MOLDED FINGER COVERS

FIELD OF THE INVENTION

The present invention relates generally to finger covers and more particularly to the construction of a finger cover designed to improve the tactility and dexterity at the fingertip of a wearer of the finger cover of this construction.

BACKGROUND OF THE INVENTION

Knitted gloves or those that are constructed of an elastomeric material (e.g., a latex glove) can be fabricated without any seams at the fingertips, which as used herein includes the tip of the thumb. Elastomeric gloves, such as latex gloves, nitrile gloves and PVC gloves, are constructed without any seams at the fingertips by molding. These gloves are made by dipping a hand form into a liquid polymer solution, and then air dried, resulting in a seamless finger polymer glove.

Another seamless finger glove example in the prior art is gloves that are first knitted in the shape of a hand, then placed on a hand form and dipped into a liquid polymer solution such as nitrile, latex, or PVC, for example, and then air dried. This results in a seamless finger polymer layer over a seamless knit finger.

Another seamless finger glove example is injection molded gloves, constructed using a two or three part metal mold, with liquid or flowable solid polymer solutions injected into the mold over a seamless knit glove. This fabrication process results in a seamless polymer layer over a seamless knit finger.

However, gloves of other materials, such as leather, cannot be fabricated out of one continuous piece of material and typically require some type of seam at the fingertip. This seam typically comes in contact with the volar surface of the fingertip, below the fingernail. Common prior art seam constructions at the fingertip include the pinch fingertip, box fingertip, rolltop fingertip and gunn cut fingertip.

As seen in FIG. 1A, illustrating a side view of a glove finger constructed using the prior art pinch fingertip, which is commonly found on work gloves, the glove finger comprises a top fabric 101, bottom fabric 102, and one or two side fabrics 103 (acting as fourchettes). With the pinch fingertip, each of these fabric pieces is sewn together in one seam 104 at the fingertip. The pinch fingertip advantageously has high durability and is of average sewing complexity. However, the pinch fingertip disadvantageously is not roomy, has many inside seams with a conglomeration of fabrics pushing up against the fingertip. As shown in FIG. 1B, showing an inside view of the glove finger when a glove is being worn, seam 104 is located against the fingertip of a finger inside the glove finger of FIG. 1A. As a result, a glove finger of the pinch fingertip construction has poor comfort for the wearer and the fingertip has poor tactility and dexterity. Further the glove finger with a pinch fingertip is not anatomically correct.

As seen in FIG. 2A, illustrating a side view of a glove finger constructed using the prior art box fingertip, which is commonly found on work gloves, the glove finger comprises a top fabric 201, bottom fabric 202 and one fourchette 203. With the box fingertip, the top and bottom fabrics are not sewn together. Instead, there are two seams 204, 205 with top fabric 201 and bottom fabric 202 sewn to the top and bottom of fourchette 203 respectively with one fourchette covering the front and sides of the finger. The box fingertip advantageously provides a very roomy and thus comfortable fingertip and is of average sewing complexity. However, the box fingertip disadvantageously is of low to average durability because the fourchette fabric at the front of the fingertip, which is typically thinner and less durable than the fabric used for the glove palm and glove back, comes in direct contact with the working surface resulting in abrasion and increased wear at the fingertip. The box fingertip also has many inside seams as shown in FIG. 2B, showing an inside view of the glove finger when a glove is being worn. As seen in FIG. 2B, seams 204 and 205 are located against the fingertip of a finger inside the glove finger of FIG. 2A. As a result, the fingertip of a glove finger using the box fingertip construction has poor tactility and dexterity.

As seen in FIG. 3A, illustrating a top view of a glove finger constructed using the prior art rolltop fingertip, which is commonly found on insulated winter gloves or specialty gloves such as tactical or sport gloves, the glove finger comprises glove palm fabric which wraps over the fingertip 302 and onto the top (dorsal) side of the finger 303. The fabric is then joined with at least one fourchette 304 and the fabric 305 on the dorsal side of the finger. The rolltop fingertip advantageously provides a very roomy fingertip, has good durability and the inside seams 306 and 307 are on the sides of the fingertip and accordingly a glove of this construction has no horizontal seam, as shown in FIG. 3B, showing an inside view of the glove finger when a glove is being worn. Thus, a rolltop configuration provides a fingertip with good tactility and dexterity. However, there still remains two seams, namely inside seams 306 and 307, albeit vertical seams, which come in contact with the volar surface of the finger. Additionally, the rolltop fingertip is of high sewing complexity, has a high cost to manufacture, and does not always provide perfect seams, and thus the rolltop fingertip is not commonly found on work gloves.

Glove fingers on a glove with the prior art gunn cut construction, which is commonly found on leather work gloves, are constructed differently depending on the particular finger. The gunn cut is typically used with the construction of leather gloves and is designed to maximize the amount of usable leather from a hide. As seen in FIG. 4A, illustrating a side view of a glove finger constructed using the prior art gunn cut construction, top piece 401 and bottom piece 402 are joined at seam 403. As seen in FIG. 4B, showing an inside view of the glove finger when a glove is being worn, seam 403 is located below the fingertip of a finger when inserted inside the glove finger.

