Patent Description:
Applicant has identified a number of deficiencies and problems associated with traditional gloves in that they are inadequate at providing both sufficient grip and abrasion resistance in wet or oily environments. Through applied effort, ingenuity, and innovation, many of these identified problems have been solved by developing solutions that are included in embodiments of the present disclosure, many examples of which are described in detail herein.

<CIT> discloses a method of forming texture comprising: providing a polymeric layer with first and second sides, wherein the polymeric layer is made from a polymeric material that gels on contact with a gelling agent, and wherein the first side is gelled, with gelling extending into the polymeric layer but not to the second side; contacting the second side of the polymeric layer with a foamy aqueous solution of surfactant (one or more), the aqueous foam being in the process of collapsing during the contacting, wherein the aqueous solution of surfactant is effective to gel the polymeric material; applying a aqueous medium to the second surface with sufficient force or agitation so as to remove a portion of the polymeric material; and curing the remaining polymeric material without, following the contacting step, further contacting the polymer layer with a gelling component.

<CIT> discloses microporous coatings based on polyurethane polyurea, and a process for the production of microporous coatings, in which a composition comprising an aqueous, anionically hydrophilised polyurethane dispersion and a cationic coagulant containing a cationically hydrophilised polyurethane polyurea dispersion is foamed and dried.

<CIT> discloses polymer compositions including blends of approximately <NUM> to approximately <NUM> percent by weight acrylonitrile butadiene copolymer and approximately <NUM> to approximately <NUM> percent by weight polychloroprene copolymer. Methods for manufacturing unsupported gloves and for supported gloves including a knitted liner with the polymer compositions, producing gloves having an ANSI abrasion resistance level <NUM>, are also disclosed.

The present invention is defined by the appended independent claims, to which reference should now be made. Specific embodiments are defined in the dependent claims. Example embodiments of the present disclosure are directed to a triple layer coated fabric and associated methods of manufacturing. In an example embodiment, a coated fabric is provided. The coated fabric includes a base coating layer. The base coating layer defines a smooth coating to resist liquid penetration to the fabric. The coated fabric also includes a middle foam coating layer that is deposited on at least a portion of the base coating layer. The foam of the middle foam coating layer is a microfoam. Throughout the description "middle foam coating" and "middle microfoam coating" will be used interchangeably, in any case the foam of the middle layer is a microfoam.

The middle foam layer defines a middle layer foam density and the middle foam layer is configured to absorb at least a portion of liquid. The coated fabric further includes an outer foam coating layer that is deposited on at least a portion of the middle foam coating later. The outer foam layer defines an outer layer foam density and the outer foam layer is configured with holes to allow liquid to penetrate to the middle foam layer, such that the outer foam layer increases the abrasion resistance of the coated fabric. The middle layer foam density is less than the outer layer foam density.

In some embodiments, the middle layer foam density is from <NUM>/L to <NUM>/L. In some embodiments, the middle layer foam density is from <NUM>/L to <NUM>/L. In some embodiments, the outer layer foam density is from <NUM>/L to <NUM>/L. In some embodiments, at least one of the base coating layer, the middle foam coating layer, or the outer foam coating layer includes a nitrile compound. In some embodiments, the nitrile compound of the at least one of the base coating layer, the middle foam coating layer, or the outer foam coating layer includes <NUM>% nitrile latex. In some embodiments, the coated fabric is used to form a glove. In some embodiments, each of the base coating layer, the middle foam coating layer, and the outer foam coating layer are applied at least to a palm area of the glove. In some embodiments, the glove is one of a mechanical glove or a chemical glove. In some embodiments, the base coating layer further includes a nylon lining.

