Note: Descriptions are shown in the official language in which they were submitted.
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THREE DIMENSIONAL GLOVE WITH PERFORMANCE-ENHANCING
LAYER LAMINATED THERETO
Inventor:
Charles A. Howland
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application
No.
61/676,021, filed July 26, 2012, which is herein incorporated by reference in
its
entirety for all purposes.
FIELD OF THE INVENTION
[0002] The invention relates to protective gloves, and more particularly,
to
three dimensional gloves that closely approximate the shape of a hand and
include
at least one performance-enhancing layer applied to an underlying glove shell.
BACKGROUND OF THE INVENTION
[0003] Protective gloves are used for a wide variety of household,
industrial,
and medical applications. Accordingly, gloves are made according to many
different methods and from many different materials, depending on the intended
application, the quantity to be produced, and the desired manufacturing cost.
[0004] There are four principle methods for manufacturing gloves. Some
gloves are created by bonding flat sheets of elastomeric films and/or nonwoven
materials to each other to form flat 2D gloves. Others are sewn from textile
rolls
and/or flat leather panels into 3D gloves that roughly approximate the shape
of a
hand. Still others, for example latex gloves, are formed by dipping hand
shaped
forms into elastomeric coating liquids, thereby forming elastomeric gloves
that
closely approximate the 3D shape of a hand. And yet others are knit by
specialized glove knitting machines into 3D gloves that closely approximate to
the
shape of a hand. While 2D gloves and 3D gloves that only roughly approximate
the shape of a hand are often cheaper to manufacture, the complex shape and \
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movement of the hand favors the use of 3D gloves that closely approximate the
true shape of a hand for comfort, grip, and dexterity.
[0005] It is sometimes desirable for a glove to include one or more
materials
that enhance its performance in one way or another. For example, it may be
desirable to include an elastomeric material on the palm and inner finger
surfaces,
so as to increase friction in those areas and enhance the glove's gripping
properties. Or it may be desirable to include a material such as para-aramid
in the
glove to increase its strength and cut resistance. The addition of other
materials
and/or fillers may be desired due to their resistance to penetration by sharp
objects, such as rose thorns or hypodermic needles.
[0006] One approach is to prepare glove materials having the desired
properties, possibly including filled and/or laminated layers, and then to
manufacture the glove from the prepared materials. However, manufacturing a
glove from such materials typically requires specialized equipment and
methods,
especially if the glove is to be formed into a shape that closely approximates
the
shape of a hand. The cost can be prohibitive, and the flexibility, thermal
properties, and/or moisture vapor penetration properties of the resulting
glove may
be unacceptable. In addition, this approach typically requires that either
half of
the glove or the entire glove be manufactured from the specially prepared
material, so that there is limited freedom to apply the enhancing materials
only
where they are needed on the glove. In addition, the prepared materials
approach
is not applicable to the fabrication of 3D knitted seamless glove shells,
where the
glove is knitted from yarn directly and there is no glove assembly.
[0007] For many applications, it is therefore desirable to add one or more
performance-enhancing layers to a pre-manufactured glove shell. For example, a
glove shell may be manufactured from cotton or from some other suitable
material
that is relatively easy to knit, dip, or otherwise form in an accurate 3D hand
shape
according to cost-effective methods well known in the art. A grip-enhancing
layer
and/or an anti-penetration layer can then be added to the palm and/or inner
finger
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surfaces so as to enhance the grip and/or increase the protective qualities of
the
glove. By adding similar layers to the back of the shell, the entire glove can
be
covered by enhancing materials if so desired.
[0008] A performance-enhancing layer can be sewn to a glove shell, but this
is
a labor-intensive step, especially if the 3D shape of the shell is to be
maintained.
Another approach is to partially or fully dip the glove shell into a coating
liquid,
whereby the accurate 3D hand shape of the glove shell is preserved. In this
approach, the basic dipping process used for making latex gloves is adapted
slightly. The sewn or knit glove shell is mounted on a hand-shaped dipping
form,
and then the form and shell are dipped together so as to coat some or all of
the
glove shell surface with the enhancing material.
[0009] However, there are many limitations that apply to dipping as a
method
for applying performance-enhancing layers to a 3D glove shell. For example,
dipping cannot be used to apply highly filler-loaded elastomers, textile
layers or
oriented films. Dipping also cannot be used to apply printed graphics to the
glove. In addition, dipping tends to provide a relatively thick coating that
significantly reduces the flexibility of the glove.
[0010] The limitations regarding filler-loaded elastomer layers applied by
dipping can be understood as follows. Obviously, any coating material applied
by
dipping must be in a liquid state when the glove shell is dipped. The
viscosity of
the liquid coating material must be low enough to permit immersion of the form
and glove shell in the coating material, and to permit excess coating material
to
flow away from the dipped shell by gravity and/or by acceleration of the
dipping
form. Blades and other types of coating control tooling are incompatible with
dipping. As a result, dipping viscosities must typically be within a range of
about
1-10K centipoise. This viscosity range precludes the use of highly
concentrated or
highly dense fillers, since either the viscosity of the coating material will
be
increased by the filler to an unacceptable level, or too much of the filler
will settle
in the dip tank and will not be applied to the glove.
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[0011] US patent 7007308, also by the present inventor, describes a method
for applying performance-enhancing layers to the inner and/or outer surfaces
of a
glove, whereby a flat, solid layer of a material having the desired properties
is
attached to a glove shell by an adhesive, such as a thermoplastic. Use of an
adhesive to attach the enhancing layer to the glove shell reduces the labor
and
manufacturing cost as compared to sewing. Use of an enhancing material that is
prepared, cut, and preformed as a solid layer before it is applied to the
glove shell
allows the performance-enhancing material to include multiple layers of
different
substances, including fillers of any density. US patent 7007308 teaches how to
use this approach for flat, 2D glove shells. However, US patent 7007308 is
silent
regarding adhesion of a solid, preformed enhancement layer to a glove shell
having an accurate 3D hand shape. In addition, US patent 70073808 is silent
regarding features and methods that reduce the likelihood that edges of the
applied
enhancing layer will peel away from the shell.
