GLOVE HAVING TWO-DIMENSIONAL INJECTION MOLDED COMPONENTS

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention generally relate to gloves and, more specifically, to gloves comprising a fabric liner having two-dimensional injection molded components adhered to the fabric liner and, optionally, an elastomeric coating adhered to the fabric liner.

2. Description of the Related Art

Gloves for the skilled trades have typically been made of leathers, which are expensive and offer little design choices for manufacturers. In addition, leather does not breathe adequately. Therefore, gloves having an injection molded component adhered to a fabric liner were developed. Molded components provide a three-dimensional molded palm portion to enable the glove to fit users. The molded components are typically fabricated from thermoplastic elastomers (TPEs), thermoplastic vulcanizates (TPVs), or thermoplastic rubbers (TPRs). Such fabric liners generally consist of fabrics that can withstand temperatures encountered during injection molding processes, e.g., 450° F.

Previously, gloves having injection-molded components have typically found use as gloves for which the injection molded components are curved and traverse, for example, the circumference of a finger, fingertip, or palm and backhand region and are not easily permanently adhered thereto unless the injection molded components further consist of a large contact area with the underlying substrate to promote adhesion. However, such gloves are very stiff and suffer from a lack of grip and flexibility and, therefore, dexterity characteristics. Furthermore, gloves having three-dimensional molded portions, which cover most of a liner and/or traverse from a palm to a backhand area, require complex molds, which are expensive. For the purposes of this disclosure, as apparent to one skilled in the art, the use of the phrase “three dimensional” when referring to a molded portion means that the molded portion is applied to a curved surface of a former or mold, i.e., the plastic is injected onto a surface that is curved or non-planar. Therefore, the three dimensional characteristic is not merely a bending or flexing of a two dimensional material but the formation of the molded portion into a three dimensional shape by injection molding the elastomeric material onto a surface approximating the shape of a human hand.

Therefore, the inventors have invented a method for applying two-dimensional injection molded components onto a planar fabric glove liner and gloves comprising a fabric glove liner and two-dimensional injection molded components.

SUMMARY

Embodiments according to the present invention comprise a variety of gloves having a fabric liner further comprising one or more two-dimensional injection-molded component(s) molded onto the fabric liner and/or onto an elastomeric coating disposed on at least part of the fabric liner, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims, are disclosed. Various advantages, aspects, and novel features of the present disclosure, as well as details of an exemplary embodiment thereof, will be more fully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1A is a back of the hand view of a fabric liner, according to embodiments of the invention;

FIG. 1B is a back of the hand view of the fabric liner of FIG. 1A having two-dimensional injection molded components disposed thereon, according to embodiments of the present invention;

FIG. 2A is a back of the hand view of a glove comprising the fabric liner having two-dimensional injection molded components of FIG. 1B, and further comprising an elastomeric coating disposed on the fabric liner, according to embodiments of the present invention;

FIG. 2B is a palm view of the glove of FIG. 2A showing the elastomeric coating disposed on the fabric liner, according to embodiments of the invention;

FIG. 3A is a cross-sectional view of a glove having two-dimensional injection molded components disposed on the fabric liner of FIG. 2A taken along line 3A-3A, according to embodiments of the invention;

FIG. 3B is a cross-sectional view of a glove having two-dimensional injection molded components and the coating disposed on the fabric liner of FIG. 2A taken along line 3B-3B, according to embodiments of the invention;

FIG. 4 depicts a palm view of a glove having two-dimensional injection molded components, according to embodiments of the invention;

FIG. 5 depicts a back hand view of a glove having a plurality of two-dimensional, injection molded components and a coating disposed thereon, according to embodiments of the invention;

FIG. 6A depicts a perspective view of an “A” side of an injection mold, according to embodiments of the invention;

FIG. 6B depicts a perspective view of a “B” side of an injection mold, according to embodiments of the invention;

FIG. 6C depicts a perspective view of a flat former for use in conjunction with the “A” and “B” sides of an injection mold, according to embodiments of the invention;

FIG. 6D depicts an assembled perspective view of the “A” side of the injection mold of FIG. 6A, the “B” side of the injection mold of FIG. 6B, and the flat former of FIG. 6C, according to embodiments of the invention; and

FIG. 7 depicts a process for forming a glove, according to embodiments of the invention.

DETAILED DESCRIPTION

Embodiments of the invention comprise at least one two-dimensional injection molded component that is molded onto a fabric liner. The at least one two-dimensional injection molded component is adhered, for example, to a flat planar region of a fabric liner. Embodiments according to the invention include a fabric liner, dressed on a flat former capable of maintaining the planarity of the knitted fabric liner and, therefore, the two-dimensional injection molded component(s) during the molding process.

Embodiments according to the invention further comprise a polymeric coating disposed on a fabric liner having at least one two-dimensional injection molded component adhered or attached to a planar region of the fabric liner via an injection molding process, i.e., injection molded directly onto the fabric liner and further comprising a polymeric, elastomeric, or latex coating disposed thereon, for example, by a dipping process known to those in the art, to form a hybrid glove comprising at least one two-dimensional polymeric injection molded component and a polymeric coating disposed on the fabric liner. Also, embodiments according to the invention comprise at least one two-dimensional injection molded onto a polymeric, elastomeric, or latex coating that is disposed on a fabric liner.