FIGS. 4C and 4D illustrate the glove palm cut in accordance with the prior art gunn cut construction. As seen in FIG. 4C, the fabric for the bottom portion of thumb 401, index finger 402 and pinky finger 403 are part of the same piece of fabric as the palm portion 404 of the glove palm. The fabric for the bottom portions of middle finger 405 and ring finger 406 come from separate pieces of fabric which are joined with the glove palm fabric of FIG. 4C.

The glove palm fabric is then joined with a glove back fabric, which is typically also constructed of leather. In contrast to the other prior art glove finger constructions discussed above, there are no fourchettes in this glove construction with the glove palm fabric portion being joined directly with the glove back (dorsal) fabric portion. The gunn cut fingertip advantageously has high durability and is of low sewing complexity and has no fourchette seams. However, the gunn cut fingertip disadvantageously has poor comfort for the wearer at the fingertip and the seams of the gunn cut fingertip are at the worst location for tactility and dexterity, namely right across the volar surface of the fingertip below the fingernail as seen in FIG. 4B. Further, because of the way the top and bottom fabrics need to be sewn together for the fingers, the construction is not form fitted to the finger.

Oftentimes individuals wearing a glove require tactility and dexterity at one or more of the glove fingertips. For example, users of smart phones in cold environments want to interact with a smart phone touch screen without removing their gloves. To do so, a glove fingertip free of seams is most desirable to improve accuracy when texting or otherwise using the smart phone.

Automotive mechanics typically need high tactility and dexterity so that they are able to better handle and manipulate tools and parts. Additionally, gloved law enforcement or military personnel require an index finger with maximum tactility for use with firing guns.

Many glove finger constructions in the prior art provide low tactility and dexterity as a result of the placement of the glove seam at the fingertip. Other constructions which do provide improved tactility and dexterity are difficult to manufacture. Accordingly, there is a need for a glove finger construction that provides both improved tactility and dexterity while at the same time either reduces the use of glove seams or simplifies the manufacturing process of glove fingers.

SUMMARY OF THE INVENTION

A finger cover designed for maximum fingertip dexterity and tactility while worn is provided. As used herein, “finger” used generically refers to any finger or thumb. The finger cover is designed for maximum tactility and dexterity while at the same time having a construction, namely a molded construction, requiring minimal seams. One or more finger covers can be attached to a glove palm to form a glove with one or more fingers of the molded construction.

Moldable materials (or fabrics), such as synthetic or natural leather can be used to construct the bottom portion of the finger cover. The material can comprise woven, knit or nonwoven fabric. Exemplary nonwoven fabrics are compressed nonwoven fabrics such as Clarino brand synthetic leather, made with nylon or polyester microfibers and a polyurethane binder. These fabrics begin as flat structures, prior to molding.

In embodiments, the fabrics being molded have an x and y dimension, denoting length and width, with a nominal thickness of 0.3 mm to 2.0 mm, and preferably between 0.5 mm and 1.3 mm. Fabrics with a nominal thickness less than 0.3 mm risk tearing during or after the molding process. Fabrics with a nominal thickness greater than 2.0 mm are undesirable, as a finger cover constructed with a fabric of greater than 2.0 mm will not have sufficient flexibility. After molding, the fabric will adopt the shape of a finger bottom, finger side and volar surface, and maintain that shape after molding. Accordingly, through the molding process a flat fabric structure is changed to a three-dimensional bottom (molded) portion with the shape of a finger bottom, side and volar section, and joined to a top portion, comprising a second fabric that rests only on the dorsal surface of the finger. The joining can be via sewing or other conventional means. This results in a two-fabric construction, with a seam only on the perimeter of the dorsal surface of the finger, avoiding the bottom, side and volar sections of the finger.

The seam extends along the perimeter of the dorsal surface of the finger and around the edge of the fingernail, connecting the top and bottom portions of the glove finger material.

The bottom (molded) portion of the finger cover is shaped by molding in order to accommodate a finger. In an embodiment, the mold used to mold the bottom portion of the finger cover is constructed to anatomically correspond to the respective finger for which the bottom portion is being molded. After molding, the bottom portion of the finger cover is joined with the top portion of the finger cover, the bottom portion extending up to the perimeter of the dorsal surface of the finger and around the edge of the fingernail so that the volar surface of the fingertip does not come into contact with a seam.

By keeping the volar surface of the fingertip free of seams, the finger cover is well-suited for use in various applications requiring high dexterity and tactility in the fingertip of a finger cover of molded construction.

It is anticipated and within the scope of the invention that the bottom portion of the finger cover to be molded can be made of various moldable materials such as synthetic leather, natural leather, reinforced fabric layer or a composite consisting of multiple fabrics. A base layer of fabric may or may not be needed for the bottom portion, depending on the material used. For example, when constructing the bottom portion out of a reinforced fabric layer, such a base layer fabric is not needed, making the finger cover more comfortable.

It is anticipated and within the scope of the invention that the top portion of the finger cover used can be of any type of material which can be joined to the molded bottom portion of the finger cover.

It is anticipated and within the scope of this invention that the bottom portion could be fabricated by using a heated male mold (with a non-heated female mold), or heated male and female molds.

It is anticipated and within the scope of this invention that the mold may be sized to generally match the anatomical measurements of a given finger. The mold may further be constructed to provide texture or creases in the moldable fabric to provide for increased gripability or flexibility of the finger cover.