[0012] What is needed, therefore, is a glove having a 3D shape that closely
approximates the shape of a human hand, wherein the glove includes a
performance-enhancing layer adhesively applied to a 3D hand-shaped knit or
woven glove shell, and whereby the performance-enhancing layer includes at
least
one feature that cannot be provided by dipping of the glove shell in a coating
material.
SUMMARY OF THE INVENTION
[0013] The present invention is a glove having a 3D shape that closely
approximates the shape of a human hand, wherein the glove includes a
performance-enhancing layer adhesively applied to a 3D hand-shaped knit or
woven glove shell, and whereby the performance-enhancing layer includes at
least
one feature that cannot be provided by dipping of the glove shell in a coating
material.
[0014] The method of the present invention includes preparing a solid,
thin,
flat, performance-enhancing layer, referred to herein as the "laminate
preform," or
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simply as the "laminate." The laminate preform includes a laminating adhesive
on
one of its outer surfaces. The 3D glove shell is placed on a 3D laminating
form
that provides a smooth, wrinkle-free laminating surface. The laminate preform
is
then placed on the glove shell so that the layer of laminating adhesive is in
contact
with the laminating surface, and pressure is applied at an elevated
temperature so
as to adhesively attach the laminate layer to the glove shell.
10015] In embodiments, the 3D laminating form includes opposing flat
surfaces, and the laminating pressure is applied by a platen press, a roller
press, or
some other type of press that is designed to apply pressure to a substantially
planar surface. In other embodiments, the laminating surface is curved or
otherwise shaped, and the laminating pressure is applied by a bladder press or
a
vacuum bag press. This adhesion process can include all the typical process
variables used in lamination, including heat, pressure and reactive adhesives.
The
lamination adhesive can include a thermoplastic, a pressure sensitive
adhesive,
and/or a reactive adhesive.
[0016] For measuring the flexibility benefits of the present invention, we
have
selected the ASTM D4032 - 08 standard test method for stiffness of fabric by
the
circular bend procedure. This test uses a standard 4" x 8" test coupon. We
have
modified this method to use the palm and back of the gloves under test. After
slitting the glove up one side and removing the fingers and thumb, the
remaining
coupon for an extra-large glove is very nearly 4 inches x 8 inches. The
circular
bend test is sensitive to small changes in the glove and laminate system. In
some
cases we find that it is necessary to precondition the palm-back glove test
coupons
by multiple runs on the circular bend test to reach stable conditioned values.
In
the case of conditioned test values, we run the test 10 times and use the
average of
the results from tests 8, 9, and 10 as the stable, conditioned circular bend
result.
[0017] Embodiments of the present invention include laminate preforms that
are much thinner than can be achieved with dipping processes. In some
embodiments, the thickness of the laminate preform is between 25 microns and
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microns, which provides a low bending stiffness. Even in the embodiments where
textile inserts and textile components are used in the laminate preforms, the
circular bending stiffness is much lower than what can be provided by a dipped
glove, and very much lower than what is found in gloves that include multiple
layers of protective textile and dipped surfaces.
[0018] In embodiments, penetration of the lamination adhesive into the
glove
shell is controlled, since the stiffness of the glove tends to increase as
more
adhesive penetrates into the textile of the glove shell, and soft, flexible
gloves are
typically desired. The use of non-liquid thin film adhesives in embodiments of
the
present invention provides excellent adhesion and very controlled and limited
penetration of the lamination adhesive into the textile shell. In embodiments,
thin
adhesive films of between 6 and 50 microns are used, so as to provide only
limited
penetration of the adhesive into the fibers of the glove shell. This approach
is
combined in some embodiments with thin laminate preforms to maximize the
circular bending performance.
[0019] In various embodiments, the glove shell is reversibly deformable,
whereby it is deformed while it is on the 3D laminating form and then returns
to
its accurate 3D hand-shape after the laminate preform is applied and the
resulting
glove is removed from the form.
[0020] In embodiments, the performance-enhancing feature provided by the
laminate that cannot be provided by dipping is an oriented film, a highly
filler-
loaded elastomer, a fabric layer, and/or printed graphics. In some
embodiments,
preparation of the laminate preform includes printing, roll to roll coating,
extrusion, stenting, blown extrusion, weaving, and/or knitting.
[0021] As discussed above, a primary method in the prior art for applying
coating layers to gloves is dipping. Gloves are dipped for a number of
reasons.
The most important are:
= Coatings create a barrier film on the glove that protects the wearer
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= Coatings have higher coefficients of friction than textiles, so they
improve
the grip of the glove
= Coatings have higher abrasion resistance than textiles and improve the
durability of the glove.
[0022] In embodiments, the laminate preforms of the present invention offer
the same benefits. However, the materials and processing options enabled by
the
present invention can deliver these benefits with much lower impact on the
stiffness of the glove.
[0023] Note that the present invention is highly suitable for combination
with
the teachings of US patent 7007308, also by the present inventor.
[0024] One general aspect of the present invention is a glove having a
three-
dimensional shape that approximates the shape of a human hand. The glove
includes a knit or woven glove shell having a three-dimensional shape that
approximates the shape of a human hand, the glove shell having an interior
surface
and an exterior surface, and a laminate preform bonded by a lamination
adhesive
layer to a portion of the exterior surface of the glove shell, the laminate
preform
including an enhancement feature that cannot be provided by dipping the glove
shell into a liquid coating material.