In another example embodiment, a method of manufacturing a coated fabric is provided. The method includes applying a base coating layer formulation. The base coating layer defines a smooth coating to resist liquid penetration to the fabric. The method also includes applying a middle foam coating layer formulation on at least a portion of the base coating layer. The middle foam layer defines a middle layer foam density and the middle foam layer is configured to absorb at least a portion of liquid. The method further includes applying an outer foam coating layer formulation on at least a portion of the middle foam coating layer. The outer foam layer defines an outer layer foam density and the outer foam layer is configured with holes to allow liquid to penetrate to the middle foam layer, such that the outer foam layer increases the gripping ability and abrasion resistance of the coated fabric. The middle layer foam density is less than the outer layer foam density.

In some embodiments, the method also includes applying a first coagulant to the fabric prior to the step of applying the base coating layer. In some embodiments, the method also includes applying the first coagulant to the fabric prior to the step of applying the middle foam coating layer. In some embodiments, the method also includes applying a second coagulant to the fabric prior to the step of applying the outer foam coating layer. In some embodiments, the method also includes applying a third coagulant to the fabric prior to the step of applying the outer foam coating layer. In some embodiments, the method also includes heating the coated fabric on a hand model prior to the step of applying the base coating layer. In some embodiments, the method also includes heating the coated fabric after the step of applying the outer foam coating layer. In such an embodiment, at least one of the base coating layer, the middle foam coating layer, or the outer foam coating layer are vulcanized in response to the heat. In some embodiments, the applying the outer foam coating layer further comprises washing out the uncoagulated coating on the surface of the fabric after the application of the outer foam coating layer. In some embodiments, the first coagulant is a calcium nitrate compound, the second coagulant is a acetic acid compound, and the third coagulant is a calcium nitrate compound. In some embodiments, the coated fabric is a glove.

The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of some aspects of the invention. Accordingly, it will be appreciated that the above-described embodiments are merely examples and should not be construed to narrow the scope of the invention in any way. It will be appreciated that the scope of the invention encompasses many potential embodiments in addition to those here summarized, some of which will be further described below.

Having described certain example embodiments of the present disclosure in general terms above, reference will now be made to the accompanying drawings. The components illustrated in the figures may or may not be present in certain embodiments described herein. Some embodiments may include fewer (or more) components than those shown in the figures.

The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used herein, terms such as "front," "rear," "top," etc. are used for explanatory purposes in the examples provided below to describe the relative position of certain components or portions of components. Furthermore, as would be evident to one of ordinary skill in the art in light of the present disclosure, the terms "substantially" and "approximately" indicate that the referenced element or associated description is accurate to within applicable engineering tolerances.

The term "comprising" means including but not limited to, and should be interpreted in the manner it is typically used in the patent context. The phrases "in one embodiment," "according to one embodiment," and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment). If the specification describes something as "exemplary" or an "example," it should be understood that refers to a non-exclusive example.

Grip performance is one of the key features to a useful working glove. In environments with heavy exposure to liquids (e.g., water or oil), traditional gloves may not allow for the user's hands to remain dry, which affects the gripping ability of the glove. Additionally, traditional gloves with desirable gripping characteristics lack the abrasion resistance desired. Various embodiments of the present disclosure thus allow for, in some examples, abrasion resistant fabric that maintains high gripping performance by using a middle foam coating layer to absorb liquid, while an outer foam coating layer, in some examples, provides the abrasion resistance. Various embodiments herein discuss use with gloves, but the coating process and coated fabrics of example embodiments may be used in various applications.

As discussed herein, example embodiments may be described with reference to a coating process that allows, in some examples, for optimized grip and abrasion resistance when applied to gloves (e.g., mechanical or chemical gloves) or other wearables, such as other personal protection equipment (e.g., helmets and/or protective shoes). In this regard, fabric, composite or other structures as described herein as coated fabric may, in some examples, refer to a three coating layer structure. For the sake of clarity of description, example embodiments of the present application are herein described with reference to "three layers" refer to the number of coating layers (e.g., a base coating layer, a middle foam coating layer, and an outer foam layer) and may not include additional non-coating layers, such as a glove liner.

