Abstract:
A reinforced glove includes a substrate, typically in the form of a shell having the shape of a human hand, and a protective coating disposed on the substrate to form a composite therewith. The shell and any integral or non-integral reinforcing elements are at least partially covered by the protective coating, which penetrates such reinforcing elements to thereby improve the bond between the shell and reinforcing elements, whereby the durability, strength and grippability of the glove are enhanced.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims the priority of the U.S. Patent Application Ser. No. 60/856,558 filed Nov. 3, 2006, the entire disclosure of which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to multilayer, reinforced gloves and methods for manufacturing such gloves. 
       BACKGROUND OF THE INVENTION 
       [0003]    Gloves of the prior art are constructed of various materials and are used for various purposes. For example, the prior art includes workman gloves, surgical gloves, driving gloves, household gloves, skiing gloves, and gloves for providing warmth. Gloves of the prior art have typically been formed from leather, polyvinyl-chloride, rubber, and fabric. It is also known in the art to provide composites, such as fabric gloves dip-coated with a natural or nitrile rubber. 
         [0004]    The prior art also includes gloves having fabric and leather reinforcing elements that are mechanically fastened to a glove. For example, the prior art includes fabric and leather strips sewn onto the outer surface of the glove. The fabric and leather reinforcing elements are positioned on sections of the glove corresponding to the fingertips, the knuckles, the wrist, the palm, and/or the back side of the hand. Although fabric and leather reinforcing elements increase a glove&#39;s grip and wear resistance, they are expensive materials and must be mechanically fastened to the glove. This increases the total manufacturing cost of the glove, as well as the final retail price paid by consumers. 
         [0005]    It is also known in the art to provide a glove having polyvinylchloride patches bonded to an underlying fabric. For example, U.S. Pat. No. 6,185,747 discloses polyvinylchloride patches that are metal-screened to the fibers of the underlying fabric. Unfortunately, the bond between the screened polyvinylchloride and the fibers causes the fibers to stiffen, which in turn causes discomfort and potential irritation to the hands of a person wearing the glove. Furthermore, the fabric of the glove is exposed in multiple locations, such as in the areas between the polyvinylchloride patches. This forms vulnerable areas that have low wear resistance and that are easily susceptible to puncture and/or chemical penetration. 
         [0006]    What is needed in the art is a glove that provides good grippability at a low cost and does so without unnecessarily compromising the wear resistance or comfort of the glove. 
       SUMMARY OF THE INVENTION 
       [0007]    In accordance with the present invention, a glove, which includes a shell in the shape of a human hand, is reinforced over at least a portion of the shell and then coated so as to at least partially cover the shell, including its reinforced portion. The shell can be reinforced integrally by, for instance, making a portion of it thicker than the rest of the shell. If the shell has a knit construction, the reinforced portion can be formed by knitting thicker (i.e., lower gauge) threads into the shell at desired locations on the palm side and/or the back side of the shell. Once the shell is coated, the result is a composite glove having a plurality of reinforced portions that enhance the durability, grippability and/or comfortability of the glove. It is also possible to reinforce the shell using independent reinforcing elements that are attached to the palm side and/or the back side of the shell by the coating. The result, in this instance, is a reinforced, multi-layered glove having enhanced durability, grippability and/or comfortability. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    For a more complete understanding of the present invention, reference is made to the following description of various exemplary embodiments thereof taken in conjunction with the accompanying drawings, in which: 
           [0009]      FIG. 1  is a top plan view of a palm side of a glove constructed in accordance with one exemplary embodiment of the present invention; 
           [0010]      FIG. 2  is a view similar to  FIG. 1 , except that a portion of a coating layer of the glove has been removed to show an underlying shell and reinforcing element; 
           [0011]      FIG. 3  is a top plan view of a back side of the glove shown in  FIG. 1 ; 
           [0012]      FIG. 4  is sectional view, taken along section line  4 - 4  of  FIG. 1  and looking in the direction of the arrows, of the glove shown in  FIG. 1 ; 
           [0013]      FIG. 5  is an exploded perspective view of the glove shown in  FIG. 1 ; and 
           [0014]      FIG. 6  is a top plan view of a palm side of a glove constructed in accordance with another exemplary embodiment of the present invention, an outer coating layer of the glove having been removed so that an underlying shell and reinforcing elements are visible. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    Referring to  FIGS. 1-3  and  5 , there is shown a glove  10  which includes a shell or substrate  12  (see  FIG. 2 ), a reinforcing element  14  and a coating layer  16 . The shell  12  is in the form of a conventional fabric glove and includes a plurality of finger portions  18 , a palm side  20  and a back side  22 . More particularly, the shell  12  can have a string-knit construction which provides a seamless shell, or a sewn-knit construction which provides a shell having seams. Alternatively, the shell  12  can be woven, knitted, or non-woven, including but not limited to bonded fiber, stitched bonded, needle punched, spun bonded and spun lace are examples of textile types which can be used. 
