated, and all ar~ believed to be within the scopc of the claims below.

Figure 5 illustrates a half cut-resistant glove.

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Claims (16)

1. Claim 1. A composite yarn structure, the yarn being in strand form and structured to include an isolated core material which may have a hazardous characteristic thereto; which composite yarn is of the type utilized for knitting or weaving fabrics for apparel products, for production of industrial fabrics for braiding, for production of cordage, or for production of non-woven goods; said composite yarn structure including: A) a basic core member formed of one or more selected materials including wire, fiberglass, thermoplastics, filaments, or spun fibers, or combinations thereof, with said basic core member being longitudinally oriented relative to the finished strand of said yarn; B) at least one core containment barrier being formed of a selected material having a first melt temperature; C) an adhesive component associated with said basic core member and said core containment barrier; said adhesive component including one or moreselected thermoplastic materials having a second melt temperature which is lowerthan said first melt temperature of said core containment barrier; D) a fused fiber layer formed by the heat fusion of said adhesive layer and said core containmentlayer; whereby said composite yarn demonstrates flexibility sufficient to enable the conventional processes of manufacturing the desired end product.
2. Claim 2. A composite yarn structure according to claim 1 wherein said basic core member is comprised of at least one strand of aramid and at least one strand of multifilament thermoplastic positioned in parallel relationship to said strand of aramid thermoplastic strands being of a prescribed denier; and said thermoplastic having a melt temperature lower than that of said aramid component.
3. Claim 3. A composite yarn structure according to claim 1 wherein said basic core member is comprised of a plurality of strands of wire material of a prescribed gauge.
4. Claim 4. A composite yarn structure according to Claim 1 wherein said adhesive component is formed of a thermoplastic material selected from the groupincluding polypropylene; ultra-low, low, high, or ultra-high density polyethylene; low melt nylon polyamide; polyamide blends, and low-melt polyesters.
5. Claim 5. A composite yarn structure according to Claim 1 wherein said core containment barrier is formed of a material selected from the group including:
   polyester, nylon, aramid, high-density polyethylene, ultra-high-molecular-weightextended chain polyethylene, cotton, wool, polycotton blends, rayon, or TFE
   flurocarbon, PBO, PBZT, PTI.
6. Claim 6. A composite yarn structure, the yarn being in strand form andstructured to include an isolated core material which may have a hazardous characteristic thereto; which composite yarn is of the type utilized for knitting, for braiding, for weaving fabrics for apparel products, for production of industrial fabrics, for production of cordage, or for production of non-woven goods; said composite yam structure including;
   A) A basic core member formed of a selected material or combination of materials including wire, fiberglass, thermoplastics, filaments, or spun fibers; said core being longitudinally oriented relative to the finished strand;
   B) an adhesive component positioned intermediately of said basic core member and subsequent overlying layers; said adhesive component encapsulating said basic core member and isolating said basic core member from subsequent overlying layers; said adhesive layer including one or more selected thermoplastic materials which, when heat treated, forms a fused fiber layer between said basic core and any additional outer layers, demonstrates flexibility sufficient to enable the processes of knitting and weaving;
   C) at least one outer layer overlying said adhesive layers, said outer layer being formed of n selected material having a melt temperature higher than that of said thermoplastic material used to form said adhesive layer;
   D) at least one cover layer formed of a selected material and being applied around the underlying layers to a prescribed thickness;
   whereby said composite yarn structure enables use of core materials traditionally considered of a hazardous nature by isolating said core material from subsequent outer layers, while retaining the flexibility and cut-resistance necessary for the knitting or weaving of fabrics, protective apparel, and the like.
7. Claim 7. A composite yarn structure according to Claim 6 and further including said basic core member having:
   A) a first component comprised of a selected filamentary material being longitudinally oriented relative to the finished composite yarn strand;
   and B) a second component comprised of at least one stand of wire material of a prescribed gauge; said strand of wire material being helically wrapped around said longitudinally first component a prescribed number of turns per linear inch of said finished composite yarn strand.
8. Claim 8: A composite yarn structure according to Claim 6 and further including: said basic core member having:
   A) A first component comprised of a selected filamentary material being longitudinally oriented relative to the finished composite yarn strand;
   and B) at least one strand of wire material of a prescribed gauge being parallel to said basic core member.
9. Claim 9: A composite yarn structure according to Claim 7 wherein said filamentary material which comprises said first component is fiberglass.
10. Claim 10: A composite yarn structure according to Claim 7 wherein said filamentary material which comprises said first component is asbestos.
11. Claim 11: A composite yarn structure according to Claim 7 wherein said filamentary material which comprises aid first component is a carbon fiber.
12. Claim 12: A composite yarn structure according to Claim 7 wherein said first component is comprised of at least one strand of Aramid and at least one strand of multifilament thermoplastic having a melt temperature lower than that of said aramid, and positioned is parallel relationship to said aramid; each of said aramid and said polyethylene strand being of a prescribed denier.
13. Claim 13: A composite yarn structure according to Claim 7 wherein said first component is comprised of a plurality of strand of steel wire material of a prescribed gauge.
14. Claim 14: A composite yarn structure according to Claim 6 wherein said adhesive component is formed of a thermoplastic material selected from the groupincluding polypropylene; ultra-low, low, high, or ultra-high density polyethylene; low-melt nylon polyamide; polyamide blends; and low-melt polyesters, or blends.
15. Claim 15: A composite yarn structure according to Claim 14 wherein said adhesive component is formed of a prescribed number of strands of .006"
    terpolyamid.
16. Claim 16: A composite yarn structure according to Claim 6 wherein said outer cover layer is formed of A material selected form the group including polyester, nylon, aramid, high density polyethylene, cotton, wool, polycotton blends, rayon, PBO, PBZT, PBI, TFE fluorocarbon, ultra-high molecular-weight extended chain polyethylene.