With reference to <FIG>, a coated glove <NUM> implementing and/or otherwise composed of an example three layer coating is illustrated. As shown, the glove <NUM> may be manufactured or otherwise formed with three layers of coating manufactured in line with an example embodiments discussed herein. For example, the glove <NUM> may have a fabric <NUM>, a base coating layer <NUM>, a middle foam coating layer <NUM>, and an outer foam layer <NUM>. As shown, the coatings <NUM>, <NUM>, <NUM> may be applied to at least a portion of the glove (e.g., all three coatings are applied to the palm where they may be most useful during operation). In a preferred embodiment, the base coating layer <NUM> may be defined at least in the palm region and the interior of each digit of the coated fabric (e.g., in an instance in which the fabric is a glove shape). For example, the base coating layer <NUM> may coating wrap partially around each digit at a digit proximal end and completely around the digit at a digit distal end. In various embodiments, the middle foam coating layer <NUM> may be deposited on at least a portion the base coating layer <NUM>, such that the middle foam coating layer <NUM> may be defined at least in the palm region and the interior of each digit of the coated fabric (e.g., in an instance in which the fabric is a glove shape). In various embodiments, the outer foam coating layer <NUM> may be deposited on at least a portion the middle foam coating layer <NUM>, such that the outer foam coating layer <NUM> may be defined at least in the palm region and the interior of each digit of the coated fabric (e.g., in an instance in which the fabric is a glove shape). In various embodiments, the three layer coated fabric and method of manufacturing the same may be used in either chemical gloves or mechanical gloves. In various embodiments, the material of the fabric <NUM> may depend on the type of glove. In various embodiments, the fabric <NUM> may be any material that is capable of being coated with the base coating later <NUM>. For example, the fabric <NUM> may be a glove liner. In various embodiments, the fabric <NUM> may be a material used for a mechanical or chemical glove. In various embodiments, the fabric <NUM> may be a material such as nylon, polyester, cotton, highperformance polyethylene (HPPE), aramid, stainless steel, glass fiber, rayon, polypropylene (PP), basalt, spandex, and/or the like.

In various embodiments, the three layer coated fabric and method of manufacturing the same may also be used in various applications, not limited to gloves. In various embodiments, the three layer coating discussed herein may be applied to other PPE. In an example embodiment, the three layer coating discussed herein may be applied to a helmet. For example, the base coating layer <NUM> may be applied to at least a portion of the helmet material, with the middle foam coating layer <NUM> applied at least partially onto the base coating layer <NUM>, and the outer foam coating layer <NUM> applied at least partially onto the middle foam coating layer <NUM>. In an example embodiment, the three layer coating discussed herein may be applied to a protective shoe. For example, the base coating layer <NUM> may be applied to at least a portion of the protective shoe material, with the middle foam coating layer <NUM> applied at least partially onto the base coating layer <NUM>, and the outer foam coating layer <NUM> applied at least partially onto the middle foam coating layer <NUM>. In various embodiments, the three layer coating may be applied to various other applications with similar results to those discussed herein.

<FIG> and <FIG> are cross-sectional views of a three layer coating in accordance with an example embodiment. Additionally, <FIG> is a micro view of the middle foam coating layer <NUM> of an example embodiment and <FIG> is a micro view of the outer foam coating layer <NUM> of an example embodiment. In various embodiments, the base coating layer <NUM> may be a smooth nitrile coating. In various embodiments, the base coating layer <NUM> may include a composite of at least one of a nitrile latex (e.g., X <NUM> and/or XVT-LA), pH modifier (e.g., KOH solution), curing package (e.g., Sulphur dispersion, ZDEC dispersion, and/or ZnO dispersion), pigment/filler (e.g., TiO2 and/or Black pigment), and/or thickening agent (e.g., CMC solution). In various embodiments, the base coating layer <NUM> may be approximately <NUM>% to <NUM>% nitrile latex. In various embodiments, the base coating layer <NUM> may be approximately <NUM>% to <NUM>% nitrile latex. For example, the base coating layer <NUM> may be approximately <NUM>% nitrile latex. In various embodiments, the base coating layer <NUM> may be relatively thin (e.g., less than the middle foam coating layer <NUM>). In an example embodiment, the base coating layer <NUM> may be approximately <NUM> millimeters to <NUM> millimeters thick. In various embodiments, the base coating layer <NUM> may be thinner and/or thicker in various examples based on the abrasion resistance and/or grip requirements of the coated fabric.