[0025] In embodiments, the enhancement feature is a textile layer, an
oriented
film, a layer of graphics, an elastomeric layer including a filler having a
density
that would cause the filler to settle if added to the liquid coating material,
or an
elastomeric layer including a filler having a density that, if added to the
liquid
coating material, would increase a viscosity of the liquid coating material,
thereby
rendering the liquid coating material unsuitable for dip-coating the glove
shell.
[0026] In some embodiments, the enhancement feature is an elastomeric layer
including a filler having a density of between 2 and 14. In other embodiments,
the
laminate preform includes a grip layer on an outer surface thereof. In certain
embodiments, the lamination adhesive layer has a surface energy greater than
30
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mJ/m2. And in various embodiments the lamination adhesive layer includes at
least one of a thermoplastic, a pressure sensitive adhesive, and a reactive
adhesive.
[0027] In some embodiments, the lamination adhesive layer is one of SBR and
urethane. In other embodiments the lamination adhesive layer is a film having
a
thickness of between 6 microns and 50 microns.
[0028] In various embodiments the bonding of the laminate preform to the
glove shell is such that a 1 inch ASTM T peel sample having the same bonding
properties would have a 5 average peak peel forces of greater than 5 lbf/inch.
[0029] In certain embodiments, the glove shell is knit or woven from a
textile
having a total surface energy of greater than 40 mJ/m2. In some embodiments,
the
glove shell is knit or woven from one of cotton and nylon.
[0030] In embodiments, the laminate preform includes an exposed upper
layer,
whereby the upper layer and the lamination adhesive layer extend beyond any
intervening layers so that the perimeter of the upper layer is bonded by the
lamination adhesive layer directly to the glove shell. In some of these
embodiments the upper layer is a thermoplastic urethane, and the glove shell
is
knit or woven from nylon. In other of these embodiments the upper layer is an
elastomeric film of greater than 100% elongation.
[0031] Various embodiments further include an inner laminate preform bonded
to an inner surface of the glove shell. And some embodiments further include
an
inner cut-and-sew glove lining.
[0032] Another general aspect of the present invention is a method of
manufacturing a glove having a three-dimensional shape approximating the shape
of a human hand, the glove including a laminate preform attached by a
lamination
adhesive to a portion of an underlying glove shell. The method includes
providing
a glove shell having a three-dimensional shape that approximates the shape of
a
human hand, preparing a flat, solid laminate preform, the laminate preform
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including an exposed layer of lamination adhesive, providing a three
dimensional
laminating form having a hand-shaped region, the hand-shaped region including
a
smooth laminating surface, placing the glove shell on the laminating form so
that
the glove shell surrounds the hand-shaped region, and so that a portion of the
glove shell conforms closely to the laminating surface without any seam or
wrinkle, placing the laminate preform on the glove shell above the laminating
surface, the exposed layer of lamination adhesive being in direct contact with
the
glove shell, applying a pressure above ambient pressure at a temperature above
ambient temperature to the assembled laminate preform, glove shell, and
laminating form, thereby causing the lamination adhesive to bond the laminate
preform to the glove shell, and removing the glove shell with the laminate
preform
bonded thereto from the laminating form.
[0033] In embodiments, the hand-shaped region of the laminating form
includes
a pair of opposing areas that are overlapping, substantially flat, and
substantially
parallel to each other, the laminating surface being included in one of the
opposing areas.
[0034] In some embodiments applying pressure to the assembled lamination
preform, glove shell, and laminating form includes applying pressure using at
least
one of a platen press, a roll press, a belt press, and a nip roll press.
[0035] In various embodiments the laminating surface is a non-flat, smooth
surface. And in some of these embodiments applying pressure to the assembled
lamination preform, glove shell, and laminating form includes applying
pressure
using at least one of a bladder press and a vacuum bag press.
[0036] In some embodiments, the glove shell is reversibly deformable,
placing
the glove shell on the laminating form includes deforming the glove shell, and
removing the glove shell with the laminate preform bonded thereto from the
laminating form includes allowing the glove shell with laminate preform bonded
thereto to recover substantially to the pre-deformation shape of the glove
shell.
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[0037] In some of these embodiments, the shape recovery of the glove shell
is
disproportionately located in regions of the glove shell to which the laminate
preform is not bonded, thereby causing a warping deformation of the laminate
preform. In other of these embodiments placing the glove shell on the
laminating
form includes increasing the circumferences of the glove shell fingers by a
factor
of between 10% and 60%.
[0038] Various embodiments further include, before placing the lamination
preform on the glove shell, removing substantially all spin finish and
lubricants
from the portion of the glove shell that conforms closely to the laminating
surface,
such that a Soxhlet extraction with acetone yields less than 1.5% by weight of
the
textile.
[0039] Certain embodiments further include, before placing the lamination
preform on the glove shell, removing substantially all spin finish and
lubricants
from the portion of the glove shell that conforms closely to the laminating
surface,
such that a Soxhlet extraction with acetone yields less than 0.5% by weight of
the
textile.
[0040] In some embodiments the laminate preform includes at least one of a
textile layer, an oriented film, a layer of graphics, a filler having a
density that
would cause the filler to settle if added to the liquid coating material, and
a filler
having a density that, if added to the liquid coating material, would increase
a
viscosity of the liquid coating material, thereby rendering the liquid coating
material unsuitable for dip-coating the glove shell.
[0041] In other embodiments preparing the flat, solid laminate preform
includes at least one of printing, roll to roll coating, extrusion, stenting,
blown
extrusion, weaving, and knitting.
[0042] In certain embodiments, the pressure above ambient pressure is
between
psi and 150 psi above ambient pressure. And in various embodiments the
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temperature above ambient temperature is between 200 degrees Fahrenheit and
375 degrees Fahrenheit.