         [0016]    The shell  12 , especially if it has a knit construction, may also include areas or portions (not shown) that have a gauge (i.e., number of courses of threads per inch) or strength or size different from the rest of the shell  12 , thereby providing integrally formed reinforcing portions with different texture, weight and/or integrity. For instance, such integrally formed reinforcing portions can result in raised areas having a cushioning effect if the size or gauge (i.e., diameter) of the threads in the reinforced portion is larger than the size of the threads used to make the remainder (i.e., the unreinforced portion) of the shell  12 . Rather than modifying thread size, the type of material used to make the reinforced portion could be different than the type used to make the unreinforced portion of the shell  12 , thereby providing an opportunity to enhance the durability, grippability and/or comfortability of the glove  10 . The use of a stronger (i.e., more wear-resistant) material for the reinforced portion would, by way of example, enhance durability which would, in turn, increase the useful life of the glove  10 . 
         [0017]    If the shell  12  is made from one of the foregoing constructions, suitable materials include polyester, nylon, acrylic, Kevlar®, Dyneema®, rayon, polypropylene, lyocell, glass lyocell, glass and metallic fibers, acetate, aramide, modacrylic. melamine, urethane etc., or blends thereof. The other suitable materials include all natural fibers such as vegetable fibers (i.e., cotton, flax, jute, and sisal, also including animal fibers such as wool, horsehair and silk), and synthetic fibers including regenerated cellulose, polylactic acid, polyurethane, vinyl and polyolefins. High performance specialty fibers such as aramide, polybenzimidazole, polyimide, phenolaldehyde and polysulfone are also suitable for construction of the shell  12 . The shell  12  could be made from non-fabric materials. For instance, heat-sealed plastic or rubber (natural or synthetic), as well as other elastomeric materials, might be used to form the shell  12 . 
         [0018]    Referring now to  FIGS. 1 ,  2  and  5 , the reinforcing element  14  can be any sheet-like material that has some degree of flexibility and some affinity for liquid agents used to form the coating layer  16 . The term “affinity” is used herein to define a material that can absorb or adsorb suitable liquid agents or that does not repel such agents. One suitable material for the reinforcing element  14  is a urethane foam, preferably one with a reticulated construction, having cells in the range of from about 20 per inch to about 100 per inch. Such a foam material can be provided with a thickness preferably ranging from about 0.04 inch to about 0.25 inch, and, more preferably, ranging from about 0.06 inch to about 0.12 inch. 
         [0019]    Other suitable materials for the reinforcing element  14  include knit or woven fabrics. The knit or woven fabrics have a mesh-like or somewhat open construction and are typically made from cotton, polyester, nylon, acrylic, Kevlar®, Dyneema®, rayon, polypropylene, lyocell, etc., or blends thereof. 
