The present invention relates to a glove having multiple layers and methods of manufacture thereof.
Gloves of the prior art are constructed of various materials and are used for various purposes. For example, the prior art includes workman gloves, surgical gloves, driving gloves, household gloves, skiing gloves, and gloves for providing warmth. Gloves of the prior art have typically been formed from leather, polyvinyl chloride, rubber, and fabric. It is also known in the art to provide composites, such as fabric gloves dip-coated with a natural or nitrile rubber.
The prior art also includes gloves having fabric and leather reinforcing elements that are mechanically fastened to a glove. For example, the prior art includes fabric and leather strips sewn onto the outer surface of the glove. The fabric and leather reinforcing elements are positioned on sections of the glove corresponding to the fingertips, the knuckles, the wrist, the palm, and/or the back side of the hand. Although fabric and leather reinforcing elements increase a glove's grip and wear resistance, they are expensive materials and must be mechanically fastened to the glove. This increases the total manufacturing cost of the glove, as well as the final retail price paid by consumers.
It is also known in the art to provide a glove having polyvinyl chloride patches bonded to an underlying fabric. For example, U.S. Pat. No. 6,185,747 discloses polyvinyl chloride patches that are metal-screened to the fibers of the underlying fabric. Unfortunately, the bond between the screened polyvinyl chloride and the fibers causes the fibers to stiffen, which in turn causes discomfort and potential irritation to the hands of a person wearing the glove. Furthermore, the fabric of the glove is exposed in multiple locations, such as in the areas between the polyvinyl chloride patches. This forms vulnerable areas that have low wear resistance and that are easily susceptible to puncture and/or chemical penetration.
What is needed in the art is a glove that provides good grip at a low-cost and does so without unnecessarily compromising the wear resistance or comfort of the glove.
Preferred embodiments of the invention overcome the disadvantages and shortcomings of the prior art by providing a multilayer glove that includes a fabric substrate, an intermediate layer of resilient material, and an outer layer of resilient material. The fabric substrate is in the form of a glove and has an outer surface. The intermediate layer of resilient material is preferably applied to the fabric substrate so as to completely cover at least a portion of the outer surface of the fabric substrate. The outer layer of resilient material is preferably bonded to one or more selected areas of the intermediate layer such that the outer layer is separated from the fabric substrate by the intermediate layer. The intermediate layer and the outer layers may be formed from the same resilient material or from different resilient materials.
In a first embodiment of the invention, the fabric substrate is formed from a one piece seamless string-knit having the shape of a glove. However, any suitable fabric may be used, such as a woven, nonwoven, or knit fabric. The intermediate layer is preferably formed from a protective coating, such as nitrile rubber foam. However, any suitable resilient material may be used, such as silicone, polyurethane, polyvinyl chloride or other 100% solid plastic resins, solvent solutions of similar resins, as well as natural rubber or synthetic rubber solutions or emulsion forms of plastic or rubbers. These materials also may be expanded or foamed. These materials may be expanded or foamed. In the first embodiment of the invention, the fabric substrate and the intermediate layer form a composite. In some embodiments of the invention, the multilayer glove 10 includes a substrate formed from plastic and/or rubber.
In the first embodiment of the invention, the outer layer comprises one or more reinforcing elements that bond with the protective coating. However, any suitable resilient material may be used, such as silicone, polyurethane, polyvinyl chloride or other 100% solid plastic resins, solvent solutions of similar resins, as well as natural rubber or synthetic rubber solutions or emulsion forms of plastic or rubbers. These materials also may be expanded or foamed. The reinforcing elements preferably have a substantially uniform thickness that is in the range of about twenty mil to about eighty mil, though the reinforcing elements can be of a thickness outside this range.
Each individual reinforcing element preferably has one or more openings, referenced herein as relief areas, formed therethrough. The plurality of reinforcing elements preferably also forms relief areas therebetween. The relief areas are preferably positioned so as to be aligned with the joints and creases of a human hand inserted into the multilayer glove.
In a second embodiment of the invention, at least one of the reinforcing elements is formed to have a first color, and at least another one of the plurality of the reinforcing elements is formed to have a second color. In this respect, a manufacturer may manipulate the colors of the reinforcing elements to form a novel design.
Additional embodiments of the invention are disclosed herein. For example, the multilayer glove may have reinforcing elements positioned at the areas of the fabric substrate corresponding with the knuckles and fingertips of the hand. As another example, the multilayer glove may have a reinforcing element with a mesh pattern formed therein. Methods for manufacturing a multilayer glove are also disclosed herein.