[0043] Some embodiments further include preparing a flat, solid inner
laminate
preform, the inner laminate preform including an exposed layer of inner
lamination adhesive and placing the inner laminate preform on the laminating
form before placing the glove shell on the laminating form, so that the inner
lamination adhesive is in direct contact with the inner surface of the glove
shell,
where applying pressure to the assembled laminate preform, glove shell, inner
laminate preform, and laminating form causes the inner lamination adhesive to
bond the inner laminate preform to the inner surface of the glove shell.
[0044] And other embodiments further include attaching a cut-and-sew inner
liner inside of the glove shell before placing the inner lining and glove
shell on
the laminating form.
[0045] The features and advantages described herein are not all-inclusive
and,
in particular, many additional features and advantages will be apparent to one
of
ordinary skill in the art in view of the drawings, specification, and claims.
Moreover, it should be noted that the language used in the specification has
been
principally selected for readability and instructional purposes, and not to
limit the
scope of the inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] Figure lA is a front perspective view of a laminating form and a
laminate preform before assembly;
[0047] Figure 1B is a front perspective view of a laminating form, a glove
shell, and a laminate preform assembled in preparation for lamination;
[0048] Figure 1C is a cross sectional view of Figure 1B taken through the
finger region;
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[0049] Figure 1D is a cross sectional view of Figure 1B taken through the
palm
region;
[0050] Figure 2A is a cross sectional view similar to Figure 1D, but of an
embodiment wherein the laminate preform includes a graphics layer between an
outer layer and an adhesive layer;
[0051] Figure 2B is a front view of an embodiment similar to Figure 2A,
showing a graphics layer visible below a transparent outer layer;
[0052] Figure 3 is a cross sectional view similar to Figure 2, but of an
embodiment wherein the laminate preform includes an oriented film between an
outer layer and an adhesive layer, the outer layer and adhesive layers being
extended beyond the film layer so that the circumference of the outer layer is
bonded directly to the glove shell;
[0053] Figure 4 is a cross sectional view similar to Figure 3, but of an
embodiment wherein the laminate preform includes a fabric layer between the
outer layer and the adhesive layer;
[0054] Figure 5 is a cross sectional view similar to Figure 4, but of an
embodiment wherein the laminate preform includes both a fabric layer and a
filled
elastomer layer between the outer layer and the adhesive layer;
[0055] Figure 6 is a cross sectional view similar to Figure 3, but of an
embodiment that also includes an inner laminate preform bonded to an inner
surface of the glove shell;
[0056] Figure 7 is a cross sectional view similar to Figure 3, but of an
embodiment that also includes a cut-and-sew liner attached within the glove
shell;
[0057] Figure 8A is a cross-sectional view similar to Figure 1C, except
that the
glove shell fingers are reversibly deformed by the fingers of the laminating
form;
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[0058] Figure 8B is a cross sectional view of the glove fingers of Figure
8A
after having been removed from the laminating form and having recovered from
deformation;
[0059] Figure 9 is a cross sectional view of the embodiment of Figure 1C
being
laminated in a platen press;
[0060] Figure 10 is a cross sectional view of an embodiment similar to the
embodiment of Figure 1C but wherein the laminate preform extends to the sides
of
the glove shell fingers, the embodiment being laminated in a bladder press;
[0061] Figure 11A is a bar graph comparing a knit glove with no applied
enhancement layer with a knit glove to which a TPU laminate preform has been
applied, and demonstrating that the knit glove with laminate preform is 72%
softer
than a knit glove that has been palm dipped;
[0062] Figure 11B is a bar graph showing that a knit glove with a TPU and
textile laminate preform applied to the palm is 48% softer than a knit glove
that
has been palm-dipped with PVC only;
[0063] Figure 11C is a bar graph showing that a knit glove with a para-
aramid
textile and urethane laminate preform applied to the palm is 54% softer than a
para-aramid knit glove that has been palm dipped with only nitrile;
[0064] Figure 11D is a bar graph showing that a knit glove with a TPU
laminate preform and including a textile insert is 82% softer than a knit
glove that
has been nitrile dipped; and
[0065] Figure 11E is a bar graph showing that a knit glove with a TPU
laminate
preform applied to the palm and including a 2 ply textile insert is 98% softer
than
a knit glove with a latex palm dip and a 3-ply textile insert.
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DETAILED DESCRIPTION
[0066] The present invention is a glove having a 3D shape that closely
approximates the shape of a human hand, wherein the glove includes a
performance-enhancing layer adhesively applied to a 3D hand-shaped knit or
woven glove shell, and whereby the performance-enhancing layer includes at
least
one feature that cannot be provided by dipping of the glove shell in a coating
material.
[0067] With reference to Figures lA and 1B, the method of the present
invention includes preparing and assembling one or more solid, flat,
performance-
enhancing layers 100, referred to herein collectively as the "laminate
preform," or
simply as the "laminate." The knit or woven 3D glove shell 102 is placed on a
3D
laminating form 104 that provides at least one smooth, wrinkle-free laminating
surface 106, and the laminate preform 100 is then placed in contact with the
laminating surface 106.
[0068] With reference to Figures 1C and 1D, which are cross-sectional views
as
indicated in Figure 1B, a non-liquid, thin film laminating adhesive 108 is
included
between the laminate preform 100 and the glove shell (and in some embodiments
also between layers of the laminate preform). In embodiments, the laminate
adhesive 108 is a solid at ambient pressure and temperature, and is included
at
least on one of the outward-facing surfaces of the laminate preform 100.
[0069] Pressure is then applied to the assembled laminating form 104, glove
shell 102, and laminate preform 100 at an elevated temperature, so as to
adhesively bond the laminate preform 100 to the glove shell 102.
[0070] Of course, because there are no sewing attachments between the
laminate preform 100 and the glove shell 102, as is typical in glove
assemblies of
the prior art, it is important that the laminate preform 100 be well bonded to
the
glove shell 102, since poor bonding could result in premature product failure.