FIG. 1A is a back of the hand view of a fabric liner 102, according to embodiments of the invention. The fabric liner 102 comprises a thumb portion 110, index finger portion 112, a middle finger portion 114, ring finger portion 116, a pinky finger portion 118, upper knuckle area 128, back of the hand portion 130, and a cuff portion 122. A cuff ring 109 is also optionally knitted within the fabric liner 102. Fabrication of knitted liners for gloves is well-known in the art, for example, as described in commonly assigned U.S. Pat. No. 7,246,509, incorporated herein by reference in its entirety. The fabric liner 102, which may be, for example, knitted or woven, comprises a material that is heat resistant to facilitate attachment of the at least one two-dimensional injection molded component (discussed further below). For example, the melting or processing temperature for the material of which the two-dimensional injection-molded component is comprised, may be 350°-500° F. and approximately the same for the fabric liner 102 yarn. In some embodiments, irrespective of the melting or processing temperature of the base material or resin for the injection molded component, the material or resin will comprise additives, such as low molecular weight additives and/or plasticizers, which depresses the melting or processing temperature to below 400° F., so that the melting temperature of the material of a fabric liner, e.g., the fabric liner 102, is approximately the same or complementary with that of the material of which the injection molded component(s) is comprised, which can promote adhesion of the two-dimensional injection molded component(s) to the fabric liner 102. For example, HPPE, elastane yarns, e.g., SPANDEX®, rayon, nylon 6 and/or the like have melting points less than 400° F.

The fabric liner 102 may be knitted from a monofilament or a yarn comprising many fibers and/or filaments, such as cottons, rayons, nylons, polyesters, and the like and may further comprise elastomeric materials (e.g., natural or synthetic rubber), such as SPANDEX®. The fabric liner 102 may be knitted using a main yarn, i.e., a single layer, or with a plaited yarn knitted with the main yarn, i.e., a multi-layer liner. Additionally, the knitted fabric liner may comprise high performance yarns, such as high-performance polyethylene (HPPE). In some embodiments, yarns comprise cut resistant yarns, such as, but not limited to, steel wire, glass fibers, carbon fibers and filaments, ultra-high molecular weight polyethylenes, nylons, p-aramids, m-aramids, aliphatic nylons, aromatic nylons, NOMEX®, TWARON®, KEVLAR®, DYNEEMA®, SPECTRA®, VECTRAN®, and the like or any composite or blend of the fibers and materials. Furthermore, fabric liners comprise, for example, a composite yarn including at least one core yarn and at least one wrapping yarn as disclosed in commonly-assigned U.S. Pat. No. 8,074,436, which is herein incorporated by reference in its entirety. At least one exemplary blended yarn according to the invention comprises a cut-resistant composite yarn comprising 90% HPPE and 10% glass fiber, which is gel, wet, or dry spun into a core yarn and is subsequently wrapped with, for example, 2X-50 denier polyamide wrapping yarns (such as nylon 66). Similarly, a blended yarn according to the invention comprises a composite yarn that includes, for example, a 140, 150, or 160 denier filament of 90% HPPE, which may be stretch-broken and 10% mineral fibers, e.g., basalt and/or glass fibers that are gel, wet, or dry spun to form a core yarn and wrapped with a 2X-50 denier polyamide wrapping yarn, resulting in an, e.g., 257-289 dtex composite yarn. In at least one embodiment according to the invention, the HPPE fibers are the same length as the mineral fibers, for example, 90-150 mm. Furthermore, any wrapping yarn may be, for example, 30 denier to 140 denier or any denier therebetween. Therefore, a core yarn or filament comprising 90% HPPE and 10% glass fibers having, for example, 140-221 denier, and wrapped with a 2X-40, 2X-50, 2X-60, or 2X-70 to 2X-140 denier polyamide and/or polyester wrapping yarns are contemplated herein.

At least one exemplary embodiment comprises one or more flame-resistant yarns, which can be via a chemical treatment or an inherent property of the base engineering resin, for example, modacrylics, polybenzimidazole (PBI), polysulphonamide (PSA), oxidized acrylics, partially oxidized acrylic, and combinations thereof. Additionally, any fabric liner, such as the fabric liner 102, comprises yarns that melt and/or degrade at very high temperatures, for example, oxidized polyacrylonitrile or carbon fiber yarns, which can be especially appropriate for a glove specified for an oil and gas worker. The fabric liner 102 may also comprise hydrophobic and/or hydrophilic yarns, which can provide a push-pull effect to wick moisture from one area of the glove to another, as is disclosed in commonly-assigned U.S. Pat. No. 9,127,382, which is herein incorporated by reference in its entirety.

The fabric liner 102 may be knitted, for example, using one or more 13-gauge, 15-gauge, or 18-gauge needles. In general, 13-gauge needles are capable of knitting 600 denier yarns, 15-gauge needles are capable of knitting 260-400 denier yarns, and 18-gauge needles are capable of knitting 40-221 denier yarns, wherein a 40 denier yarn has a smaller diameter than a 221 denier yarn, which, in turn, has a smaller diameter than a 260-400 denier yarn, etc. Therefore, 18-gauge knitted liners comprise thinner yarns, which are commensurately more flexible than 15-gauge knitted liners. Similarly, 15-gauge knitted liners are thinner than 13-gauge knitted liners. In at least one exemplary embodiment of the invention, the fabric liner 102 is a 15 gauge knitted liner that comprises a p-aramid yarn, such as KEVLAR®, a polyamide, such as nylon 6 or nylon 66, and an elastane yarn, such as SPANDEX®.

FIG. 1B is a back of the hand view of the fabric liner 102 of FIG. 1A having two-dimensional injection molded components disposed thereon, according to embodiments of the present invention. The fabric liner 102 comprises two-dimensional injection molded components 140 and 142 on the index finger 112 and the upper knuckle area 128 respectively. The two-dimensional injection molded components 140 and 142 comprise polymeric resins injected, transferred, or cast onto the fabric liner 102 via an injection molding process or, in some embodiments, cast, transfer molded, or compression molded onto the fabric liner 102. The two-dimensional injection molded component 140, for example, is disposed as a bumper for impact resistance of the index finger 112 as described above on glove 160. The two-dimensional injection molded component 140 comprises a first end 202 and a second end 204 with one or more middle portions 206 disposed therebetween. Disposed between each middle portion 206 and an adjacent middle portion 206 are windows as discussed more fully below. The two-dimensional injection molded component 142 comprises lateral holes 150 and 152 on a first portion 146 and a second portion 148 respectively and a plurality of longitudinal holes 154 on a third portion 147 disposed therebetween, as described more fully below.