         [0020]    The reinforcing element  14  can also be made from non-woven fabrics constructed by any known process, such as airlaid, spun bound, spunlace (e.g., Ahlstrom Green Bay, Inc. Grades SX-392, SX-252 and SX-600), melt blown, carded/bonded and needle punched processes. Like the knit and woven fabrics, the non-woven fabrics can be constructed from cotton, polyester, nylon, acrylic, Kevlar®. Dyneema®, rayon, polypropylene, lyocell, etc., or blends thereof. Other materials suitable for the reinforcing element  14  are perforated plastic films, plastic foams, reticulated foams, plastic netting and molded plastic. Rubber sheeting, rubber foams, molded rubber, and soft metal (e.g., bronze and aluminum) mesh and screening are also suitable. Leather, reconstituted leather (e.g., perforated leather) and low quality leather are suitable as well. Preferably, all of these materials should have an open construction. The term “open construction” is used herein to define a characteristic or property which allows liquid agents used to form the coating layer  16  to more readily penetrate or permeate the reinforcing element  14 . 
         [0021]    When a fabric material (e.g., knit, woven or non-woven fabric) is used to make the reinforcing element  14 , the preferred weight of the fabric material can range from about 1.0 oz per square yard to about 8 oz per square yard. Of course, the fabric material could have a weight outside this range, depending upon the type of fiber used and the degree of reinforcement desired. 
         [0022]    In certain cases, it may be preferable to perforate or die cut openings in the reinforcing element  14  to achieve satisfactory penetration/permeation of the coating agent (to be described in greater detail hereinafter) into the reinforcing element  14 . If desired, an anti-vibration effect can be achieved by selecting an appropriate material for the reinforcing element  14 . For instance, a reticulated urethane foam or a bonded non-woven fabric (e.g., 6 denier polyester bonded fiber) having a thickness of about 0.12 inch can be used as the reinforcing element  14  to achieve such an effect. 
         [0023]    It may be desirable to provide one or more pressure relief areas  24  in the reinforcing element  14  for enhanced flexibility or conformity of the glove  10  to the hand of a user. In addition, the reinforcing element  14  could be replaced with a plurality of reinforcing elements, the size, shape and/or location thereof being variable. For instance, while the reinforcing element  14  shown in  FIGS. 1 and 2  is applied to the palm side  20  of the shell  12  with portions thereof extending onto the finger portions  18 , the back side  22  of the shell  12  could be reinforced in a similar manner using multiple reinforcing elements (not shown). For instance, a reinforcement element can be positioned in the knuckle-area (not shown) on the back side  22  of the shell  12  in order to provide additional protection to the knuckles of the wearer of the glove  10 . 
         [0024]    The reinforcing element  14  provides enhanced cushioning to the hand of a user. The reinforcing element  14  also increases the tensile strength of the glove  10 , while functioning as an abrasion-resistant and cut-resistant element. Accordingly, the shell  12  can be made from a comfortable material (e.g., fabric) and then reinforced with the reinforcing element  14 . 
         [0025]    The reinforcing element  14  could be dispensed with, if the shell  12  is provided with an integrally formed reinforcing portion as described above. Alternatively, the reinforcing element  14  could be used, as a supplement, in combination with any such integrally formed reinforcing portion. 
         [0026]    The coating layer  16 , which permanently adheres the reinforcing element  14  to the shell  12 , can be made from any suitable liquid coating agent adapted for absorption or adsorption by the reinforcing element  14  or from such an agent that is not repelled by the reinforcing element  14 . Suitable coating agents include any elastomeric compound known in the art, such as natural rubber latex, synthetic rubber latices (e.g., neoprene, nitrile (Rheichold/Dow TYLAC 68074-06) or urethane). Other suitable materials for the coating layer  16  include silicone, polyurethane, polyvinylchloride or other 100% solid plastic resins, and solvent solutions of similar resins. All of the foregoing materials could be expanded or foamed. In certain instances, the coating layer  16  might be formed from neoprene and/or styrene butadiene rubbers. 