Two factors are critical to the quality of the bond between the laminate
preform
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100 and the glove shell 102. First, the surface of the glove shell fiber must
be free
of spin finish and lubricants that are used in production of yarns and
textiles. A
suitable scouring process is generally required, and the Soxhlet extraction
with
acetone must be below 1.5% by weight of the textile, with a more preferred
value
of 0.5% for best durability of the bond.
[0071] The
second factor that is critical to the quality of the bond is the surface
match of the glove shell fiber and the lamination adhesive 108. Both surface
energies must be high enough to make wetting and long term bonding
thermodynamically favorable. In embodiments, the glove shell textile has a
total
surface energy of greater than 40mJ/m2. Cotton and nylon meet these criteria,
whereas PET fiber does not without a modifying treatment or coating. In
embodiments, the adhesive surface energy is greater than 30mJ/m2. SBR and
urethane adhesives meet this surface energy requirement. These examples are
not
intended to be exhaustive, and many fiber and adhesive combinations can
provide
the adhesion performance required by this invention. In wear trials, it has
been
found that a laminate preform bonded to the glove shell tested using ASTM
D1876 - 08 standard test method for peel resistance of adhesives (T-Peel Test)
with a 1" wide peel sample that has 5 average peak peel forces of greater than
5
lbf/inch will meet the requirements of this invention for durability.
[0072] The
bonding of the laminate preform 100 to the glove shell 102 can use
any of various adhesive processes. Thermoplastic, pressure-sensitive, and
reactive
adhesives are all effective. In embodiments, penetration of the lamination
adhesive 100 into the glove shell 102 is controlled, since the stiffness of
the glove
shell 102 tends to increase as more adhesive penetrates into the textile of
the glove
shell 102, and soft, flexible glove shells 102 are typically desired. The use
of
non-liquid thin film adhesives 108 in the present invention provides excellent
laminate adhesion and very controlled and limited penetration of the
lamination
adhesive 108 into the textile of the glove shell 102. In embodiments, thin
adhesive films 108 of between 6 and 50 microns are used, so as to provide only
limited penetration of the adhesive 108 into the fibers of the glove shell
102.
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[0073] A key aspect of the present invention is the capacity to combine
glove
shells 102 having accurate hand-shapes with solid laminate preforms 100 that
include features which cannot be provided by glove shell dipping methods.
Printed graphics, high filler loaded elastomers, textile layers, and oriented
films
are all important examples of materials and features that can only be included
in
the enhancing layer if the enhancing layer is prepared ahead of time as a
solid, flat
laminate preform 100. This approach allows such features to be added to the
flat,
solid laminate preform 100 by using such methods as printing, roll to roll
coating,
gravure coating, extrusion, stenting, blown extrusion, weaving, and/or
knitting,
before the laminate preform 100 is laminated onto the glove shell 102. It is
important to note that, in embodiments, the laminate preform production
methods
have very tight control of materials properties and tight control of the
preform
thickness. In some embodiments the thicknesses of the adhesive and other film
layers are controlled to less than +/- 5 microns.
[0074] In the embodiment of Figures 1A-1D, the laminate preform 100 is a
single layer of elastomeric film 110 combined with a thermoplastic adhesive
108.
In the embodiment of Figures 2A and 2B, the laminate preform 100 includes a
graphics layer (fusable ink) 200 included between a grip layer (thermoplastic
urethane, "TPU") 202 and the adhesive layer 108. The ability to include such
graphical layers in the laminate preform 100 provides opportunities for
durable
labeling and branding that cannot be obtained when enhancement layers are
applied by dipping. Of course, graphics can always be applied to the surface
of a
finished glove, but then the graphics will not be embedded within nor
protected by
by the performance-enhancing layer.
[0075] In various embodiments, a digital inkjet, a screen printing, or a
web
press printing process is used to form a graphics layer 200 on top of the
adhesive
layer 108. In a second laminate preforming step, the graphics layer 200 is
protected with an abrasion layer 202 laminated over the print layer. This
three ply
laminate preform 100 is then applied to the glove shell 102 by thermoplastic
bonding of the adhesive layer 108 during the lamination step. Because the
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graphics layer is built on a smooth polymeric or elastomeric film, fine detail
and
print quality are preserved. This fine print detail is not possible when
printing
directly on the surface of a textile or on a dipped textile surface.
[0076] As discussed above, the adhesive strength and quality of the bond
between the laminate preform 100 and the glove shell 102 is one important
factor
in preventing failure of the bond and maintaining the integrity of the
laminated
glove. Another important factor is the edge condition of the bond between the
laminate preform 100 and the glove shell 102. It can be shown that the peel
resistance of an elastic film is higher than the peel resistance of a high
modulus
film when bonded at the same specific adhesive strength. The reason for this
is
that an elastic film stretches and spreads the stress at the peel point,
whereas a
hard film cannot stretch and deform. As a result, a peel crack is propagated
at
lower loads for hard films.
[0077] Embodiments in which thermoplastic urethane ("TPU") film is bonded
to a nylon glove shell 102 provide excellent results in this regard, because
the
TPU is low modulus (400-500% elongation at break), and the nylon is also low
modulus for fiber (30% elongation at break). Even in embodiments where the
glove shell 102 has a high modulus, use of a low modulus laminate preform 100
provides better peel resistance as compared to a high modulus laminate preform
100. In various embodiments, elastomeric films of greater than 100% elongation
are included in the laminate preform 100.
[0078] With reference to Figures 3 and 4, in certain embodiments where a
top
layer 202 of a multi-layer laminate preform 100 has a low modulus, but one or
more layers below the top layer have a high modulus, the edge of the laminate
preform is "stepped" by extending the top layer 202 beyond the lower layers,
so
that the top layer 202 is directly bonded to the glove shell 202. This
approach
provides a high peel condition at the edge of the laminate preform 100, even
when
stiff layers are included in the central region of the laminate preform 100.