The at least one injection molded component may be fabricated from a polymeric material such as thermoplastic vulcanizates, thermoplastic rubbers, thermoplastic elastomers, and the like, and/or blends and/or alloys thereof. Some embodiments according to the invention include injection molded components, such as two dimensional injection molded components, that are non-Newtonian, i.e., the material of which the injection molded components are comprised are shear-thinning or shear-thickening materials. For example, a dimethyl siloxane hydroxyterminated polymer, sold by Dow Corning Inc. or any of several shear thickening polymers sold by D3O of London, UK, all of which can be injection molded, for example, onto a fabric liner or other substrate. In some embodiments, the injection molded components comprise thermoplastic polyolefins, such as polyethylene, polypropylene, and the like. In some embodiments, the two-dimensional injection molded components comprise engineering resins, such as aliphatic or aromatic nylons, acrylonitrile-butadiene-styrene, nitrile-butadiene rubbers, vinyls, polyesters, saturated styrene block copolymer thermoplastic elastomers (SEBS), polyurethanes, thermoplastic polyurethane alloys, modified-styrenics, styrene-butadiene-styrene, and polybutylene terephthalate resins, other thermoplastics, and/or blends and/or alloys thereof. In some exemplary embodiments, the injection molded components comprise silicon resins, which can be applied via liquid injection molding, or poly(vinyl chloride) plastisols, which can be applied by injection molding, compression molding, transfer molding, and/or casting. Silicones, which are generally soft, provide excellent dimensional stability and chemical resistance over a wide range of temperatures while providing impact resistance. Additionally, the viscosity of silicones, approximately 1500-2500 centipoises, and low processing pressures, e.g., 500-5000 psi, helps prevent strikethrough of the silicone through the fabric liner, thereby providing a larger processing window and, in turn, more comfortable gloves. It is to be understood that any of the foregoing polymeric materials can be adhered to a fabric liner without using glues, epoxies, or adhesives, or via sewing or stitching, i.e., can be injection molded, transfer molded, compression molded, and or applied via casting methods to a fabric liner or a polymeric coating on a fabric liner.

In some embodiments, the rubbers, elastomers, vulcanizates, olefins, and other thermoplastic resins, etc., of which the two-dimensional injection molded components are comprised, further comprise fillers and/or reinforcements, such as silica, metallic and ceramic powders, glass-fibers, and the like to provide grip, texture, strength, and other physical properties. Such fillers and reinforcements can, for example, comprise between 1-60% of a material by weight, tailored to end properties for various applications. Other additives are added as needed, such as for flame- and arc-retardance, adhesion promoters, ultra-violet stabilization, hardness, pigments, and the like. Also, any two-dimensional injection molded component may be foamed, using chemical blowing agents and/or physical blowing processes, for example, MuCELL® technology as sold by Trexel, Inc.

FIG. 2A is a back of the hand view of a glove 160 comprising the fabric liner 102 having two-dimensional injection molded components 140 and 142 of FIG. 1B, and further comprising an elastomeric coating 162 disposed on the fabric liner 102, according to embodiments of the present invention. The coating 162 comprises a palm dip as shown. The palm dip of the coating 162 is characterized in that it covers the crotches between the fingers 112, 114, 116, and 118 and the thumb 110. As can be seen, the coating 162 optionally extends to a border 207 formed by the coating 162 and an edge of the two dimensional injection component 140. As discussed more fully below, a two-dimensional injection molded component may be molded onto other areas of the glove 160, such as any finger, thumb, and/or palm. Also, embodiments according to the invention comprise dips other than a palm dip, e.g., a knuckle dip, a ¾ dip, or a full dip, etc. In general, the less the fabric liner is covered by a coating or the fewer two-dimensional injection molded component(s), the more ventilated and flexible the glove formed therewith will be.

FIG. 2B is a palm view of the glove 160 of FIG. 2A showing the elastomeric coating 162 disposed on the fabric liner 102, according to embodiments of the invention. For a palm dip, the coating 162 covers the thumb 110 and the fingers 112, 114, 116, and 118, as well as part of the cuff 122, terminating at a palm-cuff border 164. The elastomeric coating 162 comprises, for example, an elastomeric, polymeric, or latex composition, such as a natural rubber, synthetic polyisoprene composition, polyurethane, or the like. The elastomeric composition 162, for at least one exemplary embodiment according to the invention, comprises a nitrile-butadiene composition, such as at least one of KRATON® nitrile-butadiene resins, which have melting points between approximately 400 to 490° F. Also, at least one two-dimensional injection molded component may also be disposed on the cuff 122 for use as, for example, a pull tab 166, a donning/doffing aid, additional protection, decoration, indicia of the type of glove, or to depict a logo or trademark.

The glove 160 therefore has excellent impact-resistant properties from the two-dimensional injection molded components 140 and 142, on either or both of the palm side region and back hand side region as well as being chemical resistant because of the coating 162 without sacrificing the dexterity and flexibility of the glove because the coating 162 is not as stiff as would be a three-dimensional injection molded component that would traverse an area in which a glove needs to flex, i.e., from a knuckle on the back hand region to the corresponding area on the palm side of a finger or palm. Furthermore, gloves having two-dimensional injection molded components that need to flex in at least one direction, i.e., laterally and/or longitudinally, are inherently more flexible, as compared with gloves having three-dimensional injection molded components, which typically need to flex both laterally and longitudinally at the same time.

The two-dimensional injection molded components 140 and 142 protect the wearer from impacts using a resilient material such as flexible thermoplastic. Also two-dimensional injection molded components 140 and 142 are positioned in high wear regions of the glove 160 to provide reinforcement and extend the life of the glove 160. Also, by leaving the back of the glove 160 uncoated (as with a palm dip), the glove 160 is flexible and remains ventilated. Workers and all other glove wearers, including construction workers, industrial workers, and other laborers may find such a glove useful in protecting their hands as well as for comfort. At least one exemplary embodiment according to the invention comprises a two dimensional injection molded component injection molded directly onto the coating 162 (not shown). Adhesion of the two-dimensional injection molded components to the coating 162, such as the two-dimensional injection molded components 140 and 142, comprise one or more primers, for example, a flexible primer. Primers include chemical primers for adhering, for example, polyolefins to nitrile-butadiene, polyurethane, polychloroprene, or any combination thereof and/or two-dimensional nitrile-butadiene, polyurethane, polychloroprene injection molded components to nitrile-butadiene, polyurethane, polychloroprene coatings, or any combination thereof as are known to those in the art.