The middle foam coating layer <NUM> is a microfoam coating. In an example embodiment, the middle layer foam density may be approximately <NUM> kilograms (kg) per Liter (L) to approximately <NUM>/L. In some embodiment, the middle layer foam density may be from approximately <NUM>/L to approximately <NUM>/L. For example, the middle layer foam density may be approximately <NUM>/L. In various embodiments, the middle foam coating layer <NUM> may have approximately <NUM> bubbles per square millimeter. In various embodiments, the lower the foam density, the higher the amount of bubbles per square millimeter. In an example embodiment, the more bubbles in the coating may allow for increased grip, but may also slightly decrease the abrasion resistance. In various embodiments, the middle foam coating layer <NUM> may include a composite of at least one of a nitrile latex (e.g., Synthomer X <NUM>), pH modifier (e.g., KOH solution), surfactant (e.g., SDBS and/or Foam stabilizer/BASF A-<NUM>), curing package (e.g., Sulphur dispersion, ZDEC dispersion, and/or ZnO dispersion), pigment/filler (e.g., TiO2 and/or Black pigment), and/or thickening agent (e.g., CMC solution). In various embodiments, the base coating layer <NUM> may be approximately <NUM>% to <NUM>% nitrile latex. In various embodiments, the base coating layer <NUM> may be approximately <NUM>% to <NUM>% nitrile latex. For example, the base coating layer <NUM> may be approximately <NUM>% nitrile latex. In various embodiments, the thickness of the middle foam coating layer <NUM> may affect the gripping ability of the coated fabric (e.g., a higher thickness of the middle foam coating layer <NUM> and/or other layers may, in some examples, result in better performance, but with reduced abrasion resistance). In an example embodiment, the middle foam coating layer <NUM> may be approximately <NUM> millimeters to <NUM> millimeters. In various embodiments, the middle foam coating layer <NUM> may be thinner and/or thicker in various examples based on the abrasion resistance and/or grip requirements of the coated fabric.

In various embodiments, the outer foam coating layer <NUM> may be a wash foam coating. In various embodiments, the outer layer foam density may be higher than the middle layer foam density. In an example embodiment, the outer coating foam density may be approximately <NUM>/L. In various embodiments, the outer foam coating layer <NUM> may have less bubbles per square millimeter than the middle foam coating layer <NUM>. For example, in an instance in which the outer layer foam density is approximately <NUM>/L, the outer foam coating layer <NUM> may have approximately <NUM> bubbles per square millimeter. As such, the outer foam coating layer <NUM> may provide increased abrasion resistance to the coated fabric, in some examples. In various embodiments, the outer layer foam density may be based on the desired abrasion resistance of the coated fabric. For example, the outer layer foam density may be approximately <NUM>/L in an instance the coated fabric is desired to give good abrasion resistance for <NUM> cycles (e.g., the coated fabric may be capable of passing the EN <NUM> standard for <NUM> cycles). In various embodiments, the coating may be adjusted in order to provide more abrasion resistance (e.g., capable of performing at the EN <NUM> standard for <NUM> cycles or more). In various embodiments, the level of abrasion resistance may be based on the outer foam density (e.g., a lower foam density may be used for coated fabrics that require less abrasion resistance). In various embodiments, the thickness of the outer foam coating layer <NUM> may affect the abrasion resistance of the coated fabric (e.g., a higher thickness of the outer foam coating layer <NUM> may, in some examples, result in a higher abrasion resistance with reduced hand-feel (grip)). In an example embodiment, the outer foam coating layer <NUM> may be approximately <NUM> millimeters to <NUM> millimeters. In various embodiments, the outer foam coating layer <NUM> may be thinner and/or thicker in various examples based on the abrasion resistance and/or grip requirements of the coated fabric.