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[0079] In the embodiment of Figure 3, a high modulus oriented film 300 is
included between the grip layer 202 and the adhesive layer 108, and in Figure
4 a
high modulus textile layer 400 is included between the grip layer 202 and the
adhesive layer 108.
[0080] Figure 5 is similar to Figure 4 except that a filled polymer layer
500 is
included beneath the textile layer 400. In Example #3 described below, 600-50
grit 5 silicon carbide grain is used as a filler in one of the prefabricated
elastomer
layers. In various embodiments, ceramic and/or metallic fillers are included
which have specific gravities of between 2 and 14. Fillers having such high
densities would segregate in a low viscosity coating, such as a coating
applied by
dipping. However blade coating and extrusion are very effective for production
of films with dense fillers that can be included in the laminate preform. In
one
example, Styrene Butadiene rubber elastomer was dissolved in solvent and a
ceramic grain was mixed in at 10K centipoise. This mix 500 was coated to a
film
using a knife over roll process. In a similar example, a 200 and 660 grit
coating
having a viscosity of between 2500 and 5000 cps was applied to a chloroprene
film as part of a laminate preform 100. Many other powdered, fibrous, and
platelet type fillers are included in embodiments of the present invention to
impart
valuable permeability, cut, abrasion, flame, heat, and other properties to the
laminate preform 100, where such fillers at their required loadings result in
excessive viscosity that would prevent them from being used in a dip coating
process.
[0081] With reference to Figure 6, embodiments of the present invention
include a second laminate preform 600 that is laminated to the inner surface
of the
glove shell 102. In the embodiment of Figure 6, a layer 600 that mechanically
resists cuts and punctures is placed between the 3D laminating form 104 and
the
glove shell 102, so that it is laminated to the inner surface of the glove
shell 102.
The outer laminate preform includes an oriented polymer film 300 between a TPU
grip layer 202 and an adhesive layer 108.
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[0082] With reference to Figure 7, in various embodiments a cut-and-sew
liner
700 is attached inside of the glove shell 102, and is included with the glove
shell
102 on the 3D laminating form 104. The resulting glove includes the cut-and-
sew
liner in its interior and the laminate preform on its exterior surface, with
the knit
or woven glove shell 102 in between.
[0083] With reference to Figure 8A, in various embodiments, the glove shell
102 is reversibly deformable, whereby its shape is deformed while it is
mounted
on the 3D laminating form 104. In embodiments, this is helpful in providing
the
smooth, crease-free area that is required for lamination. Figure 8A is a cross-
sectional illustration of such an embodiment taken through the finger region.
With reference to Figure 8B, the glove shell fingers return to their accurate,
rounded 3D finger-shapes after the laminate preform 100 is applied thereto and
the
resulting glove is removed from the 3D laminating form 104.
[0084] In various embodiments the laminate preform is designed to work with
the 3D laminating form 104 to increase the wrap of the laminate preform 100
around portions of the hand. As illustrated in Figure 8A, the 3D laminating
form
104 can elongate the fingers of the glove shell 102 to increase the size of
the flat
bonding face 106. The resulting warp of the laminate preform 100 is thereby
increased after the glove shell 102 is removed from the 3D laminating form 104
and returns to its 3D hand-shape.
[0085] An important aspect of some embodiments of the invention is the way
in
which the glove shell 102 contracts after it is removed from the 3D lamination
form 104. In embodiments, the glove shell fingers are elongated in their
circumference by between 10 and 60% when the glove shell 102 is on the 3D
laminating form 104. This increases the surface area of the glove shell
fingers
that is wrinkle free and monotonic in surface curvature (fully flat is not
required),
and is thereby available for bonding of the laminate preform thereto. After
the
lamination step, the 3D laminating form 104 is removed and the glove shell 102
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can recover its shape. The laminated area tends not to recover, but instead
tends
to retain its laminated width.
[0086] In some of these embodiments a laminate preform 100 is not applied
to
the backs of the finger and hand regions of the glove shell, so that most of
the
shape recovery takes place in these unlaminated regions. The result is that
after
the glove is removed from the 3D laminating form 104, a higher percentage of
the
finished finger circumference is covered by the laminate preform 100 than was
covered when the glove was on the 3D laminating preform. If the ratio of width
to
thickness on the 3D laminating preform 104 is 10:1 for example, then 40% of
the
elongated circumference is readily bonded to the laminate perform 100, and the
ratio of back of hand and sides to laminate width is approximately 4:6.
However,
after removal from the 3D laminating form 104, if the back of hand and sides
contract by 50%, the laminated length will have a ratio to the back and sides
of 4:
3, significantly increasing the coverage of the laminate preform 100 in the
relaxed
glove.
[0087] In the embodiments of Figures lA through 8B, the 3D laminating form
104 includes opposing flat surfaces 106, and the lamination pressure can be
applied by a press such as a platen press that is designed to apply pressure
to a
substantially flat surface. This is illustrated in Figure 9, where a cross
section of
the finger regions illustrated in Figure 1C are shown as being pressed at an
elevated temperature between a pair of hot press platens 900, 902. In
embodiments, the lamination temperatures range from 200 degrees Fahrenheit to
375 degrees Fahrenheit for bonding of the laminate preform 100 to the glove
shell
102, and the applied lamination pressures range from 5 psi to 150psi. The
layer
904 shown between the upper platen 900 and the glove is a conforming layer
that
is made from a heat resistant elastomer and improves the uniformity of contact
between the glove and the press platen face.
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[0088] While Figure 9 is illustrated as a vertical platen press, in similar
embodiments a roll press, a belt press, and/or a nip roll press is used to
laminate
the laminate preform 100 to the glove shell 102.