Additionally, embodiments of the invention comprise adhering two-dimensional injection molded components to a polymeric, elastomeric, or latex coating by partially curing the coating and subsequently directly injection molding the two-dimensional injection molded components thereon. Also, some embodiments comprise a polymeric, elastomeric, or latex material for the coating having a melting point or processing temperature that is complementary with the temperature of the TPRs, TPVs, or TPEs injected into the mold that form the two-dimensional injection molded component discussed herein. Complementary in this context indicates that melting and/or processing temperatures for materials comprising injection molded components and coatings are approximately the same, which is defined as being within approximately 50-100° F. of each other for the purpose that adhesion is promoted without burning or destroying features. Without intending to be bound by theory, it is believed that at least some of the fibers and/or filaments comprising the knitted fabric liner is impregnated with the polymer of the injection molded component, promoting a strong adhesion between the injection molded component and the knitted fabric liner. The combination of appropriate melting or processing temperatures, injection, clamp, and mold cavity pressures, generally, low pressure, in some embodiments, less than 1000 psi, and in some embodiments, less than 500 psi, and inherent and processing viscosities of the engineered materials, along with the tightness of the knit structure and a complementary function regarding the melt temperature of the knitted fabric liner and the injection molded component, allows the design of a glove having optimum flexibility, dexterity, and tactility balanced with other desirable protective properties, such as grip, abrasion-, impact-, flash-, and arc-resistance, and the like. In other words, at least one knitted liner, e.g., the knitted liner 102, comprises fibers or filaments or monofilaments or yarns or core yarns or wrapping yarns, or the like, having a melting point that is complementary with the melting point of the injection molded component(s) adhered thereto to promote adhesion, according to at least one exemplary embodiment of the invention.

FIG. 3A is a cross-sectional view of the glove 160 having the two-dimensional injection molded component 140 disposed on the fabric liner 102 of FIG. 2A taken along line 3A-3A, according to embodiments of the invention. The two-dimensional injection molded component 140, for example, is disposed as a bumper for impact resistance of the index finger 112 as described above on the glove 160. The two-dimensional injection molded component 140 comprises a first end 202 and a second end 204 with one or more middle portions 206 disposed therebetween. Disposed between each middle portion 206 and an adjacent middle portion 206 are windows 208, which provide flexibility. It is to be noted that the two-dimensional injection molded component 140, as well as all other two-dimensional injection molded components, has a flat side 220. The flat side 220 is adhered to, in this example, the finger 112 of the fabric liner 102 while the liner is on a flat former (discussed below) to create a planar region on the fabric liner 102 for adherence to two-dimensional injection molded component 140. The two-dimensional injection molded component 140 is molded flat because the former to which the fabric liner 102 is dressed, as discussed in more detail below, is flat.

In practice, any two-dimensional injection molded component disclosed herein, and not limited to 140, 142 may have a plurality of middle portions 206, which are spaced apart to define at least one window 208 disposed therebetween, and the windows 208, as shown, may comprise different widths. Additionally, the first end 202, the second end 204, and the middle portion 206 may further comprise tapered (or chamfered) surfaces 210, which will further promote impact resistance because the tapered surfaces 210 promote any impact to be a glancing impact. To enhance usefulness, such as for gripping, tactility, flexibility, dexterity, impact-resistance, abrasion-resistance, as well as for comfort, the two-dimensional injection-molded components 140 and 142, and others (not shown) may be contoured to provide additional application specific functionality as described below.

The two-dimensional injection molded components may have varied thicknesses across a cross-section of one area, for example, a finger area, knuckle area, palm area, and the like. Additionally, the two-dimensional injection molded components may have one or more surface textures (i.e., Electric Discharge Machining (EDM) finishes 1-9 or SPI finishes A-1 through D-3), and the like. Rougher finishes enhance gripping properties (for example, for two-dimensional injection molded components molded to a palm side of a glove) while smoother finishes allow glancing impacts to deflect more easily and therefore absorb less energy, i.e., better impact resistance, promoting safety. At least one exemplary embodiment according to the invention comprises a surface texture comprising multi-faceted cavities/indentations, as disclosed in commonly assigned U.S. Pat. Nos. 7,771,644 and/or 8,522,363, each of which is incorporated herein by reference in its entirety.

Different thicknesses and different topographies, as discussed further below, of the two-dimensional injection molded components, such as the two-dimensional injection molded components 140 and 142 are also contemplated herein for any embodiment in accordance with the invention, such as ranging from approximately 0.010 to 0.500 of an inch (0.025-1.25 cm), which are designed for application-specific purposes. Any two-dimensional injection molded component according to embodiments of the invention may have a varied thickness or for embodiments having more than one injection molded component, even where one component has a non-varied thickness, other components may have different thicknesses. For example, a cut resistant fabric liner may have further protection provided by injection-molded components located on an index finger and thumb for a carpenter's glove; for a mason's glove, the finger tips may have two dimensional injection molded components for abrasion resistance, impact resistance, and gripping properties; while for a sheet metal worker's glove, only the palm and finger tips may have the two-dimensional injection-molded components, further comprising two-dimensional injection molded in the finger crotches to protect against cuts.