A glove utilizing one or more finger covers made in accordance with this invention can have from one finger cover to five finger covers (including the thumb). In one exemplary embodiment, where tactility and dexterity are required for each digit, such as in connection with the use of a smart phone touch screen, each digit is made in accordance with the molded finger covers of this invention. In an embodiment designed for touch screen use the bottom portion of the finger cover would include a touchscreen sensitive material at the distal end of the bottom portion of the finger.

In one exemplary embodiment, the finger cover design can be selectively applied to specific fingers of a glove, such as in the case of a glove intended for use by law enforcement personnel where the finger cover design can be applied only to the index (trigger) finger.

In one exemplary embodiment, the bottom portion of the finger cover can include multiple fabric layers being molded together. For example, an inner thermal insulation substrate can be molded with a leather outer layer (outer substrate) to provide thermal insulation. A cut resistant knit fabric inner substrate can be molded with a synthetic leather outer layer (outer substrate) to provide cut resistance. In an embodiment with the molding of multiple layers, the inner substrate can be one continuous piece which can either be the same shape as the outer substrate or it could be smaller and located over a portion of the finger, such as only the palmar side of the finger. In an exemplary embodiment where the inner substrate comprises bulky thermal insulation, the inner substrate can be comprised of multiple discrete pieces located away from the flex joints of the finger cover, which allows for the inclusion of bulky items in the finger cover without affecting its flexibility.

In one exemplary embodiment, stiff fabrics can be molded to form the bottom portion of the finger cover and provide puncture resistance yet at the same time be more comfortable than cut and sewn gloves.

It is anticipated and within the scope of the invention that in addition to gun and touch screen uses, one of ordinary skill in the art would be able to use finger covers of this invention for other uses such as for sport gloves or dress gloves.

The advantages provides by this invention is a finger cover or glove that provides comfort, tactility, and durability through the absence of seams on the volar surface of the finger, while providing the benefits of the molded fabric or fabrics. The benefits include one or more of comfort, smoothness, breathability, high durability, sweat absorption, flame resistance, heat resistance, cold resistance, cut resistance, puncture resistance, conductivity for touchscreen applications and electrical insulation. Additionally, many individuals prefer the feel of natural or synthetic leather on their hand and fingers, compared to existing seamless glove constructions such as polymer or knit/polymer gloves.

According to an exemplary embodiment of the present invention, there is provided a finger cover comprising a top portion, a bottom portion made of a moldable material, and a seam joining the top and bottom portions, wherein the top portion is configured to cover the length of the dorsal surface of a finger, the bottom portion is configured to cover the length of the volar surface of the finger, and the bottom portion is configured to extend up the perimeter of the finger of to a point approximately perpendicular with the dorsal surface of the finger and the fingernail at the distal portion of the finger.

In an embodiment, the bottom portion further comprises an inner layer molded with an outer layer. The inner layer may be comprised of resistant knit fabric and the outer layer may be comprised of leather or synthetic leather.

In an embodiment, the outer surface of the bottom portion, namely the surface configured to face away from the volar surface of the finger, has crease points located along the length of the bottom portion in locations corresponding to the joints of the finger.

In an embodiment, there is provided a method of fabricating a finger cover comprising the steps of providing a top portion adapted to cover the length of the dorsal surface of a finger, providing a bottom portion made of a moldable material, configured to cover the length of the volar surface of the finger of a person wearing the glove, and further wherein the bottom portion is configured to extend up the perimeter of the finger to a point approximately perpendicular with the dorsal surface of the finger and the fingernail at the distal portion of the finger and joining the top portion and bottom portion at a seam such that the bottom portion extends up the perimeter of the finger to a point approximately perpendicular with the dorsal surface of the finger and the fingernail at the distal portion of the finger.

In an embodiment, the method further comprises forming the bottom portion by carrying out the following steps: providing a piece of glove material, providing a male mold shaped so that the glove material can be molded into the shape of a bottom portion of a finger cover, providing a female mold shaped to surround the sides of the male mold with a first spacing between the male and female molds, placing the piece of glove material over the male mold, placing the female mold over the piece of glove material to create a piece of molded glove material, with a portion of the piece of glove material not in contact with the male mold extending from a periphery of the male mold comprising a piece of unmolded glove material, removing the female mold after a predetermined amount of time, removing the molded piece of glove material from the male mold, and cutting off one end of the piece of molded glove material and trimming the piece of unmolded glove material in its entirety from the piece of glove material, with the remaining piece of molded glove material forming a bottom portion of glove material with an opening adapted for insertion by a finger.

In an embodiment, the male mold is heated to a first temperature and in an embodiment the female mold is heated to a second temperature.

In an embodiment, the female mold further includes a cover surrounding the top of the male mold with a second spacing between the male and female molds.

In an embodiment, the first spacing equals the second spacing.

In another embodiment, a glove is provided comprising a glove palm, a glove back, with the glove palm joined to the glove back to form the glove, said glove having fingers, wherein at least one of the fingers comprises a top portion, a bottom portion made of a moldable material, a seam joining the top and bottom portions, wherein the top portion is configured to cover the length of the dorsal surface of a finger, the bottom portion is configured to cover the length of the volar surface of the finger, and further wherein the bottom portion is configured to extend up the perimeter of the finger of to a point approximately perpendicular with the dorsal surface of the finger and the fingernail at the distal portion of the finger.