[0089] In other embodiments, the laminating surface 106 of the 3D
laminating
form 104 is curved or otherwise shaped, although it is always smooth and free
of
creases. In embodiments where increased wrap-around of the laminate preform
100 on the glove shell 102 is desired, and/or where the laminating surface 106
is
not flat, bladder presses and vacuum bag techniques are used to apply the
laminating pressure. With reference to Figure 10, the conformability of the
bladder or vacuum bag 1000 permits the laminate preform 100 to wrap around the
fingertips and fourchette area of the glove shell. Figure 10 illustrates an
embodiment where the laminate preforms 100 extend to the sides of the glove
shell fingers 104, and a bladder 1000 is forced either pneumatically or
hydraulically against the tops and sides of the glove shell fingers, thereby
laminating the fingers on three sides. By using two laminate preforms 100,
this
approach can provide complete coverage of the glove shell 102. In the same
way,
a bladder press or a vacuum bag press can be used to apply laminating pressure
to
a laminate preform 100 that is placed against a smooth, curved surface 106
such as
the palm of an accurately hand-shaped 3D laminating form 104.
[00901 One of the benefits of the present invention in various embodiments
is
the thinness of the laminate preform that can be provided, and the resulting
flexibility of the glove. For measuring these benefits, we have selected the
ASTM
D4032 - 08 standard test method for stiffness of fabric by the circular bend
procedure. This test uses a standard 4" x 8" test coupon. We have modified
this
method to use the palm and back of the gloves under test. After slitting the
glove
up one side and removing the fingers and thumb, the remaining coupon for an
extra-large glove is very nearly 4 inches x 8 inches. The circular bend test
is
sensitive to small changes in the glove and laminate system. In some cases, we
find that it is necessary to precondition the palm-back glove test coupons by
multiple runs on the circular bend test to reach stable conditioned values. In
the
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case of conditioned test values, we run the test 10 times and use the average
of the
results from tests 8, 9, and 10 as the stable conditioned circular bend
result.
[0091] Embodiments of the present invention include laminate preforms that
are much thinner than can be achieved with dipping processes. In some
embodiments, the thickness of the laminate preform is between 25 microns and
75
microns, which provides a low bending stiffness. Even in embodiments where
textile inserts and textile components are used in the laminate preforms, the
circular bending stiffness is much lower than what can be provided by dipped
gloves, and very much lower than what is found in gloves that include multiple
layers of protective textile and dipped surfaces.
[0092] Figure 11A is a bar graph comparing a knit glove with no applied
enhancement layer with a knit glove to which a TPU laminate preform has been
applied, and demonstrating that the knit glove with laminate preform is 72%
softer
than a knit glove that has been palm dipped. The first values in the graph are
the
thickness and bending stiffness of a 13g 210 Denier nylon glove shell at
approximately 400g of bending stiffness. The next set of values refers to the
same
shell after application thereto of a 3 ply 60 micron laminate of TPU with a
graphics layer. As can be seen from the data, the lamination process reduces
the
thickness of the knit, resulting in a slightly thinner glove even with the
addition of
the laminate preform. The third set of data refers to a directly comparable
palm-
coated dipped glove with a typical dipping thickness of 300-350 microns. As
can
be seen from the graph, the lamination process produces a glove that is almost
as
soft as the uncoated knit at 410 vs 440 grams, and the invention results in
gloves
with less than 1/3 of the stiffness of comparable dipped gloves.
[0093] Figure 11B presents a flexibility comparison using the circular
bending
test described above, showing that a knit glove with a TPU and textile
laminate
preform applied to the palm is 48% softer than a knit glove that has been palm-
dipped with PVC only. Figure 11C presents a similar flexibility comparison,
showing that a knit glove with a para-aramid textile and urethane laminate
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preform applied to the palm is 54% softer than a para-aramid knit glove that
has
been palm dipped with only nitrile. Figure 11D presents a similar flexibility
comparison, showing that a knit glove with a TPU laminate preform and
including
a textile insert is 82% softer than a knit glove that has been nitrile dipped.
And
Figure 11E presents a similar flexibility comparison, showing that a knit
glove
with a TPU laminate preform applied to the palm and including a 2 ply textile
insert is 98% softer than a knit glove with a latex palm dip and a 3-ply
textile
insert.
Examples
[0094] Example 1: Knit shell with insert and laminate preform including
grip
and graphics layers
= Glove shell: 210 denier nylon 13 gauge knit shell
= Insert: 220 denier of construction 100x 60 epi of PET fiber woven or 30
denier Nylon at 100x100 epi bonded inside the shell
= Laminate preform:
o Grip layer: polyether thermoplastic urethane ("TPU")of hardness 80
shore of 25 microns thickness
o CYK graphics layer: fusible inks of 5-12 microns thickness
o Adhesive Layer: polyether thermoplastic urethane adhesive layer, 25
micron thick, that bonds the graphics layer and grip layer to the
glove shell at 350 degrees Fahrenheit
= Manufacturing Process: The adhesive layer is printed with the graphics
layer, then the grip layer is laminated on top of the other two layers to
complete the 3-ply laminate preform material. The 210 denier knit shell is
mounted on the 3D laminating form. The laminate preform material is cut
to shape and laminated to the glove shell on the 3D laminating form in a
platen press at 350F.
[0095] Example 2: Knit shell with TPU/grain-elastomer/30 denier nylon
woven/PSA laminate preform
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= Glove shell: 210 denier nylon 13 gauge knit shell
= Insert: 220 denier 100x 60 epi of PET fiber woven or 30 denier nylon at
100x100 epi bonded inside the glove shell
= Laminate preform:
o Grip layer: Polyether thermoplastic urethane of hardness 85 shore of
25 microns thickness
o CYK graphics layer: fusible inks of 5-12 microns thickness
o Adhesive tie layer: Polyether thermoplastic urethane adhesive
between 12 and 25 microns thick
o Mechanical layer: 30 denier woven nylon 100x100epi
o Filler layer: SB rubber in solvent with 220 + 600 grit silicone
carbide filler added in a 4.5:1 ratio to the elastomer by weight
o Adhesive: Rosinated SBR blend in a solvent-based pressure sensitive
adhesive (PSA)
= Manufacturing process: The grip layer is printed with the graphics layer.