The two-dimensional injection molded components 140,142 (as well as any other two-dimensional injection molded component described herein) may have a specific composition commensurate with a particular application. For example, particles may be added to the elastomeric material, of which the two-dimensional injection molded component 140 is comprised, to facilitate abrasion resistance, surface grip, antimicrobial properties, enhanced anti-vibration characteristics, enhanced impact characteristics, and/or enhanced flexibility or visibility. The addition of such materials to achieve these characteristics may be added in various amounts to tailor the desired characteristic to the application of the glove. To enhance abrasion resistance the elastomeric material of the component may be selected for hardness or inorganic additives such as boron nitride may be mixed in the elastomeric material. Additives for flame resistance, such as for a welder's glove, such as metal hydroxides and/or fumed silicas, may be compounded into the elastomeric material(s).

The hybrid gloves, i.e., gloves comprising a knitted liner, a polymeric coating, and at least one injection molded component discussed herein may be customized to provide only the characteristics and properties for specific service applications. For example, a glove for an oil and gas worker requires exceptional grip under oily conditions, cut-resistance, impact-resistance, flame-resistance as well as dexterity, a glove for an electrician requires high dexterity and puncture-resistance in the fingertips and breathability (so that moisture and sweat are not an issue), and a glove for a carpenter requires thin fingertips for dexterity and impact-resistance features to protect the back of hands. A glove for a mason requires abrasion resistance and superior grip for fingertips, as well as impact-resistance on both the palm and backhand area, a glove for a plumber requires grip, breathability, and liquid-resistance, and a glove for a laborer requires durability, impact-resistance, breathability, all while being appropriate for winter and summer use. Gloves for more general uses, i.e., for use for many different tasks, e.g., digging, welding, using hand tools, etc., e.g., an HVAC worker, are also contemplated according to embodiments of the invention.

For example, and not by way of limitation, a glove for use by masons can comprise a composition such as the following. At least one exemplary embodiment according to the invention comprises two dimensional injection molded components that include resins such as styrene-ethylene/butylene-styrene (SEBS) and/or styrene-ethylene/propylene-styrene (SEPS). At least one suitable saturated styrene block copolymer (SEBS), providing good abrasion resistance and hardness properties (for example, a Shore A durometer hardness of 25), is grade RTP 2799SX 127556 A TPE, sold by the RTP Co. Additives for SEBS or SEPS can comprise sand, silica, ultraviolet additives, pigments, and the like. In some embodiments, the TPE grade by weight is approximately 95 percent or more. A material for the injection molded components for an oil and gas glove can comprise thermoplastic vulcanizate elastomer, such as grade RTP 2899 X 128802 B by the RTP Co. and further comprise flame retardance and ultraviolet stabilizers. Embodiments for an oil and gas glove may comprise between 80-100 percent by weight material grade RTP 2099 E X 117792 C, a thermoplastic urethane alloy (TPU), a flame retardant, and an adhesion promoter, increasing the adherence of the material to, for instance, polycarbonate, ABS, and polyesters. In at least one exemplary embodiment of the invention, the 2D injection molded components comprise a TPU blended with TPE-SEBS resin and/or a TPE supplied by Allod Werkstoff GmbH & Co.

To enhance surface grip, the surface of the two-dimensional injection molded components may be roughened using a chemical treatment, the mold for the injection molded component may emboss a surface texture onto the component (EDM finishes, as described above), particles may be embedded in the surface (e.g., sand, silica) or the like for grip and durability.

To enhance antimicrobial properties, antimicrobial materials such as iodine, silver, zinc, silane quaternary ammonia salt, or the like may be incorporated into the two-dimensional injection-molded component or in the knitted fabric liner. Such materials neutralize or kill any microbes that contact the surface of the component and/or are active for biostatic properties. Antimicrobial gloves may be used by food/health workers and/or medical personnel.

To enhance anti-vibration characteristics, the surface of the glove 160 must mitigate mechanical stresses that physically deform the glove material. Such deformation may arise from a motor (continuous vibration), an impact (single event vibration), electrical (piezo-electric effect), water flow, and the like. Upon deformation, both longitudinal and shear waves components (a mechanical wave) is imparted into the glove surface and propagates thru the glove material. The wave continues propagating until attenuated by imperfections and features in the glove material. Imperfections and features selected to attenuate waves may include porosity, reinforcing materials, laminations, differing material phases, and the like.

In other applications for the glove 160, impact resistance may be selectively enhanced by utilizing zonal application of thickened regions within the injection molded component, or using particular materials for the component such as shear thickening fluids as part of the component. As such, a glove may be designed to improve hand protection for users.

Also, at least one finger of the fabric liner 102 may comprise a conductive yarn that contacts the finger of a wearer. If the elastomeric composition of which the coating 162 is comprised has a conductive material admixed therein, a user can operate a capacitive touchscreen without removing the glove 160. Similarly, if at least one two-dimensional injection molded component disposed on at least one palm side fingertip of an electrically conductive fabric liner 102, i.e., an index finger, is comprised of a material doped with an electrically conductive material, a user could operate a capacitive touchscreen with removing the glove. In other embodiments, the injection-molded components comprise elastomers or other polymers that are fire- and/or heat resistant or arc-resistant. Such gloves find use with oil and gas workers, chefs, first responders, electricians, welders or any application where heated or electrically enabled articles are moved or touched.

FIG. 3B is a cross-sectional view of the glove 160 having the two-dimensional injection molded component 142 and the coating 162 disposed on the fabric liner 102 of FIG. 2A taken along line 3B-3B, according to embodiments of the invention. The two-dimensional injection molded component 142 comprises a first portion 146, a second portion 148, and a third portion 147 disposed therebetween. As shown, the first portion 146 comprises a through hole 150, which traverses the first portion 146 laterally. The second portion 148 comprises a blind hole 152, which traverses the second portion 148 laterally. The third portion 147 comprises three through holes 154, traversing the third portion 147 longitudinally. In practice, the glove 160, as any other glove according to embodiments of the invention, may comprise a plurality of the longitudinal through holes 154, the lateral blind hole 152, and the lateral through hole 150 on any portion of any two-dimensional injection molded component or, for example, the third portion 147 may comprise one, two, three, or any reasonable number of through holes or blind holes, or being oriented in any direction, laterally or longitudinally. Some embodiments may comprise one or more two-dimensional injection molded components in which the through holes criss-cross for additional flexibility.