In various embodiments, the outer foam coating layer <NUM> may include a composite of at least one of a nitrile latex (e.g., X <NUM> and/or XVT-LA), pH modifier (e.g., KOH solution), surfactant (e.g., SDBS), curing package (e.g., Sulphur dispersion, ZDEC dispersion, and/or ZnO dispersion), pigment/filler (e.g., TiO2 and/or Black pigment), and/or thickening agent (e.g., CMC solution). In various embodiments, the base coating layer <NUM> may be approximately <NUM>% to <NUM>% nitrile latex. In various embodiments, the base coating layer <NUM> may be approximately <NUM>% to <NUM>% nitrile latex. For example, the base coating layer <NUM> may be approximately <NUM>% nitrile latex. In some embodiments, the outer foam coating layer <NUM> may have one or more bubbles <NUM>, such that the liquid can penetrate the outer foam coating layer <NUM> and be absorbed by the middle foaming coating layer <NUM>. For example, the wash foam process may allow for a thinning coating in which the holes have a higher diameter (e.g., as shown by the bubbles <NUM> in <FIG> compared to the bubbles <NUM>). In such an embodiment, the outer foam coating layer <NUM> may remain relatively dry during use (e.g., remain relatively dry in an instance in which a liquid is introduced to the glove while being worn by the user).

Referring now to <FIG>, a method of manufacturing a three layer coated fabric in accordance with various embodiments is provided. Various embodiments of the method described may be carried out in a different order than described herein, unless explicitly stated otherwise. Additional operations may also be completed during the method of manufacturing a three layer coated fabric, therefore the following steps are not exhaustive. In various embodiments, the three layer coated fabric may be a glove. In some steps discussed herein, temperatures referenced may only be exemplary and may not be prohibitive.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include heating the fabric. In some embodiments, the fabric may be heated on a model. For example, in an instance the fabric is a glove, the glove may be heated on a hand model. In various embodiments, the fabric may be heated to approximately <NUM> degrees Celsius. In various embodiments, different temperatures may be used in an instance in which pulse times are adjusted (e.g., a lower temperature may require a longer pulse time). For example, in some embodiments, the fabric may be heated to approximately <NUM> degrees Celsius to <NUM> degrees Celsius. Referring now to Block <NUM> of <FIG>, the method of manufacture may include applying a first coagulant to the fabric. In various embodiment, the first coagulant may be a compound of a positive ion (e.g., calcium nitrate) and a solvent (e.g., methanol). In an example embodiment, the first coagulant may be approximately <NUM>% to approximately <NUM>% calcium nitrate. In some embodiments, the first coagulant may be approximately <NUM>% to approximately <NUM>% calcium nitrate. For example, the first coagulant may be approximately <NUM>% calcium nitrate. In such an embodiment, the first coagulant may be approximately <NUM>% methanol.