In another embodiment, there is provided a method of fabricating a glove comprising the steps of providing a glove palm, providing a glove back, joining the glove palm to the glove back to form the glove, the glove having fingers, wherein at least one of the fingers is fabricated by the following steps: providing a top portion adapted to cover the length of the dorsal surface of a finger, providing a bottom portion made of a moldable material, configured to cover the length of the volar surface of the finger of a person wearing the glove, and further wherein the bottom portion is configured to extend up the perimeter of the finger to a point approximately perpendicular with the dorsal surface of the finger and the fingernail at the distal portion of the finger.

These and other features of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of this invention will be described with reference to the accompanying figures wherein:

FIG. 1A is a side view of the prior art pinch fingertip construction.

FIG. 1B illustrates an inside sectional side view of the glove finger of the prior art pinch fingertip construction when a glove is being worn.

FIG. 2A is a side view of the prior art box fingertip construction.

FIG. 2B illustrates an inside sectional side view of the glove finger of the prior art box fingertip construction when a glove is being worn.

FIG. 3A is a top view of the prior art rolltop fingertip construction.

FIG. 3B illustrates an inside sectional top view of the glove finger of the prior art rolltop fingertip construction when a glove is being worn.

FIG. 4A is a side view of the prior art gunn cut fingertip construction.

FIG. 4B illustrates an inside sectional side view of the glove finger of the prior art gunn cut fingertip construction when a glove is being worn.

FIGS. 4C and 4D illustrate the pieces of glove palm material used to construct a glove palm in accordance with a gunn cut construction.

FIG. 5A is a side view of the molded finger cover of this invention.

FIG. 5B is a top view of the molded finger cover of this invention.

FIG. 5C is a front view of the molded finger cover of this invention.

FIG. 5D illustrates an inside sectional side view of the molded finger cover of this invention when the finger cover is being worn.

FIGS. 6A-6I illustrate the steps of constructing the bottom piece of the molded finger cover of this invention using a heated male mold with an unheated female mold.

FIG. 6A illustrates the heated male mold and unheated female mold.

FIG. 6B illustrates an exemplary apparatus used to heat the male mold.

FIG. 6C illustrates the heated male mold and unheated female mold about to mold a piece of material.

FIG. 6D illustrates the heated male mold and unheated female mold molding a piece of material.

FIG. 6E is a section view of the heated male mold and unheated female mold configuration of FIG. 6D taken along the line 6E-6E in FIG. 6D.

FIG. 6F illustrates the molded portion of the material after the female mold has been removed from over the molded material.

FIG. 6G is a section view of the configuration of FIG. 6F taken along the line 6G-6G in FIG. 6F.

FIG. 6H illustrates the molded material after it has been removed from the male mold.

FIG. 6I is a section view of the configuration of FIG. 6H taken along the line 6I-6I in FIG. 6H.

FIG. 6J illustrates the removal of unmolded material from the molded material.

FIG. 6K illustrates the two bottom portions of molded material created by the molding process illustrated in FIGS. 6A-6K.

FIGS. 7A-7K illustrate the steps of constructing the bottom piece of the molded finger cover of this invention using heated male and female molds.

FIG. 7A illustrates the heated male mold and heated female mold.

FIG. 7B illustrates an exemplary apparatus used to heat the male mold or female mold, shown here heating the male mold.

FIG. 7C illustrates the heated male mold and heated female mold about to mold a piece of material.

FIG. 7D illustrates the heated male mold and heated female mold molding a piece of material.

FIG. 7E is a section view of the heated male mold and heated female mold configuration of FIG. 7D taken along the line 7E-7E in FIG. 7D.

FIG. 7F illustrates the molded portion of the material after the female mold has been removed from over the molded material, with the molded material remaining within the female mold.

FIG. 7G is a section view of the configuration of FIG. 7F taken along the line 7G-7G in FIG. 7F.

FIG. 7H illustrates the molded material after it has been removed from the female mold.

FIG. 7I is a section view of the configuration of FIG. 7H taken along the line 7I-7I in FIG. 7H.

FIG. 7J illustrates the removal of unmolded material from the molded material.

FIG. 7K illustrates the two bottom portions of molded material created by the molding process illustrated in FIGS. 7A-7K.

FIG. 8A illustrates a male mold in a gunn cut pattern with a molded material overlaying the male mold constructed in accordance with this invention.

FIG. 8B is a pre-assembly view of a leather glove with a gunn cut construction constructed in accordance with this invention.

FIG. 8C is a perspective view of the leather glove with a gunn cut construction of FIG. 8B constructed in accordance with this invention.

FIG. 9A is a pre-assembly view of a leather glove construction wherein each finger and thumb is constructed in accordance with this invention.

FIG. 9B is a perspective view of the leather glove with the construction of FIG. 9A constructed in accordance with this invention.