FIG. 4 depicts a palm view of a glove 300 having two-dimensional injection molded components 304 and 306, according to embodiments of the invention. The glove 300 comprises a fabric liner 302, e.g., knitted or woven, and at least one injection molded component 304. The fabric liner 302 comprises a thumb 310, an index finger 312, a middle finger 314, a ring finger 316, a little finger 318, and a cuff 322. As shown, the glove 300 has a first injection molded component 304, which ranges, for example, from 0.010 to 0.500 inches (0.01-0.5 cm) in thickness, and covers the palm of the fabric liner 302 extending to an upper palm area 330, a lower palm area 332, and a portion of the thumb 310 and is, as shown, one contiguous injection molded component. Additionally, a second injection molded component 306 covers a lower right palm area 334 and is not contiguous with the two-dimensional injection molded component 304. A thinner two-dimensional injection molded component, having a textured surface (not shown), provides additional gripping capability. The glove 300, having two or more two-dimensional injection molded components 304, 306, which are separated from each other, are inherently more flexible. Also, by incorporating molded components having varied thicknesses onto a fabric liner, more impact resistance, flexibility, dexterity, and tactility can be imparted only where needed. For example, the glove 300 comprises two-dimensional injection molded components disposed as a plurality of finger grips 328, ranging in thickness from, for example, 0.050 to 0.100 inches (0.125-0.25 cm) and may be textured for enhanced grip on the palm side of the index finger 312. Furthermore, as shown on the ring finger 316, the finger grips 328 may have a bridge 330 (which may be thinner than the finger grips 328 for added flexibility). The bridge 330, because it joins the finger grips 328, aids in simplifying the runner system used to injection polymeric materials onto the fabric liner 302 (as discussed herein) as is known to those of skill in the art.

FIG. 5 depicts a back hand view of a glove 400 having a plurality of two-dimensional, injection molded components 404, 406, and 442, and a coating 462 disposed thereon, according to embodiments of the invention. The glove 400 is at least one exemplary embodiment of the invention and comprises a fabric liner 402 in the shape of a glove having fingers 312, 314, 316, and 318 and a thumb 310 and further comprises a two-dimensional injection molded component 404, having a thickness ranging from approximately 0.050-0.500 inches (0.125-1.25 cm). The two dimensional injection molded component 404 comprises a plurality of longitudinal slits 408 and a plurality of lateral slits 410. The fabric liner 402 further comprises a cuff portion 422, a cuff ring 426, and a lower right portion 434, which comprises a two-dimensional injection molded component 406 having a longitudinal slit 410, promoting flexibility. At least one exemplary embodiment according to the invention comprises a glove 400 having the thumb 310 in a bent configuration. Furthermore, the thumb 310 may comprise a plurality of injection molded components molded thereon. By way of explanation, where the thumb 310 is in a bent configuration, it embodies two planar areas, i.e., on each side of a knuckle, either or both of which could have an injection molded component molded thereon. For example, two-dimensional molded components, such as the finger grips 328, may be molded onto the palm side or the back hand side of the thumb 310.

Specifically, FIG. 6A depicts a side view of a two-dimensional injection molded component 500 having holes 510 disposed on the fabric liner 102, according to embodiments of the invention. The two-dimensional injection molded component 500 also comprises a flat side 220, which is the side that is adhered to a planar region of the fabric liner 102, by an injection molding process. Where a two-dimensional injection molded component, e.g., the two-dimensional injection molded component 500, is molded onto the knitted fabric liner 102 directly, polymeric molecules of the two-dimensional injection molded component penetrate and become intertwined on and within interstices of the knitted fabric liner 102, promoting its adherence thereto, such that the two-dimensional injection molded component 500 could not be removed from the knitted fabric liner 102 without destroying the knitted fabric liner 102.

As shown, the two-dimensional injection molded component 500 comprises three holes 510 that traverse the two-dimensional injection molded component 500 in a lateral manner. In practice, any reasonable number of holes 510 may be molded into the two-dimensional injection molded component 500, for example, arrays of holes 510 stacked or staggered in networks, having different sizes, and other properties. Moreover, the two-dimensional injection molded component 500 may have one or more holes 510 comprising through holes, blind holes, or combinations of through holes and blind holes.

The plurality of holes 510 disposed within the two-dimensional injection molded component 500 may be formed by cams of a mold having core pins (not shown) as are known to those in the art. Additionally, the core pins may be attached to cams that are actuated by angled cam fingers that slide the core pins into and out of the injection mold as the injection mold is opened and closed during typical injection molding processes, as is discussed in U.S. Pat. No. 5,234,329, incorporated by reference in its entirety and Plastics Engineering Handbook, pp. 190-192, 5^thEd., Michael L. Berins, ©1991, the technology of which at pages 190-192 is incorporated herein by reference.

The two-dimensional injection molded component 500 comprising the holes 510 flex more easily than injection molded components having no holes. Also, the holes 510 in the two-dimensional injection molded component 500 will partially “collapse” (and return to their original shape) during an impact event, distributing the energy of the impact and resulting in a more impact resistant glove. Furthermore, by providing holes that run along one or more axes of two-dimensional injection molded components and/or molding channels of differing sizes, gloves having anisotropic physical properties can be balanced and therefore designed for specific applications, i.e., more or less flexibility in specific regions of a glove, more or less impact resistance, and the like.

FIG. 6A depicts a perspective view of an “A” side 602 of an injection mold 600; FIG. 6B depicts a perspective view of a “B” side 622 of an injection mold 600; FIG. 6C depicts a perspective view of a flat former 644 for use in conjunction with the “A” and “B” sides of the injection mold 600; and FIG. 6D depicts an assembled perspective view of the “A” side 602 of the injection mold 600 of FIG. 6A, the “B” side 622 of the injection mold 600 of FIG. 6B, and the flat former 644 of FIG. 6C, to create a glove having two-dimensional injection components injection molded on a fabric liner, according to embodiments of the invention.