Then the grip layer is laminated to the textile layer. The textile layer has
TPU
on the face side and the grain layer and PSA blade coated to the reverse side.
This completes the 6 ply laminate preform material. The 210 denier knit shell
is mounted on the 3D laminating form. The laminate preform material is cut to
shape and laminated to the glove shell on the 3D laminating form in a platen
press at 300 degrees Fahrenheit.
[0096]
Example 3: Knit shell with non-thermoplastic PU/grain-elastomer-PSA
laminate preform
= Glove shell: 210 denier nylon 13 gage knit shell
= Insert: 220 denier of construction 100x 60 epi of PET fiber woven or
140 denier 80x70 para-aramid woven or 30d Nylon at 100x100 epi bonded
inside the shell
= Laminate preform:
o Grip layer: Cast non-thermoplastic polyester urethane of hardness 95
shore of 25 microns thickness
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o CYK graphics layer: fusible inks of 5-12 microns thickness
o Filler layer: SB rubber in solvent with 220 + 600 grit silicone carbide
filler added at a 4.5:1 ratio to the elastomer by weight
o Adhesive: Rosinated SBR blend in solvent-based pressure sensitive
adhesive (PSA)
= Manufacturing process: The grip layer is cast from a reactive mixture of
polyol and isocyanate, cured, and then printed with the graphics layer. Then
the grain layer and PSA layers are roll-coated to the glove shell side of the
laminate preform. This completes the 4-ply laminate preform material. The
210 denier knit glove shell is mounted on the 3D laminating form. The
laminate perform material is cut to shape and laminated to the glove shell on
the 3D laminating form in a platen press at 300 Fahrenheit.
[0097] Example 4: Knit shell with Neoprene/nylon/PSA laminated preform
[0098] Example 5: Knit shell over a glove with unbonded or semi bonded
insert
glove
= Glove shell: 210 denier nylon 13 gage knit shell
= Insert: Cut-and-sew liner of 200 denier x 400 denier para-aramid of
110x65 epi of construction woven, bonded inside the glove shell
= Laminate preform:
o Grip layer: Polyester thermoplastic urethane of hardness 85 shore 25
microns thick
o CYK graphics layer: fusible inks of 5-12 microns thickness
o Adhesive tie layer: Polyester thermoplastic urethane adhesive 25
microns thick
= Manufacturing process: The grip layer is printed with the graphics layer,
then the grip layer is laminated to the adhesive layer. This complete the 3-
ply
laminate preform. The 210 denier knit glove shell is mounted on the 3D
laminating form. The laminate preform material is cut to shape and laminated
in a platen press at 350 degrees Fahrenheit to the glove shell on the 3D
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laminating form. After removal from the 3D laminating form the glove shell is
bonded to the sewn liner.
[0099] Example 6: Cut and sew shell with TPU/Inkjet/TPU laminate preform
= Shell: 100 denier nylon 50 gage knit with 10% 70 denier lycra in a full
fourchette cut-and-sew shell
= Insert: 220 denier of construction 100x 60 epi of PET fiber woven or 30
denier Nylon at 100 x 100 epi, bonded inside the glove shell
= Laminate preform:
o Grip layer: Polyester thermoplastic urethane of hardness 85 shore 25
microns thick
o CYK graphics layer: fusible inks 5-12 microns thick
o Adhesive: Polyester thermoplastic urethane adhesive layer that bonds
the graphics layer and grip layer to the glove shell at 350 degrees
Fahrenheit
= Manufacturing Process: The adhesive layer is printed with the graphics
layer, then the grip layer is laminated to the other two layers to complete
the 3-
ply laminate preform material. The 210 denier knit shell is mounted on the 3D
laminating form. The laminate preform material is cut to shape and bonded to
the glove shell on the 3D laminating form in a platen press at 350 degrees
Fahrenheit.
[00100] Example 7: Vacuum or bladder press formed laminate preform,
[00101] Example 8: Double sided laminate preform on palm and back surfaces
of the glove shell, with overlaps at the finger tips and the fourchettes (see
Figure
7)
= Shell: 210 denier nylon 13 gage knit shell
= Insert: Full cut and sew glove of a suitable fabric having a 220 denier
construction 100 x 60 epi of PET fiber woven, or 30 denier Nylon at 100 x 100
epi, or 200 denier x 400 denier 110 x 65 epi para-aramid bonded inside the
glove shell
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= Laminate preform:
o Grip layer: Polyester thermoplastic urethane of hardness 85 shore of 25
microns thickness
o CYK graphics layer: fusible inks of 5-12 microns thickness
o Adhesive layer: Polyester thermoplastic urethane adhesive layer that
bonds the graphics layer and grip layer to the glove shell at 350 degrees
Fahrenheit
= Manufacturing process: The adhesive layer is printed with the graphics
layer, then the grip layer is laminated to the other two layers to complete
the 3-
ply laminate preform material. The 210 denier knit shell is mounted on the 3D
laminating form. The laminate preform material is cut to shape and laminated
to the glove shell on the 3D laminating form in a platen press at 350 degrees
Fahrenheit. Then the assembled knit shell and laminate preform are bonded to
the cut-and-sew insert glove.
[00102] The foregoing description of the embodiments of the invention has been
presented for the purposes of illustration and description. It is not intended
to be
exhaustive or to limit the invention to the precise form disclosed. Many
modifications and variations are possible in light of this disclosure. It is
intended
that the scope of the invention be limited not by this detailed description,
but
rather by the claims appended hereto.
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