For a more complete understanding of the present invention, reference is made to the following detailed description of various exemplary embodiments considered in conjunction with the accompanying drawings, in which:
Referring to
The fabric substrate 16 has a shape similar to a human hand. The fabric substrate 16 is preferably string-knit. However, the fabric substrate 16 may be formed from any suitable natural or synthetic material, such as a woven, nonwoven, or knit fabric. In some embodiments of the invention, the multilayer glove 10 includes a substrate formed from plastic and/or rubber.
The protective coating 18 is preferably dip-coated onto the fabric substrate 16. The protective coating 18 may be disposed on part or all of the fabric substrate 16. Preferably, the protective coating 18 is at least disposed on those portions of the fabric substrate 16 alignable with the fingers, knuckles, and palm of the human hand. The protective coating 18 is preferably formed from nitrile, and is more preferably formed from nitrile foam rubber. However, any suitable resilient material may be used, such as silicone, polyurethane, polyvinyl chloride or other 100% solid plastic resins, solvent solutions of similar resins, as well as natural rubber or synthetic rubber solutions or emulsion forms of plastic or rubbers. These materials also may be expanded or foamed. In some embodiments of the invention, the protective coating 18 is formed from neoprene and/or styrene butadiene rubbers.
As discussed above, the fabric substrate 16 and the protective coating 18 preferably form a composite 12. In this regard, the fabric substrate 16 and the protective coating 18 each contribute desirable properties to the composite 12 as a whole. For example, in the preferred embodiments, the fabric substrate 16 provides comfort to a person wearing the multilayer glove 10, while the protective coating 18 increases the wear resistance of the multilayer glove 10 and decreases the susceptibility of the multilayer glove 10 to puncture and/or chemical penetration.
Continuing with principal reference to
Preferably, the thickness of a reinforcing element 14, referenced herein as RET, is substantially uniform throughout the reinforcing element 14. It is also preferable that the variance in thickness RET of a reinforcing element 14 not be so great as to be immediately detectable by the naked human eye. The thickness RET of a reinforcing element 14 is preferably between one mil and one hundred fifty mil, and is more preferably between twenty mil and eighty mil. It should be obvious to one skilled in the art that the stated preferences regarding thickness do not necessarily apply to the relief areas 24, 24′.
The reinforcing elements 14 are preferably formed from nitrile rubber and are more preferably formed from nitrile foam rubber. However, any suitable resilient material may be used, such as silicone, polyurethane, polyvinyl chloride or other 100% solid plastic resins, solvent solutions of similar resins, as well as natural rubber or synthetic rubber solutions or emulsion forms of plastic or rubbers. These materials also may be expanded or foamed. In some embodiments of the invention, the protective coating 18 is formed from neoprene and/or styrene butadiene rubbers.
As discussed above, the reinforcing elements 14 preferably bond with the protective coating 18. Such bonding is preferably a chemical bond and is more preferably a vulcanized bond. Such vulcanized bonding is preferably caused by the reinforcing elements 14 being cured while on the protective coating 18 for integration therewith. Suitable bonding may be caused by other processes, such as molding. In some embodiments of the invention, the reinforcing elements do not bond with the fabric substrate 16.
It is recognized that bonding of reinforcing elements is enhanced by making the coating material similar to the reinforcing material, such as by using a nitrile rubber dipped coating in the intermediate layer and Nitrile rubber in the outer layer. By way of example, if it was desired to have a natural rubber coated glove reinforced with Nitrile rubber, it would be advantageous to blend the Nitrile rubber with at least some natural rubber to enhance bonding of the two layers. Further, this would take place in most cases when the rubber materials were in latex form.
The multilayer glove 10 may include additional features (not shown), such as a cuff, hook and loop fasteners, finger and/or knuckle guards, additional layers, a label, a clasp for securing a pair of multilayer gloves together, and any other suitable feature(s) that are now or hereafter known in the art. For example, a sample embodiment (not shown) of the multilayer glove 10, has the following features: (1) a composite 12 having a fabric substrate 16 and a protective coating 18 disposed on a portion of the fabric substrate 16 corresponding with the palm; (2) a plurality of reinforcing elements 14 bonding to the protective coating 18 at the palm; (3) a fabric weave fastened to the composite 12 at the back of the fingers; (4) finger guards fastened to the fabric weave; (5) a logo sewn onto the composite 12; and (6) a Velcro cuff strap.
It should be clear to one skilled in the art that the multilayer glove 10, generally, and/or the composite 12 can include additional layers, structures, and/or materials as desired. By way of nonlimiting example, the multilayer glove 10 may include an additional layer (not shown) disposed between the fabric substrate 12 and the protective coating 18. As another example, an additional layer (not shown) may be disposed between the protective coating 18 and the reinforcing elements 14 to form a composite.
