MULTI-LAYER MATERIAL WITH ONE OR MORE EMBEDDED FUNCTIONAL LAYERS

Abstract

Please replace the current Abstract with the below language:

A multi-layer material comprises a textile substrate layer, a functional layer arranged on the textile substrate layer, and a coating covering the functional layer and the textile substrate. The multi-layer material further includes a textile cover layer arranged between the functional layer and the coating. An adhesive layer is arranged between the functional layer and the textile cover layer. The textile substrate is woven or knitted from one yarn and the textile cover layer is woven or knitted from an identical yarn.

Claims

14. A multi-layer material comprising: a textile substrate layer; a functional layer arranged on the textile substrate layer; a coating covering the functional layer and the textile substrate; a textile cover layer is arranged between the functional layer and the coating; and an adhesive layer arranged between the functional layer and the textile cover layer, wherein the textile substrate layer is woven or knitted from one yarn and the textile cover layer is woven or knitted from an identical yarn.

15. The multi-layer material according to claim 14, wherein the functional layer comprises at least one of: (1) a sticker; and (2) a printed structure.

16. The multi-layer material according to claim 14, wherein the functional layer comprises at least one of: (1) conductor tracks; (2) sensors; and (3) flexible circuit boards.

17. The multi-layer material according to claim 14, wherein the functional layer is printed onto the textile substrate layer.

18. The multi-layer material according to claim 14, wherein the functional layer is laminated onto the textile substrate layer.

19. The multi-layer material according to claim 14, wherein the functional layer is glued onto the textile substrate layer.

20. The multi-layer material according to claim 14, wherein the coating is a polymer coating.

21. The multi-layer material according to claim 20, wherein the polymer coating comprises one of: (1) polyvinyl chloride; (2) nitrile rubber; and (3) polytetrafluoroethylene.

22. The multi-layer material according to claim 14, wherein the textile cover layer completely covers the functional layer .

23. The multi-layer material according to claim 14, wherein the textile cover layer comprises a plurality of openings in a region over the functional layer.

24. The multi-layer material according to claim 23, wherein the coating comprises a plurality of openings that correspond with the plurality of openings in the textile cover layer.

25. The multi-layer material according to claim 23, further comprising functional components arranged on the coating, wherein the functional components are in electrical contact with the functional layer.

26. The multi-layer material according to claim 23, further comprising functional components arranged on the coating, wherein the functional components are in thermally conductive contact with the functional layer.

27. The multi-layer material according to claim 14, wherein the multi-layer material is formed into a piece of personal protective equipment.

28. A knitted glove comprising: a multilayer material that comprises, a textile substrate layer; a functional layer arranged on the textile substrate layer; a coating covering the functional layer and the textile substrate; a textile cover layer is arranged between the functional layer and the coating; and an adhesive layer arranged between the functional layer and the textile cover layer, wherein the textile substrate layer is woven or knitted from one yarn and the textile cover layer is woven or knitted from an identical yarn, and wherein the multilayer material is formed as a glove.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The invention will be explained in more detail in the following based on embodiments shown in the figures, in which:

[0026] FIG. 1 illustrates a cross-sectional view through an embodiment of a multi-layer system;

[0027] FIG. 2 illustrates a plan view of an embodiment of a multi-layer system having an opening in the region of the functional layer and functional components on the coating; and

[0028] FIG. 3 illustrates a cross-section through the embodiment of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

[0029] FIG. 1 is a cross-section through a multi-layer system without a coating. It shows the textile substrate 1 and the functional layer 2 fixed thereon. An adhesive layer 3 is shown between the cover layer 4 and the functional layer 2. The adhesive layer 3 may comprise a hot glue or hot-melt adhesive that becomes connected to the cover layer 4 and functional layer 2 under the influence of pressure and heat.

[0030] The cover layer 4 shown extends beyond the functional layer 2, such that the cover layer 4 overlaps with the edges of the functional layer 2. This overlap protects the functional layer 2 against locally applied forces that could facilitate detachment of the functional layer 2 from the textile substrate 1.

[0031] In the figure, the cover layer 4 is shown thinner than the substrate. Regardless of the thickness, both layers can be produced from the same yarn.