         [0027]    The coating layer  16  bonds to the shell  12 , while permeating and penetrating the reinforcing element  14  to thereby securely attach it to the shell  12 . More particularly, the coating layer  16  permeates or penetrates the reinforcing element  14  through its intersticies or openings. The bonds formed within the intersticies (not shown) of the reinforcing element  14  prevent the reinforcing element  14  and the coating layer  16  from bunching-up or folding onto themselves as the glove  10  is flexed by a user&#39;s hand, thereby providing greater comfort to the user and excellent durability for the glove  10 . Preferably, the reinforcing element  14 , including its peripheral edges  26 , is encapsulated or enveloped by the coating layer  16 . As a result, the coating layer  16  forms a fillet-like border  28  (see  FIG. 4 ) along the peripheral edges  26  of the reinforcing element  14 , thereby providing added protection to such edges. Depending upon the construction of the reinforcing element  14 , the coating layer  16  could be absorbed directly into the material forming the reinforcing element  14 . 
         [0028]    The glove  10  can be made using the following process or method. First, the shell  12  is applied to a three-dimensional mold or two-dimensional form (not shown) which is in the shape of a human hand. Next, the reinforcing element  14  is applied to the shell  12  on the palm side  20  thereof. More particularly, the reinforcing element  14  can be applied loosely to the shell  12 ; or it can be temporarily affixed thereto using any conventional mechanism, such as a light spray adhesive. After such affixation of the reinforcing element  14 , the shell  12  is dipped into a liquid bath of a suitable coating agent at an angle such that an area  30  (see  FIG. 3 ) on the back side  22  of the shell  12  is free of the coating agent. This free area  30  is provided so as to improve the breathability of the glove  10 . If breathability is not a concern, then the entire shell  12  can be dipped into the coating bath, thereby eliminating the free area  30 . After the shell  12  is removed from the bath, the coating agent applied to the shell  12  is cured in a conventional manner to form the coating layer  16 . For instance, the shell  12  can be oven-dried in accordance with methods known in the glove manufacturing industry. After curing, the shell  12  is removed from the mold, resulting in the formation of a unique reinforced, multi-layer glove. It should be noted that alternate methods of applying the coating can be used. Screen printing and spray coating are among some alternate methods to the dipping process. An elastic strap  32  is then attached to a wrist portion of the shell  12 . A loop and fastener (not shown) may be attached to the elastic strap  32 . Alternate wrist treatments include an overcast hem or gauntlet cuff. 
         [0029]    Depending upon the thickness and construction of the reinforcing element  14 , the reinforcing element  14  can be readily observed on the glove  10 . However, in some instances, it may be desirable to further highlight the appearance of the reinforcing element  14  from the rest of the glove  10 . By selecting the reinforcing element  14  from the variety of the materials available, varying the thickness of the reinforcement or the degree of openness of the reinforcing element  14 , the reinforced areas, after coating, can be visually and tactilely highlighted so that the glove  10  can be readily determined to be reinforced. Additionally, this can be accomplished by providing the reinforcing element  14  in a contrasting color (e.g., the reinforcing element  14  can be highlighted in black, while the shell  12  can be provided in white). The coating layer  14  could then be formulated with varying degrees of translucency to enhance the desired highlighting effect. Such a highlighting effect can be achieved by screen printing the contrasting color (e.g., black) over the portion of the coating layer  16  overlying the reinforcing element  14 . 
         [0030]    Referring to  FIG. 6 , a glove  10 ′ includes a reinforcing element  14 ′ having pads  14 A′- 14 G′ positioned on a palm side  20 ′ of the glove  10 ′, including finger portions  18 ′ thereof. For ease of manufacturing and handling, the pads  14 A′- 14 G′ are attached together by connecting strips  15 A′- 15 F′ (i.e., small segments made from the same material as the pads  14 A′- 14 G′ themselves). 
         [0031]    The preferred embodiments disclosed herein provide for a reinforced, multilayer glove that achieves many desirable objectives (e.g., grippability, durability, comfortability, etc.) at a relative low manufacturing cost. Various reinforcement elements enhance the properties of the gloves depending on the materials, and the form of the materials (e.g., knit, nonwoven, molded part, etc.), that are utilized in the construction of same. The invention also improves glove performance characteristics such as abrasion resistance, vibration isolation, thermal insulation, and protection against hand injuries. Nevertheless, it should be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the present invention. Accordingly, all such variations and modifications, including those discussed above, are intended to be included within the scope of the invention.