Referring to
With reference to
The reinforcing material(s) that form the reinforcing elements 114, 126 are preferably pigmented prior to being cured and/or dried, so as to cause the coloring of each reinforcing element 114, 126 to be disposed therethrough, respectively. The reinforcing elements 114, 126 may be positioned at any suitable location. As shown, it is preferred that the reinforcing elements 114, 126 be positioned directly on the coating layer 18 for bonding therewith. In an alternative embodiment, one or more additional reinforcing elements 126 may be disposed on top of one more of the reinforcing elements 114 (not shown).
Referring to
With reference to
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With reference to
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With principal reference to
At securing step 534, an operator secures an end of a former 650 to the fabric substrate 16 and another end of the former 650 to a conveyor system (not shown). The former 650 preferably comprises a flat steel plate for spreading the fabric substrate 16 into a flat, hand-shaped form; however, the former 650 may comprise a three dimensional ceramic structure. The conveyor system preferably advances the fabric substrate 16 through the steps of assembly method 532.
At coating step 536, the conveyor system dips the fabric substrate 16 into a coating material, such as nitrile rubber. Any suitable coating material may be used, however, any suitable resilient material may be used, such as silicone, polyurethane, polyvinyl chloride or other 100% solid plastic resins, solvent solutions of similar resins, as well as natural rubber or synthetic rubber solutions or emulsion forms of plastic or rubbers. These materials also may be expanded or foamed. In some embodiments of the invention, the coating material may be neoprene and/or styrene butadiene rubber.
At curing step 538, the coating material is cured and/or dried, preferably forming a composite 12 having the fabric substrate 16 and the protective coating 18. As discussed, additional layers and/or materials may, in some embodiments of the invention, be positioned over the protective coating 18 and/or between the fabric substrate 16 and protective coating 18.
At application step 540, a reinforcing material 660, such as nitrile latex rubber, is applied in a liquid state to the protective coating 18 to form reinforcing elements 14. However, the reinforcing elements 14 can be strengthened to increase cut and abrasion resistance by adding reinforcing fibers and/or reinforcing mineral fillers such as Nylon, polyester, Kevlar fibers, Mica, calcium carbonate, etc.
Referring to
Referring to
The mesh members 628 shown in
Referring to
In some embodiments of the assembly method 532, a sheet 658 may have openings, rather than mesh members 628, formed therein (not shown). In said embodiments, a mesh member 328, such as that shown in
In some embodiments of the assembly method 532, the logo 430 and bands of elastomer may be applied, preferably around the wrist and contemporaneously with the reinforcing elements 14.
Referring to
Although the preferred embodiments of the application step 540 have been herein shown and described in detail, it should be appreciated by one skilled in the art that there are other ways in which reinforcing material can be passed through a mesh member to form reinforcing elements. For example, a glove substrate could be fully or partially enclosed within a mask having mesh members formed therein. The enclosed glove substrate could be dipped into a reinforcing material, such as nitrile or another material. As another example, reinforcing material could be applied to the protective coating and the reinforcing materials could be shaped by applying solvents, acids, and/or other chemicals to desired areas of the reinforcing material. The reinforcing elements could also be molded.
At curing step 542, the conveyor system transports the glove substrate 12 and reinforcing elements 14 to apparatus for drying and/or curing. The reinforcing elements 14 preferably form a vulcanized bond with the protective coating 18.
At application step 544, additional reinforcing material may be applied to the outer surface of the glove substrate. This is particularly useful for manufacturing the multilayer glove 110 shown in
At curing step 546, the additional reinforcing elements 126 are cured. It should be clear to one of ordinary skill in the art that application step 544 and curing step 546 are analogous to application step 540 and curing step 542, and that said steps can be repeated as desired to add reinforcing elements of a third color, a fourth color, etc. In some embodiments of the invention, the additional reinforcing elements 126 of the second color may be disposed on top of the reinforcing elements 114 of the first color.
At removal step 548, the operator removes the multilayer glove 10 from the former 650 and the conveyor system returns to its initial position, where the operator can place a new fabric substrate 16 on the former 650 for processing in accordance with the steps of assembly method 532.
Preferred embodiments of the invention presented herein thus provide for a multilayer glove that has a good grip at a low manufacturing cost. In the preferred embodiments, the materials are preferably durable, long-lasting, aesthetically pleasing and provide good wear resistance and comfort. It will be understood that the embodiments of the present invention described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and the scope of the invention. All such variations and modifications, including those discussed above, are intended to be included within the scope of the invention as defined in the appended claims.
The present application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/562,920, filed Apr. 16, 2004, which is hereby incorporated by reference in its entirety for all purposes.
Number | Date | Country | |
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60562920 | Apr 2004 | US |