In an example embodiment, the first coagulant may be applied to the fabric by dipping the fabric into the first coagulant. In an example embodiment, the first coagulant may be applied to the fabric for approximately <NUM> second to <NUM> seconds. In an example embodiment, the fabric may be dipped into the first coagulant for approximately <NUM> seconds. For example, the fabric may be dipped into the first coagulant at a speed of approximately <NUM> centimeters per second (cm/s) with a stay time of <NUM> seconds, a leaching time of <NUM> seconds, and an evening time of <NUM> seconds (e.g., two cycles of dipping may be used to even the first coagulant). In some embodiments, the first coagulant may only be applied to a portion of the fabric (e.g., only the portion of the fabric in which the base coating layer is to be applied). For example, in an instance in which the fabric is a glove, only the palm of the glove may be dipped into the first coagulant.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include applying a base coating layer formulation to the fabric. As discussed above, the base coating layer formulation may be a smooth nitrile (e.g., a nitrile latex compound). In various embodiment, the base coating layer formulation may be applied by dipping the fabric into base coating layer formulation. In various embodiments, the applying of the base coating layer formulation may take approximately <NUM> to approximately <NUM> minutes. For example, the fabric may be dipped into the base coating layer formulation at a speed of approximately <NUM> centimeters per second (cm/s) with a stay time of approximately <NUM> second and an evening time of approximately <NUM> seconds (e.g., two cycles of dipping may be used to even the base coating layer). In some embodiments, the fabric may be shaken in the base layer coating formulation to remove excess nitrile rubber (e.g., to reduce the thickness of the coating). For example, the fabric may be shaken approximately <NUM> times to remove excess nitrile rubber. In various embodiments, less or no shaking may occur in an instance in which there are no thickness limitations. In various embodiments, the fabric may be rotated during the dipping process for uniform coating level. In some embodiments, the base coating layer may be prevulcanized after the application of the base coating layer formulation is completed. For example, the fabric may be heated at approximately <NUM> degrees Celsius for approximately <NUM> to <NUM> minutes before the steps of Block <NUM>. In a preferred embodiment, the base coating layer <NUM> may be defined at least in the palm region and the interior of each digit of the coated fabric (e.g., in an instance in which the fabric is a glove shape). In some embodiment, the base coating layer may coating wrap partially around each digit at a digit proximal end and completely around the digit at a digit distal end.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include applying the first coagulant to the fabric again. In various embodiments, the first coagulant may be the same or similar coagulant discussed in reference to Block <NUM>. In an example embodiment, the first coagulant may be applied to the fabric by dipping the fabric into the first coagulant. In an example embodiment, the first coagulant may be applied to the fabric for approximately <NUM> second to <NUM> seconds. In an example embodiment, the fabric may be dipped into the first coagulant for approximately <NUM> seconds. For example, the fabric may be dipped into the first coagulant at a speed of approximately <NUM> centimeters per second (cm/s) with a stay time of <NUM> seconds, a leaching time of <NUM> seconds, and an evening time of <NUM> seconds (e.g., two cycles of dipping may be used to even the first coagulant). In some embodiments, the first coagulant may only be applied to a portion of the fabric (e.g., only the portion of the fabric in which the middle foam coating layer is to be applied). For example, in an instance in which the fabric is a glove, only the palm of the glove may be dipped into the first coagulant.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include applying a middle foam coating layer formulation on at least a portion of the middle foam coating layer. As discussed above, the middle foam coating layer formulation may be a microfoam nitrile (e.g., a nitrile latex compound). In various embodiment, the middle foam coating layer formulation may be applied by dipping the fabric into middle foam coating layer formulation. In various embodiments, the applying of the middle foam coating layer formulation may take approximately <NUM> to <NUM> second (e.g., <NUM> seconds). For example, the fabric may be dipped into the middle foam coating layer formulation at a speed of approximately <NUM> centimeters per second (cm/s) with a stay time of approximately <NUM> second, a shaking time of approximately <NUM> seconds, and an evening time of approximately <NUM> seconds (e.g., two cycles of dipping may be used to even the middle foam coating layer). In some embodiments, the fabric may be shaken in the middle foam coating layer formulation to remove excess nitrile rubber (e.g., to reduce the thickness of the coating). In various embodiments, the shaking of the fabric may allow the middle foam coating layer to be thinner and spongy than an instance in which the fabric is not shaken during the application. In various embodiments, the fabric may be rotated during the dipping process for uniform coating level. In various embodiments, the resulting middle foam coating layer may have a middle layer foam density of approximately <NUM> kilograms (kg) per Liter (L) to approximately <NUM>/L. In some embodiment, the middle layer foam density may be from approximately <NUM>/L to approximately <NUM>/L. For example, the middle layer foam density may be approximately <NUM>/L. In a preferred embodiment, the middle foam coating layer <NUM> may deposited on at least a portion of the base coating layer. For example, the middle foam coating layer <NUM> may be defined at least in the palm region and the interior of each digit of the coated fabric (e.g., in an instance in which the fabric is a glove shape). In some embodiment, the middle foam coating layer may coating wrap partially around each digit at a digit proximal end and completely around the digit at a digit distal end.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include applying a second coagulant to the fabric. In various embodiment, the second coagulant may be a compound of a positive ion (e.g., acetic acid) and a solvent (e.g., methanol). In an example embodiment, the second coagulant may be approximately <NUM>% to approximately <NUM>% acetic acid. In some embodiments, the second coagulant may be approximately <NUM>% to approximately <NUM>% acetic acid. For example, the second coagulant may be approximately <NUM>% acetic acid. In such an embodiment, the second coagulant may be approximately <NUM>% methanol.