FIGS. 10A-10D are section views illustrating of exemplary embodiments the glove finger of FIG. 9A, taken along the line 10A, B, C, D-10A, B, C, D.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

FIGS. 5A-5D illustrate side, top, front and sectional views of a finger cover constructed in accordance with an exemplary embodiment of the present invention. Initially referring to FIG. 5A, a side view of a finger cover constructed in accordance with an exemplary embodiment of the present invention, the embodiment of the finger cover described herein includes top portion 501, bottom portion 502 and seam 503. Top portion 501 covers the dorsal portion of the finger and extends to the end of the nail covering the fingertip. Bottom portion 502 surrounds the volar surface of the finger and extends up the sides of the finger to a point approximately perpendicular with the dorsal surface of the finger and the fingernail at the distal portion of the finger.

Top portion 501 and bottom portion 502 are joined together by seam 503. One of ordinary skill in the art would recognize that top portion 501 and bottom portion 502 can be joined by any number of means including stitching or welding.

FIG. 5B illustrates the top view of a finger cover constructed in accordance with an exemplary embodiment of the present invention. When looking at the finger cover from the top view, top portion 501 is visible, with seam 503 present along the perimeter of the finger cover as illustrated in FIG. 5B.

FIG. 5C illustrates the front view of a finger cover constructed in accordance with an exemplary embodiment of the present invention. When looking at the finger cover from the front view, top portion 501 is visible, joined together with bottom portion 502 at seam 503.

With the construction of a finger cover in accordance with the exemplary embodiment shown in FIGS. 5A-5C, the volar surface of the fingertip of a wearer does not come in contact with any seams, allowing the wearer to have increased tactility and dexterity when wearing a glove with fingers with this construction. This is illustrated in FIG. 5D, which shows a sectional view inside the finger cover, illustrated with a finger inside the finger cover. As is illustrated in FIG. 5D, the volar surface of the fingertip of the wearer does not come in contact with seam 503 which is located at a point approximately perpendicular with the dorsal surface of the finger and the fingernail at the distal portion of the finger.

Bottom piece 502 is preferably fabricated from a moldable material by one of two methods, the Heated Male Mold method illustrated in FIGS. 6A-6K, or the Heated Male/Female Mold method illustrated in FIGS. 7A-7K. Both FIGS. 6A-6K and 7A-7K illustrate exemplary mold configurations used to create finger covers which can be used for bottom portions of the middle and ring fingers of a glove constructed in accordance with a gunn cut construction. One or ordinary skill in the art will recognize that tooling at the production level may differ from the exemplary tooling presented in these figures.

In the Heated Male Mold method illustrated in FIGS. 6A-6K, the male mold 604 is heated, and female mold 605 is unheated. In the Heated Male/Heated Female Mold method illustrated in FIGS. 7A-7K, the male mold 704 is heated, and female mold 705 is heated. The Heated Male Mold method is preferably used for synthetic and natural fabrics, the Heated Male/Female Mold method is preferably used for providing texture or creases in synthetic and natural fabrics.

FIG. 6A illustrates the two components of the Heated Male Mold method, namely male mold 604 and female mold 605. Male mold 604 is constructed of a heat conducting material and can be heated either by conductive heating as shown in FIG. 6B or any other method known by one of ordinary skill in the art such as resistive heating, convective heating or inductive heating. In one embodiment, heated male mold 604 is fabricated of a metallic material such as aluminum or steel. When inductive heating is used, male mold 604 must be fabricated from steel or any other material suitable for inductive heating. Female mold 605 is preferably fabricated out of a non-heat conducting material and is shaped to surround the sides of male mold 604 as illustrated by FIGS. 6A, 6D and 6E. Female mold 605 surrounds the sides of male mold 604 with a spacing between male mold 604 and female mold 605. In one exemplary embodiment female mold 605 is fabricated out of wood. In the embodiment illustrated in FIGS. 6A-6K, female mold 605 has an open top. In one exemplary embodiment (not shown), mold 604 has protrusions extending vertically from the surface of the mold to form crease points in the bottom portion of the finger cover (e.g., bottom portion 502 of FIG. 5 or bottom portion 602 of FIG. 6) to enable the finger cover to have flex joints. In such an embodiment (not shown), female mold 605 has a closed top and covers male mold 604, surrounding the male mold in its entirety with a spacing between the male mold 604 and female mold 605.

In an embodiment (not shown), male mold 604 is sized based on the anatomical measurements of the particular finger cover the bottom portion is being molded for. For example, mold 604 would be sized larger when being used to mold a bottom portion for a middle finger than a pinky finger, which is the anatomically smaller digit.

In another exemplary embodiment (not shown), the spacing between female mold 605 and male mold 604 is variable to adjust for different materials being molded. It has been observed that when the spacing is too small, the material being molded will shear. In contrast, if the spacing is too great, the final molded shape is poor and uneven. In an embodiment where female mold 605 has a closed top, the spacing between the sides of male mold 604 and female mold 605 may vary from the spacing between the top of male mold 604 and female mold 605.