Specifically, FIG. 6A depicts a perspective view of an “A” side 602 of an injection mold 600, according to embodiments of the invention. The “A” side 602 comprises cavities 604, 606, 608, 610, and 620, correspond to similar cavities on a “B” side as discussed below. The cavity 610 further comprises cores 612 and 614, which can be used to mold features such as the two-dimensional injection molded components discussed above, for example, the first end 202, the second end 204 and the middle portion 206 discussed above. The cores 612 and 614 are the “negative” of the molded features of the two-dimensional injection molded components. Also, the “A” side 602 further comprises a cavity 616, which can be used to mold a two-dimensional injection molded component on, for example, the back hand area of a glove. The “A” side 602 also comprises half of a sprue bushing 646a (for receiving the nozzle of a barrel of an injection molding machine, not shown) and guide holes 660, which are capable of receiving guide pins located on the “B” side 622, when the injection mold 600 is closed, as discussed below.

FIG. 6B depicts a perspective view of a “B” side 622 of an injection mold 600, according to embodiments of the invention. The “B” side 622 comprises cavities 624, 626, 628, 630, and 632 which correspond to cavities 604, 606, 608, 610, and 620 respectively on the “A” side, as discussed above. The cavities 624, 626, 628, 630, and 632 can further comprise cores, similar to the cores 612, 614, or cavity 616, as discussed above, which would dispose a two-dimensional injection molded component on the palm side of a glove. The “B” side 622 also comprises half of a sprue bushing 646b, which, when the “A” side 602 and the “B” side 622 are assembled, form a sprue bushing, discussed below. Also, the “B” side 622 comprises guide pins 662, which, when the “A” side 602 and the “B” side 622 are assembled, are received into the guide holes 660, discussed above.

FIG. 6C depicts a perspective view of a flat former 644 for use in conjunction with the “A” side 602 and the “B side 622 of the injection mold 600, according to embodiments of the invention. The flat former 644 is in the general shape of a hand and comprises a little finger portion 634 having an end 674, a ring finger portion 636 having an end 676, a middle finger portion 638 having an end 678, an index finger portion 640 having an end 680, a thumb portion 642, and a handle 645. The flat former 644 comprises a palm side 625 as depicted and also comprises a corresponding backhand side 627. Embodiments according to the invention include a flat former 644 wherein at least one area, e.g., the little finger portion 634, the end 674, the ring finger portion 636, the end 676, the middle finger portion 638, the end 678, the index finger portion 640, the end 680, the thumb portion 642, the palm side 625 or the backhand side 627 is flat such that the flat former 644 can maintain the planarity of the knitted fabric liner during the injection molding of a two-dimensional molded component to a respective area of a glove.

It is to be noted that at least one of the little finger portion 634, the ring finger portion 636, the middle finger portion 638, the index finger portion 640, a thumb portion 642 palm side 625 and the corresponding backhand side 627 of the flat former 644 is flat. A two-dimensional injection molded component is to be molded to a fabric liner on a flat side of the flat former 644. In other words, the flat former 644 comprises a flat surface on the side to which the two-dimensional injection molded component will be molded, whether on the palm side 625 or the back hand side 627 because the flat former 644 maintains the flatness, i.e., planar region of the fabric liner during molding in the region in which the two-dimensional component will be molded to the fabric liner. If a fabric liner will have two-dimensional injection molded components molded on both the palm side 625 and the back hand side, the flat former 644 will be flat on each of the palm side 625 and the back hand side 627. Because the flat former 644 corresponds to an area on a knitted liner on which the two-dimensional injection molded components, will be disposed flat on a surface that adheres the two-dimensional injection molded components to the fabric liner dressed on the flat former 644 and, accordingly, the two-dimensional injection molded components do not traverse any edges, i.e., remain on either a palm side or a backhand side of the fabric liner. The flat former 644 is typically placed in an injection mold in a manner in which a longitudinal axis, i.e., an axis running from a cuff to a fingertip, was parallel with the parting line of the injection mold. In other words, if the fabric liner were cut in half along the longitudinal axis, one half would comprise part of each finger, thumb, and cuff of the back hand while the other half would comprise part of each finger, thumb, and cuff of the palm side. A parting line of an injection mold is defined as the point at which two halves of an injection mold meet, and, therefore, one half of the fabric liner discussed above would be in a first half of the injection mold and the other half of the fabric liner 102 would be in a second half of the injection mold. Embodiments according to the invention comprise at least one two-dimensional injection molded component, as discussed herein, that is molded onto a fabric liner 102, and optionally disposed on one or both sides of the injection mold parting line.

FIG. 6D depicts an assembled perspective view of the “A” side 602 of the injection mold 600 of FIG. 6A, the “B” side 622 of the injection mold 600 of FIG. 6B, and the flat former 644 of FIG. 6C, according to embodiments of the invention. As shown, the “A” side 602 further comprises a first half of a sprue bushing 646 (along the parting line of the injection mold 600) and a second half of a sprue bushing 630 (located solely on the “B” side 622). Any injection mold can comprise one or multiple sprue bushings so that a thermoplastic or other material can be injected into various cavities of the mold. The sprue bushing 630 is capable of mating with a nozzle 652, that is part of an injection molding barrel 656 that contains a plasticating screw 654 for melting and injecting a plastic material, which when injected into an injection mold is delivered via a runner and gate system (not shown), as is known to those in the art, to at least one of the cavities 604, 606, 608, 610, 620, 624, 626, 628, 630, and 632 and becomes a two-dimensional injection molded component, as discussed above. Also, the “A” side 602 comprises four mounting holes 666. In practice, the “A” side 602 may comprise any reasonable number of mounting holes for mounting the injection mold 600 to an injection molding machine. The “B” side 622 similarly comprises mounting holes (not shown). Also, as is known to those in the art, an additional mounting plate (not shown) having mounting holes may be assembled with each of the “A” side 602 and “B” side 622.