In an example embodiment, the second coagulant may be applied to the fabric by dipping the fabric into the second coagulant. In an example embodiment, the second coagulant may be applied to the fabric for approximately <NUM> second to <NUM> seconds. In an example embodiment, the fabric may be dipped into the second coagulant for approximately <NUM> seconds. For example, the fabric may be dipped into the second coagulant at a speed of approximately <NUM> centimeters per second (cm/s) with a stay time of approximately <NUM> seconds until the middle foam coating layer <NUM> may be approximately fully coagulated. In some embodiments, the second coagulant may only be applied to a portion of the fabric (e.g., only the portion of the fabric in which the outer foam coating layer <NUM> is to be applied). For example, in an instance in which the coated fabric is a glove, only the palm of the glove may be dipped into the second coagulant. In some embodiments, the fabric may be rotated while being dipped into the second coagulant. In various embodiments herein, other methods of application may be used other than dipping (e.g., spraying) for one or more of the applications of the coating formulations and/or coagulants discussed herein.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include applying a third coagulant to the fabric. In various embodiment, the third coagulant may be a compound of a positive ion (e.g., calcium nitrate) and a solvent (e.g., methanol). In an example embodiment, the third coagulant may be approximately <NUM>% to approximately <NUM>% calcium nitrate. In some embodiments, the third coagulant may be approximately <NUM>% to approximately <NUM>% calcium nitrate. For example, the third coagulant may be approximately <NUM>% calcium nitrate. In such an embodiment, the third coagulant may be approximately <NUM>% methanol.

In an example embodiment, the third coagulant may be applied to the fabric by dipping the fabric into the third coagulant. In an example embodiment, the third coagulant may be applied to the fabric for approximately <NUM> second to <NUM> seconds. In an example embodiment, the fabric may be dipped into the third coagulant for approximately <NUM> seconds. For example, the fabric may be dipped into the third coagulant at a speed of approximately <NUM> centimeters per second (cm/s) with a stay time of approximately <NUM> seconds, a leaching time of approximately <NUM> seconds, and an evening time of approximately <NUM> seconds. In some embodiments, the third coagulant may only be applied to a portion of the fabric (e.g., only the portion of the fabric in which the outer foam coating layer <NUM> is to be applied). For example, in an instance in which the fabric is a glove, only the palm of the glove may be dipped into the third coagulant. In various embodiments, the fabric may be rotated while being dipped into the third coagulant.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include applying an outer foam coating layer formulation on at least a portion of the middle foam coating layer. As discussed above, the outer foam coating layer formulation may be a wash foam nitrile (e.g., a nitrile latex compound). In various embodiment, the outer foam coating layer formulation may be applied by dipping the fabric into outer foam coating layer formulation. In some embodiments, the outer foam coating layer formulation may be applied to the fabric by using a dive dipping process. In various embodiment, the fabric may be dipped into the outer foam coating layer formulation for a few seconds (e.g., approximately <NUM> seconds) until the outer foam coating layer <NUM> is partly coagulated and then removed. For example, the fabric may be dipped into the outer foam coating layer formulation for two seconds, shook twice and then removed. As such, the process, in some examples, may take substantially less time than the application of the base coating layer or the middle foam coating layer. In various embodiments, the resulting outer foam coating layer <NUM> may have an outer layer foam density of approximately <NUM>/L to approximately <NUM>/L. In various embodiments, the resulting outer foam coating layer <NUM> may have an outer layer foam density higher than the middle layer foam density (e.g., the outer layer foam density may be approximately <NUM>/L). In some embodiments, the outer foam coating layer formulation may only be applied to a portion of the fabric. For example, in an instance in which the fabric is a glove, only the palm of the glove may be dipped into the outer foam coating layer formulation. In various embodiments, the fabric may be rotated while being dipped into the outer foam coating layer formulation.