In another exemplary embodiment, male mold 604 is heated to a specified target temperature. The target temperature varies depending on the type of material being molded. In general, lower temperatures are required for molding leather and higher temperatures are required for molding synthetic materials. After application of heat source 607 to male mold 604, the heat source is removed from the male mold. Temperature of the mold is monitored using thermocouple 606. As shown in FIG. 6C, material 602′ is placed over male mold 604. The material may consist of any type of moldable material, such as synthetic leather, natural leather, reinforced fabric layer or a composite consisting of multiple fabrics. As shown in FIGS. 6D and 6E, female mold 605 is placed over material 602′ and then pressed down over material 602′ and material 602′ is clamped (clamp not shown) between male mold 604 and female mold 605. In an exemplary embodiment, female mold 605 can have an open top (as shown in FIGS. 6C, 6D and 6E). In an alternative embodiment (not shown), female mold 605 can have a closed top. An open top, as shown in FIG. 6D helps cool material 602′ quicker than an embodiment where a female with a closed top is used. In an embodiment where texture or flex creases are being added into the material, female mold 605 would require a closed top to apply pressure against material 602′.

As shown in FIGS. 6D and 6E, material 602′ is held between male mold 604 and female mold 605 for a specified time without additional heat being applied, allowing male mold 604 and material 602′ to cool in order for material 602′ to maintain the shape of the mold and become a piece of molded finger material as shown in FIGS. 6F and 6G, after female mold 605 has been removed, and FIGS. 6H and 6I after material 602′ has been removed from male mold 604. The importance of the cool down time varies depending on the type of material being molded. Cool down time is especially important for materials that have flowable plastic coatings, such as a reinforced fabric with a PVC coated surface. The optimal time the material remains clamped varies depending on the material being used.

The piece of material 602′ which was not molded from contact with female mold 605 forms a piece of unmolded glove material 602′. This piece of unmolded material 602″' is trimmed from material 602′ leaving only the portion of molded material 602″. FIG. 6J illustrates this piece of unmolded material 602″' after it is trimmed from material 602′ leaving a portion of molded material 602″.

In FIG. 6K, molded material 602″ is cut into two pieces to form bottom portions 602a and 602b. In this embodiment, bottom portion 602a is used to construct the bottom portion of the ring finger of a glove constructed in accordance with a gunn cut construction and bottom portion 602b is used to construct the bottom portion of the middle finger of a glove constructed in accordance with a gunn cut construction.

In an alternative embodiment where male mold 604 and female mold 605 are sized to create a finger cover for only one finger, after the non-molded portion 602″′ is removed from the molded portion 602″ as shown in FIG. 6J, one end portion of the molded material is cut open resulting in the creation of a bottom portion for use, in an exemplary embodiment, as bottom portion 502 as illustrated in FIG. 5.

In another exemplary embodiment where only one finger cover is being constructed (not shown), material 602′ is placed over male mold 604 with material 602′ overlaying only one end of mold 604. When material 602′ is molded in this manner, it is not necessary to cut open the portion of molded material in order to create the bottom piece as molding does not occur in the area where a finger would be inserted.

Use of a non-heated female mold, as shown in FIGS. 6A-6K, is preferable in embodiments where the front of the fabric is already textured. In such an embodiment, a heated female mold could cause the fabric to lose its texture. Also when the heat is only being provided via the male mold, the heat is concentrated on the back of the fabric which keeps any texture on the front of the fabric from being melted to a smooth surface.

Table One presents thickness, temperature and time parameters for use during the molding process utilizing the Heated Male Mold method illustrated in FIGS. 6A-6K. These parameters may also be used for the Heated Male/Female Mold Method presented in FIGS. 7A-7K.

TABLE ONE

Thickness Between
Starting
Time Material

Male and Female
Mold
Maintained in

Material
Molds (mm)
Temp (° F.)
Mold (min)

AX Suede 10W
0.85
275
2

Ax Suede 10W +
0.85
275
2

Dots

AX Doe
0.70
300
3

Tongda Suede grey
0.80
275
5

PU Coated Clarino
0.80
275
7

PU Coated fabric
1.20
275
7

Sheepskin A/B
0.65
250
3

Goatskin A/B black
0.85
270
5

Duraclad Orange
0.80
315
4

Duraclad Black
0.80
315
4

The thickness between male and female molds determines the molded thickness of the material being molded. Based on the spacing (thickness) between the male and female molds, the materials listed in Table One have a thickness ranging from 0.65 to 1.20 mm. Other materials can have a molded thickness between 0.3 mm to 2.0 mm.

FIG. 7A illustrates the two components of the Heated Male/Female Mold method, namely male mold 704 and female mold 705 of the Heated Male/Female Mold method. The same mold (604 or 704) can be used for either method and constructed of the same heat conducting material. Female mold 705 is preferably made out of a heat conducting material, and in one embodiment is constructed of the same materials as male mold 704. Both male mold 704 and female mold 705 can be heated either by conductive heating as shown in FIG. 7B, using heat source 707, or any other method known by one of ordinary skill in the art such as resistive heating, convective heating or inductive heating. As shown in FIG. 7B, the temperature of male mold 704 can be measured by thermocouple 706. The temperature of female mold 705 can also be measured by thermocouple 706 (not shown).

In one embodiment, heated male mold 704 and heated female mold 705 are fabricated out of a metallic material such as aluminum or steel and female mold 705 is shaped to surround the sides of male mold 704 as illustrated by FIGS. 7A, 7D and 7E. When inductive heating is used, the mold being heated via induction must be made out of steel or any other material which can be used for inductive heating. In one exemplary embodiment (not shown), male mold 704 has protrusions extending vertically from the surface of the mold to form crease points in the bottom portion of the glove finger to enable the glove finger to have flex joints. In such an embodiment, female mold 705 has a closed top and covers male mold 704, surrounding the male mold in its entirety with a spacing between the male mold 704 and female mold 705.

