Waterproof Taped Glove and Mitten with Laminated Leather

A leather laminating method and an apparatus manufactured by applying the leather laminating method. A waterproof membrane may be sandwiched between two layers of breathable materials, and a waterproof breathable (WPB) material may be formed. The WPB material may be laminated to a leather material by using a dot adhesive, and a laminate construction may be created. The laminate construction may be cut into pieces, and the pieces may be sewn together into a hand-covering garment. The garment may be taped at seams to prevent water from passing through the garment.

DETAILED DESCRIPTION

The present invention generally relates to a method of laminating leather, which may be applied for making gloves or mittens that can be used for a variety of indoor and outdoor activities, especially in environments abundant with water or humidity. While a preferred example of laminating leather is described in detail below, a construction in accordance with the present invention may be used in a broad range of products, such as indoor and outdoor garments, as well a variety of gloves, mittens and other apparel and accessories.

One example of laminating leather in accordance with the present invention is shown inFIG. 1, where laminate100construction is described. The laminate100may include three materials arranged on top of each other in their flat form: leather101, which may constitute an outer layer of the laminate100, waterproof breathable material (WPB)102, which may be an inner element of the laminate100construction, and adhesive103, which may be placed between the leather101and the WPB102. The function of the adhesive103may be to attach the leather101to the WPB102in a high-temperature environment, when the laminate100may be formed as a result.

One of the advantages of laminating the leather101to the WPB102is that the end product, the laminate100, may constitute a waterproof leather construction, i.e., a material which may prevent water from penetrating through the leather101and from being accumulated between the leather101and the WPB102. Joining the two materials in this manner may improve breathability, weight, and the insulating and the drying capability of a garment made of the laminate100, as compared to the existing technologies, for the reasons that will be discussed in detail.

A material used for the leather101may be a natural leather material, for example, goat, cow, pig, or sheep leather, or any other leather material deemed suitable for making leather garments. Further, the material used for the leather101may be any synthetic leather material including, but not limited to, synthetic suede or rubber. Moreover, leather101may be vented, or perforated, in order to increase the overall vapor permeability of the laminate100compared to existing lamination technologies. On the other hand, in instances where waterproof properties are preferred to breathability, non-perforated leather may be applied.

Moreover, the adhesive103may constitute a film adhesive, or it may be a dot adhesive, illustrated inFIG. 1. Applying dot adhesive material improves breathability of the laminate100in comparison with existing lamination technologies, due to intermittent placement of glue within the adhesive material.

As shown inFIG. 2, the WPB102may include three layers: membrane204, and two additional layers which may sandwich the membrane204. A material used for the membrane204may be waterproof, which may render the entire WPB102construction impenetrable to water. In addition, the other two layers of the WPB102may be made of materials that may enhance the breathability of the WPB102. Namely, sandwiching the membrane204between two such materials may place a layer in-between the membrane204and the leather101, which may allow vapor from perspiration to pass through, without diminishing the waterproof properties of the WPB102, and consequently, the laminate100.

In one embodiment, illustrated inFIG. 2(a), the WPB102may constitute shell fabric “sandwich” (SFS)205construction, which may include the membrane204, face fabric (FF)206, and tricot or woven backer (TWB)207. The FF206may be made of any material deemed suitable for permeating vapor. Moreover, the FF206may be made of nylon, polyester, or any other synthetic material. In one example, the FF206may be used as an interface between the WPB102and the leather101, joined together to form the laminate100.

In another embodiment, depicted inFIG. 2(b), the WPB102may constitute soft shell fabric “sandwich” (SSFS)208construction, which may include the membrane204, the FF206, and fleece or tricot backer (FTB)209. The FF206of this embodiment may be made of any material deemed suitable for allowing vapor from perspiration to pass through. In addition, the FF206of the SSFS208may be used as an interface between the WPB102and the leather101, joined together to construct the laminate100.

In yet another example, shown inFIG. 2(c), the WPB102may constitute “pocket-liner” fabric “sandwich” (PLFS)210construction, which may include the membrane204and two TWB207layers laid over and under the membrane204. One of the two TWB207layers may be used as an interface between the WPB102and the leather101, joined together to form the laminate100.

Next, the laminate100may be cut into pieces to manufacture a variety of garments. In comparison with the existing technologies, a garment made of such material shows improved durability, because the inserted layer protects the membrane204in case of delamination.