[0032] FIG. 2 is a plan view of an exemplary embodiment of a multi-layer material having openings 6 in the cover layer 4 and coating 5. The functional layer 2 underneath the coating 5 is indicated by means of a hatched line. The openings 6 overlap and expose part of the underlying functional layer 2. In the exemplary embodiment shown, multiple contacts 8 located on the functional layer 2 are exposed. The elements of the functional layer 2 are connected via conductor tracks 9 to functional components 10 that are located on the coating 5. The functional components may be sensors or the like.

[0033] FIG. 3 is a cross-section through the system shown in FIG. 2. The functional layer 2 has been applied to the textile substrate 1. The functional layer 2 is glued to the substrate 1 by means of an adhesive layer 3. The cover layer 4 extends over the functional layer 2 and beyond the edges of the functional layer 2. The cover layer 4 comprises an opening 6 that exposes a contact 8 on the functional layer 2. The coating 5 has an opening at the same point. A conductor track 9 leads from the contact 8 to a functional component 10 that is arranged on the coating close to the opening.

[0034] The problem addressed by the invention can be explained well in technical terms based on the following example. A glove that is, for example, knitted without seams and that substantially consists of polyamide and spandex yarns forms the textile substrate. A functional layer is laminated onto said textile substrate in the region of the palm by means of a hot-pressing method. The functional layer consists of an elastic carrier film made of thermoplastic PU (TPU) and also consists of printed conductor tracks and sensor structures on the upper face.

[0035] Subsequently, the glove with the functional layer is coated with a nitrile layer. For this purpose, the glove is pulled onto a mold and immersed in a saline solution, which coagulates in contact with the salt. After coagulation, the glove is washed to remove the excess salt. Subsequently, the glove is dried and the nitrile coating vulcanizes completely.

[0036] The finished glove exhibits significantly poorer adhesion of the nitrile coating on the functional layer compared with the textile substrate. This poorer adhesion is evidenced by run-off marks and detachment of the nitrile coating from the functional layer. The abrasion test according to DIN EN 388 shows complete detachment of the nitrile layer from the TPU after less than 200 cycles.

[0037] In the solution according to the invention, the functional layer consisting of TPU with its conductor tracks is sprayed on the upper face with a layer of adhesive prior to lamination and a cover layer consisting of a knitted polyamide and spandex fabric is applied thereto.

[0038] Subsequently, the functional layer and the cover layer applied thereto are laminated onto the textile substrate as in the previous example. Then, the coating with nitrile takes place.

[0039] The gloves do not exhibit any visual differences between the coating on the textile substrate and the functional layer. Only the difference in thickness is evident from the additional layer formed by the cover layer. The abrasion test according to DIN EN 388 reaches more than 8,000 cycles in the region of the cover layer and in the region of the textile substrate.

[0040] In another embodiment, a polyamide fiber layer with an average fiber length of 0.5 mm is applied as the cover layer. At this length, the fibers are referred to as short fibers. During lamination of the functional layer, the short fibers on the upper face of the functional layer are partially pressed in. The corresponding regions are fibers that are sunk in at different depths and thus produce an inhomogeneous coating look for the cover layer. It should be noted that fibers that have not been pressed in as far provide better adhesion for the nitrile coating. The abrasion test according to DIN EN 388 thereby reaches between 500 and 2,000 cycles in the region of the cover layer before the nitrile and cover layer are worn through.

[0041] In another embodiment, an elastic woven fabric consisting of viscose and spandex is applied as the cover layer to the upper face of the functional layer. The woven fabric is provided with a thermally activatable layer of adhesive on its lower face. The layer of adhesive is not sprayed on. In this example, the textile substrate, the functional layer, and the cover layer can be laminated in a joint step.

[0042] In these examples, visual defects can be seen in the form of air bubbles, which are caused by the viscose fibers not being sufficiently wetted with saline solution. Accordingly, the nitrile dispersion coagulates in an inhomogeneous manner and with little penetration in the region of the cover layer. The abrasion test according to DIN EN 388 reaches 2,000 cycles in the region of the cover layer before the nitrile and cover layer are worn through.

[0043] List of Reference Signs

[0044] 1 Textile substrate

[0045] 2 Functional layer

[0046] 3 Adhesive layer

[0047] 4 Cover layer

[0048] 5 Coating

[0049] 6 Opening

[0050] 8 Contact

[0051] 9 Conductor track

[0052] 10 Functional component