In an embodiment (not shown), male mold 704 is sized based on the anatomical measurements of the particular finger cover the bottom portion is being molded for. For example, male mold 704 would be sized larger when being used to mold a bottom portion for a middle finger than a pinky finger, which is the anatomically smaller digit.

In another exemplary embodiment (not shown), the spacing between female mold 705 and male mold 704 is variable to adjust for different materials being molded. It has been observed that when the spacing is too small, the material being molded will shear. In contrast, if the spacing is too great, the final molded shape is poor and uneven. In an embodiment where female mold 705 has a closed top, the spacing between the sides of male mold 704 and female mold 705 varies from the spacing between the top of male mold 704 and female mold 705.

In another exemplary embodiment, male mold 704 and female mold 705 are heated to a specified target temperature. The target temperature varies depending on the type of material being molded. In general, lower temperatures are required for molding leather and higher temperatures are required for molding synthetic materials. After application of heat source 707 to male mold 704 and female mold 705, the heat source is removed from the molds. Temperature of the molds is monitored using thermocouple 706. As shown in FIG. 7C, material 702′ is placed over male mold 704. The material may consist of any type of moldable material, such as synthetic leather, natural leather, reinforced fabric layer or a composite consisting of multiple fabrics. As shown in FIGS. 7D and 7E, female mold 705 is placed over material 702′ and then pressed down over material 702′ and material 702′ is clamped (clamp not shown) between the male mold 704 and female mold 705. In an alternative embodiment, female mold 705 can have an open top (not shown) or a closed top as shown in FIGS. 7C, 7D and 7E. An open top helps cool material 702′ quicker than an embodiment where a female mold with a closed top is used. In an embodiment where texture or flex creases are being added into the material, female mold 705 would require a closed top to apply pressure against material 702′.

As shown in FIGS. 7D and 7E, material 702′ is held between male mold 704 and female mold 705 for a specified time without additional heat being applied. This allows male mold 704, female mold 705 and material 702′ to cool in order for material 702′ to maintain the shape of the mold and become a piece of molded finger material as shown in FIGS. 7F and 7G, after male mold 704 has been removed, and FIGS. 7H and 7I after material 702′ has been removed from female mold 705. The importance of the cool down time varies depending on the type of material being molded. Cool down time is especially important for materials that have flowable plastic coatings, such as a reinforced fabric with a PVC coated surface. The optimal time the material remains clamped varies depending on the material being used.

The piece of material 702′ which was not molded from contact with female mold 705 forms a piece of unmolded glove material 702′. This piece of unmolded material 702″′ is trimmed from material 702′ leaving only the portion of molded material 702″.

FIG. 7J illustrates this piece of unmolded material 702′″ after it is trimmed from material 702′ leaving a portion of molded material 702″.

In FIG. 7K, molded material 702″ is cut into two pieces to form bottom portions 702a and 702b. In this embodiment, bottom portion 702a is used to construct the bottom portion of the ring finger of a glove constructed in accordance with a gunn cut construction and bottom portion 702b is used to construct the bottom portion of the middle finger of a glove constructed in accordance with a gunn cut construction.

In an alternative embodiment where male mold 704 and female mold 705 are sized to create a finger cover for only one finger, after the non-molded portion 702″′ is removed from the molded portion 702″ as shown in FIG. 7J, one end portion of the molded material is cut open resulting in the creation of a bottom portion for use, in an exemplary embodiment, as bottom portion 502 as illustrated in FIG. 5.

In another exemplary embodiment where only one finger cover is being constructed (not shown), material 702′ is placed over male mold 704 with material 702′ overlaying only one end of mold 704. When material 702′ is molded in this manner, it is not necessary to cut open the portion of molded material in order to create the bottom piece as molding does not occur in the area where a finger would be inserted.

In one embodiment a metal female mold (heated or unheated) is used to act as a heat sink to pull heat off material 702′ quicker.

The Heated Male Mold method and Heated Male/Female Mold method are illustrated with the use of one male and female mold each for use with the molding of two finger covers for use in a gunn cut construction. However, it is anticipated and within the scope of the invention that multi-finger molds may be constructed which provide for the molding of multiple finger covers at one time including for use as glove fingers.

Turning to FIG. 8A, one such embodiment is disclosed, where male mold 804 is configured to created molded bottom portions of the thumb, index finger and pinky finger for use in a gunn cut construction made in accordance with this invention. As seen in FIG. 8A, molded portion 802 has been molded using male mold 804 and the female mold (with either an open or closed top, neither shown) has been removed.

FIG. 8B illustrates molded portion 802, with the molded bottom portions for the thumb 810, index finger 815 and pinky finger 830. Flaps 831 and 816 are unmolded portions used to create a glove of a gunn cut construction made in accordance with the invention. Molded portion 802 is combined with top portion 801 and molded bottom portions 820 (for the middle finger) and 825 (for the ring finger) to form the glove shown in FIG. 8C. As shown in FIG. 8C, bottom finger portions 820 and 825 are joined with top portion 801 including at seams 840 and 835 respectively.