In one of the examples shown inFIG. 3(a), the laminate100may be used to form long-gauntlet (LG) glove300, by sewing together pieces of the laminate100. As a result, seams311may form along lines where the pieces of the laminate join. Thus, in order to maintain the LG glove300fully waterproof, the seams311may be taped with a waterproof tape (not shown in the drawing).

Moreover, assembling the LG glove300by using as few pieces of the laminate100as possible may be desirable, in order for fewer seams311to be created, resulting in fewer paths for water to pass through the LG glove300. Accordingly, less tape would need to be used to tape the seams311, which would, in turn, enhance the breathability of the glove, considering the general characteristic of taping materials to block the vapor from passing through. In one embodiment, a “reverse-gunn-cut” pattern may be applied to minimize the number of the pieces used for manufacturing the LG glove300, as illustrated inFIG. 3.

The “reverse-gunn-cut” pattern may be created by sewing dorsal section312to palmar section313. In one example, the dorsal section312may include a backside of the second and the fifth finger cavities of the LG glove300, and the palmar section313may incorporate front portions of all four finger cavities of the LG glove300, not counting a thumb cavity. Sewing the dorsal section312to the palmar section313may be performed along a single seam, i.e. lateral seam314, thereby minimizing the number of seams created. Next, back middle portion315may be joined with the palmar section313and the dorsal section312along knuckle seam316. Further, inner thumb section317may be sewn to outer thumb section318and the construction of the two may be attached to the remainder of the LG glove300. Subsequently, all the seams may be taped, in order to preserve the waterproof capabilities of the LG glove300. On the other hand, the seams of the “reverse-gunn-cut” pattern may remain not taped, and this construction may be built with a traditional insert construction. Finally, the “reverse-gunn-cut” pattern may be made with no insert at all.

One of the advantages of this glove manufacturing pattern, in addition to limiting the number of seams in a glove, may be that, in comparison with a regular “gunn-cut” pattern, known in the art, gloves made in the “reverse-gunn-cut” pattern may be more comfortable and more durable. Namely, by reversing the gunn-cut pattern, the middle portion315may be attached to a base of the LG glove300at the knuckles area, and not at a palmar crease area, in contrast with the regular “gunn-cut” pattern. Thus, when an object is held while wearing the LG glove300, the seam attaching the middle portion315may not be located in a grab area of the LG glove300, and, thus, it would neither interfere with the bending motion of the fingers, nor be placed in a direct contact with the grabbed object. As a result, the “reverse-gunn-cut” pattern may reduce tearing of the LG glove300at the seam, and it may also render the glove300more comfortable to wear.

One embodiment of the current invention may include darts319at the middle knuckle of each finger. Such feature of the LG glove300may further improve its durability, because it may prevent puckering of taped areas of the LG glove300by providing a pre-curve fit at finger cavities.

In another example, illustrated inFIG. 4, laminate100may be used to form short-gauntlet (SG) glove400, by sewing together pieces of the laminate100. The SG glove400may be under-cuff, i.e. shortened around the wrist area.

FIG. 5shows an embodiment that may prioritize thermal insulation and breathability related benefits of a hand-cover garment made of the laminate100over its functionality and over the tactile sense that the garment permits to the fingers. In one of the examples of the present invention, pieces of the laminate100may be sewn together to form mitten500. The mitten500may contain four fingers in a same cavity, thereby further decreasing the number of seams needed to manufacture it. Namely, the mitten500may omit the middle portion315depicted inFIG. 3(b), and, thus, the knuckle seam316may be eliminated. Consequently, the taping of the seams may be reduced, which may, in turn, increase the breathability of the mitten500. Moreover, by containing four fingers together, the mitten500may expose less area surface of the fingers to the garment, thereby decreasing heat exchange between the fingers and the surrounding environment.

In one embodiment, darts524may be created in back portion525of the mitten500. Such feature of the mitten500may further improve its durability, because it may prevent puckering of taped areas of the mitten500by providing a pre-curve fit at a top portion of the mitten500.

Finally, similarly to the glove embodiments discussed above, the mitten500may be either a long-gauntlet mitten or an under-cuff mitten, shortened around the wrist area.

While various embodiments have been described, other embodiments are plausible. It should be understood that the foregoing descriptions of various examples of using laminated leather to manufacture gloves or mittens are not intended to be limiting, and any number of modifications, combinations, and alternatives of the examples may be employed.

The examples described herein are merely illustrative, as numerous other embodiments may be implemented without departing from the spirit and scope of the present invention. Moreover, while certain features of the invention may be described above only in the context of certain examples or configurations, these features may be exchanged, added, and removed from and between the various embodiments or configurations while remaining within the scope of the invention.