In some embodiments, after the fabric has been dipped into the outer foam coating layer formulation, the fabric may be rinsed (e.g., to remove the uncoagulated coating from the surface of the fabric). For example, the fabric (e.g., a glove) may be rinsed using a soft wash (e.g., low pressure and low flow) using quadrant elevation wash for approximately <NUM> seconds or longer. In a preferred embodiment, the outer foam coating layer <NUM> may deposited on at least a portion of the middle foam coating layer. For example, the outer foam coating layer <NUM> may be defined at least in the palm region and the interior of each digit of the coated fabric (e.g., in an instance in which the fabric is a glove shape). In some embodiment, the outer foam coating layer may coating wrap partially around each digit at a digit proximal end and completely around the digit at a digit distal end.

Referring now to Block <NUM> of <FIG>, the method of manufacture may include heating the fabric in an oven. In various embodiments, one or more of the coatings may be vulcanized during the heating process. For example, the fabric (e.g., a glove) may be placed in an oven at a set temperature for a set amount of vulcanize the coating. The temperature of the oven and the amount of time in the oven may be based on the coating formulations. For example, the coated fabric may be placed in an oven at <NUM> degrees Celsius for <NUM> minutes. In an example embodiment, the vulcanization process may use a plurality of ovens at different temperatures to vulcanize the coating. For example, the coated fabric may be placed for <NUM> minutes each into a first oven at approximately room temperature, a second oven at approximately <NUM> degrees Celsius, a third oven at approximately <NUM> degrees Celsius, and a fourth oven at approximately <NUM> degrees Celsius. Various embodiments may use a different number of ovens (e.g., one oven) to vulcanize the coating. In some embodiments, there may also be a pre-vulcanization before the heating in the oven (e.g., the coated fabric may be heated at <NUM> degree Celsius). Additionally, there may be one or more washing of the coated fabric before the vulcanization (e.g., an online wash may be carried out for approximately <NUM> minutes at approximately <NUM> degrees before the vulcanization). In various embodiments, the vulcanization may cause a chemical reaction in one or more layers of the coated fabric (e.g., a chemical reaction in which the sulfar and/or zinc oxide in the one or more coating layers may cross-link with one or more latex material in the coating layers may occur in one or more coating layers).

Claim 1:
A coated fabric comprising:
a base coating layer, the base coating layer defining a smooth coating to resist liquid penetration to the fabric;
a middle microfoam coating layer that is deposited on at least a portion of the base coating layer, the middle microfoam coating layer defining a middle layer foam density and the middle microfoam coating layer being configured to absorb at least a portion of liquid; and
an outer foam coating layer that is deposited on at least a portion of the middle microfoam coating layer, the outer foam layer defining an outer layer foam density and the outer foam layer being configured with holes to allow liquid to penetrate to the middle microfoam coating layer, such that the outer foam layer increases the abrasion resistance of the coated fabric,
wherein the middle layer foam density is less than the outer layer foam density.