In the embodiment of FIGS. 8A-8C, the gunn cut glove palm molded portion 801 and bottom portions 820 and 825 are molded using either the Heated Male Mold method or the Heated Male/Female Mold method. The bottom portions of the middle finger 820 and ring finger 825 can either be molded concurrently, such as shown in FIGS. 6A-6K or 7A-7K, or at separate times, as in an embodiment where one finger cover is being constructed. In the embodiment where the bottom portions of the thumb 810, index finger 815 and pinky finger 830 are molded concurrently using a multi-digit mold 804 as seen in FIG. 8A, the thumb, index and pinky finger molds are anatomically correct. In an embodiment where the middle finger 820 and ring finger 825 are of a non-molded construction (not shown) the non-molded bottom portions of the glove palm fingers can be joined to the glove back using any of the prior art fingertip constructions including with the use of fourchettes as applicable.

In the glove of FIGS. 8A-8C, the molded portions of the fingers and thumb extend up to the perimeter of the dorsal surface of the fingers and thumb around the edge of the fingernails so that the volar surface of the tip of the fingers and thumb do not come into contact with a seam.

As illustrated in FIGS. 9A and 9B, a leather glove palm has the bottom portion of each finger 915, 920, 925, 930 and thumb 910 molded and then joined with the respective top portion of each finger of the glove back 901 and cuff 931 to form a glove with a molded thumb and four molded fingers as shown in FIG. 9B. In this exemplary embodiment, each finger of the glove palm, including thumb 910, index finger 915 and pinky finger 930, as well as ring finger 925 and middle finger 920, is molded using either the Heated Male Mold method or the Heated Male/Female Mold method. The fingers shown in FIG. 9A which are attached to palm 902 of glove palm fabric can be molded concurrently or at separate times. In an exemplary embodiment these digits are molded concurrently using a multi-digit mold.

Once the fingers of the glove palm have been molded forming the bottom portions of the glove fingers, the bottom portions of the glove fingers 910, 915, 920, 925, and 930 are joined to the top portions of the glove fingers that are part of glove back 901 as shown in FIG. 9B. In the glove of FIG. 9B, the molded portion of the fingers extend up to the perimeter of the dorsal surface of each finger and around the edge of the fingernail so that the volar surface of each fingertip and the tip of the thumb does not come into contact with a seam.

Turning to FIGS. 10A, 10B, 10C, and 10D, various constructions are illustrated that can be used for the finger cover of the present invention, or one or more fingers of a glove such as shown in FIGS. 8B and 9B. In this embodiment, these constructions are shown as applying to thumb 910 of the glove shown in FIG. 9B. As shown in FIG. 10A, the bottom portion can be a single layer of moldable material 1002.

With reference to FIG. 10B, the bottom portion can be comprised of a multi-layer construction consisting of outer layer 1002, inner layer 1010 and sandwiched material 1015. This multi-layer construction provides the wearer of the finger cover with localized protection from one or more conditions or substances such as impacts, vibration, heat, and cold (depending on the thermal properties of sandwiched material 1015). Sandwiched material 1015 can comprise foam, gel, or similar material and is located on the bottom of the bottom portion 1002 (and not its sides) to provide thermal, vibrational, or other protection.

With reference to FIG. 10C, sandwiched material 1020 is located uniformly between the inner layer 1010 and outer layer 1020 in order to provide additional protection to the finger. This multi-layered construction with a uniform distribution of sandwiched material 1020 provides the wearer of the finger cover with protection from exposure to one or more conditions or substances such as external punctures, heat, cold, cuts, chemicals, water, oils, and blood.

With reference to FIG. 10D, sandwiched material 1025 is located intermittently between the inner layer 1010 and outer layer 1025 to provide protection against one or more conditions or substances such as punctures, cuts, heat, cold and impacts.

In the embodiments represented by FIGS. 10A, 10B, 10C, and 10D, outer layer 1002 may be comprised of materials such as leather, synthetic leather, non-woven compressed fabrics, aramid, woven fabrics, knit fabrics or cut-resistant knit fabrics. Inner layer 1010 may be comprised of materials such as aramid, para-aramid, wool, cotton, nylon, polyester, cut-resistant polymers, cut-resistant knit fabrics, polyethylene, leather or synthetic leather. The sandwiched material 1015, 1020 or 1025, may be comprised of materials such as aramid, para-aramid, foam, gel, rubber, wool, stainless steel, cut resistant polymers, dispersed hard polymer plates, polyethylene, or fluid barrier polymers.

While the gunn cut is typically used for the fabrication of leather gloves, it is anticipated and within the scope of the invention that the gloves of FIGS. 8 and 9 can be constructed with glove palms of any moldable material.

It is anticipated and within the scope of the invention that any combination of molded fingers can be used ranging from one finger to five fingers to form a glove with one or more fingers with a molded construction.

It is anticipated and within the scope of the invention that the female and male molds used to construct the molded fingers and thumb could be curved to provide for a curved finger that is more in the form of the natural shape of the hand.

Now that embodiments of the present invention have been shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. The spirit and scope of the present invention is to be construed broadly.

MOLDED FINGER COVERS

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