As shown, the flat former 644 extends from the “A” side 602 and the “B” side 622 and can be seen when the injection mold 600 is assembled and closed. In practice, the design of both the “A” side 602 and the “B” side 622 could be modified to enclose the ends 674, 676, 678, and 680 within the “A” side 602 and the “B” side 622, as is known to one in the art.

To apply two-dimensional injection-molded components to the knitted liner 102, the knitted liner 102 is dressed on the flat former 644. The flat former 644, as shown and described above with respect to FIG. 6C, is typically made of a metal, such as steel or aluminum and is in the general shape of a hand, although the mold may comprise any suitable material, such as aluminum, ceramics, plastics (acrylics, epoxies, or other high-melting temperature resins), wood, or the like. The flat former 644 having the knitted liner 102 (or a knitted liner having a coating disposed thereon) dressed thereon, is placed into the injection mold 600, as is known in the injection molding industry, i.e., the “cavity” of a mold, having an internal formed surface that inversely matches the positioning and contour of the components. Accordingly, the flat former 644 having the fabric liner 102 dressed thereon is a “core” part of the injection mold 600. By using an injection molding process, the two-dimensional injection molded components can be positioned at any location on the knitted liner, i.e., wherever a cavity, as described above, comprises a cavity having a desired shape, depth, width, etc. And, as discussed above, two-dimensional components are directly formed on a planar region of the fabric liner 102 or planar region of the coating disposed on the fabric liner 102, which is maintained by the flat former 644, as discussed above.

The injection molding process comprises injecting molten polymeric materials, such as TPRs, TPVs, or TPEs, under pressure into the injection mold 600. Embodiments according to the invention include dressing the knitted fabric liner 102 on the flat former 644, as discussed above, such that the TPRs, TPVs, or TPEs fills the gaps between the knitted liner 602 and a surface of at least one of the “A” side 602 or “B” side 622 of the injection mold 600. Upon cooling, the injection mold 600 is opened and the flat former 644, with the knitted liner 102 now having the two-dimensional injection-molded components disposed onto the knitted liner 102, forming a glove having at least one two-dimensional injection molded component, is removed from the injection mold 600. The glove can now be stripped from the flat former 644, and the flat former 644 can then have another knitted liner dressed thereon and be used in a subsequent injection molding cycle.

Typical injection molds comprise two mold halves, runner systems, runner plates, knock-out plates, and other componentry as is known to those in the art. Also, injection molds according to the invention may further include slides, cams, cam fingers, and the like to provide molded features within the injection molded components of the gloves, such as undercuts, cantilevers, threads, channels, and similar profiles, textures, and the like, which would otherwise be difficult to eject from the mold without damaging the molded features, i.e., the two-dimensional injection molded components.

FIG. 7 depicts a process 700 for forming a glove, according to embodiments of the invention. The process 700 starts at step 702 and proceeds to step 704, at which point a polymeric material is injected onto a planar region of a fabric liner dressed on a flat former (as discussed herein) displaced inside an injection mold. The injection mold comprises cavities, as is known to those in the art, in the shape of any two-dimensional injection molded component as discussed herein.

At step 706, the flat former, having the fabric liner with at least one two-dimensional injection molded component disposed thereon, is removed from the injection mold and delivered and/or dipped into a bath containing an elastomeric composition, such as a synthetic polyisoprene, a natural rubber, an acrylonitrile composition and/or the like. As discussed above, in some embodiments according to the invention, the two-dimensional injection molded components may be molded onto the fabric liner before the dipping step. Also, as discussed above, in some embodiments according to the invention, the two-dimensional injection molded components may be molded directly onto the coating disposed onto the fabric liner. The coating disposed thereon may have a primer, such as a chemical primer, disposed thereon before the injection molding step. Alternately, and/or additionally, embodiments of the invention include wherein the coating is partially cured for example, from 60-80° C. for 10-20 minutes before the two-dimensional injection molded components are molded directly onto the coating. In at least one exemplary embodiment of the invention, the elastomeric composition comprises a nitrile-butadiene material and/or a sandy nitrile-butadiene material.

At step 708, the fabric liner having the at least one two-dimensional injection molded component disposed thereon is dipped into the bath, disposing an elastomeric coating on the fabric liner (which may additionally cover the two dimensional injection molded components). At step 710, the coating is cured, such as by delivering the former having the at least one two-dimensional injection molded component and coating disposed on the fabric liner to an oven at an appropriate temperature as is known to those in the art, for example, from 80-120° C. for 30-50 minutes. At step 712, the process 700 ends.

With the materials for fabric liners, injection molded components, and dipped coatings discussed herein in view, a custom solution for each of the service specific applications is possible. Embodiments according to the invention further include disposing one or more two-dimensional injection molded components onto any of the application specific gloves in commonly assigned patent application, US Publ. No. 2010/0275342, which is herein incorporated by reference in its entirety.

As discussed below, the polymeric, elastomeric or latex used to make coatings disposed on the fabric liner comprises polyisoprene, nitrile-butadiene, polyurethane, polychloroprene, or any combination thereof. At least one exemplary embodiment includes an elastomeric coating comprised of highly-carboxylated acrylonitrile-butadiene rubber (NBR). Moreover, any polymeric, elastomeric, or latex coating may be foamed as is known to those in the art. Open-celled foams, generally comprising between 15-60% by volumetric air content, comprise interconnected networks of cells and are therefore breathable foams, allowing, for example, moisture and perspiration to escape from inside a glove formed therewith.

In various embodiments, a fabric liner may be knitted using conventional knitting equipment and processes or, alternatively, a Knitted Variable Stitch Design (KVSD) technology as disclosed in commonly assigned U.S. Pat. No. 6,962,064, incorporated herein by reference in its entirety. Also, the injection-molded components may be applied for aesthetic purposes to add contour or color to a glove or a labeling or logo.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

GLOVE HAVING TWO-DIMENSIONAL INJECTION MOLDED COMPONENTS

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