U.S. patent application number 11/229021 was filed with the patent office on 2007-04-19 for polymer-coated protective garment.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Jason A. Baker, Jeffrey E. Fish, Martin S. Shamis, Oomman P. Thomas, Kaiyuan Yang.
Application Number | 20070083980 11/229021 |
Document ID | / |
Family ID | 37507760 |
Filed Date | 2007-04-19 |
United States Patent
Application |
20070083980 |
Kind Code |
A1 |
Yang; Kaiyuan ; et
al. |
April 19, 2007 |
Polymer-coated protective garment
Abstract
A polymer-coated protective garment is disclosed. The garment
may be configured to fit around the arm, leg, foot or hand of a
wearer. For example, in one embodiment, the protective garment
comprises a glove. The glove includes a hollow member defining an
opening for receiving a hand. The hollow member is made from an
elastic laminate. The elastic laminate may comprise at least one
nonwoven web. The hollow member further includes an elastomeric
coating that covers at least a portion of the hollow member. In one
embodiment, for instance, the elastomeric coating covers a palm
portion and finger portions of the glove.
Inventors: |
Yang; Kaiyuan; (Cumming,
GA) ; Fish; Jeffrey E.; (Dacula, GA) ; Shamis;
Martin S.; (Alpharetta, GA) ; Baker; Jason A.;
(Alpharetta, GA) ; Thomas; Oomman P.; (Alpharetta,
GA) |
Correspondence
Address: |
DORITY & MANNING, P.A.
POST OFFICE BOX 1449
GREENVILLE
SC
29602-1449
US
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
|
Family ID: |
37507760 |
Appl. No.: |
11/229021 |
Filed: |
September 16, 2005 |
Current U.S.
Class: |
2/167 |
Current CPC
Class: |
A41D 31/185 20190201;
A41D 19/0006 20130101; A41D 31/145 20190201; A41D 19/0068 20130101;
A41D 31/125 20190201 |
Class at
Publication: |
002/167 |
International
Class: |
A41D 19/00 20060101
A41D019/00 |
Claims
1. A glove comprising: a hollow member defining an opening for
receiving a hand therein, the hollow member having an interior
surface configured to be placed adjacent to a hand when the glove
is donned and an opposite exterior surface, the hollow member
comprising an elastic laminate, the elastic laminate including at
least one nonwoven layer; and an elastomeric coating covering at
least a portion of the exterior surface of the hollow member, the
elastomeric coating comprising a natural or synthetic polymer, the
elastomeric coating forming a continuous or discontinuous film on
the exterior surface.
2. A glove as defined in claim 1, wherein the elastic laminate
comprises a spunbond laminate, a neck-bonded laminate, or mixtures
thereof.
3. A glove as defined in claim 1, wherein the hollow member
comprises a first panel attached to a second panel along a
seam.
4. A glove as defined in claim 3, wherein the seam has a thickness
of less than about 1 mm.
5. A glove as defined in claim 3, wherein the first panel and the
second panel are ultrasonically bonded together to form the
seam.
6. A glove as defined in claim 1, wherein the elastic laminate
comprises at least three layers, the layers including two outer
nonwoven layers and a middle layer comprising elastic filaments, an
elastic film, or an elastic nonwoven.
7. A glove as defined in claim 6, wherein the outer layers are
attached to the middle layer while the middle layer is in a
stretched condition such that the outer layers gather when the
middle layer is in a relaxed state.
8. A glove as defined in claim 7, wherein the outer layers comprise
spunbond webs.
9. A glove as defined in claim 1, wherein the elastic laminate has
a basis weight of from about 20 gsm to about 200 gsm.
10. A glove as defined in claim 3, wherein the first panel covers a
palm portion of the glove and comprises a neck-bonded laminate, the
second panel comprising a breathable stretch-bonded laminate.
11. A glove as defined in claim 1, further comprising a precoat
positioned in between the elastic laminate and the elastomeric
coating.
12. A glove as defined in claim 11, wherein the precoat comprises a
coagulant composition for the natural or synthetic polymer.
13. A glove as defined in claim 11, wherein the precoat comprises a
hydrophobic composition that resides on the exterior surface of the
hollow member without forming a film.
14. A glove as defined in claim 1, wherein the glove includes
finger portions, a palm portion, and a back side, the elastomeric
coating only covering the palm portion and the finger portions of
the glove.
15. A glove as defined in claim 3, wherein the glove includes
finger portions, a palm portion, and a back side, the elastomeric
coating only covering a portion of the exterior surface of the
hollow member, the elastomeric coating being present on the palm
portion and covering the seam formed between the first panel and
the second panel.
16. A glove as defined in claim 1, wherein the elastomeric coating
comprises at least two layers of the natural or synthetic
polymer.
17. A glove as defined in claim 6, wherein the middle layer
comprises a plurality of parallel elastic filaments.
18. A glove as defined in claim 6, wherein the elastic coating is
present on the exterior surface of the hollow member so as to not
substantially penetrate into the outer nonwoven layer forming the
interior surface of the hollow member.
19. A glove as defined in claim 1, wherein the natural or synthetic
polymer comprises natural rubber latex, a nitrile polymer,
polyvinyl chloride, a polyurethane, a silicone polymer, an acrylic
polymer or a block copolymer.
20. A glove as defined in claim 1, wherein the natural or synthetic
polymer of the elastomeric coating comprises a styrenic block
copolymer.
21. A glove as defined in claim 1, wherein the elastomeric coating
is present on the exterior surface of the hollow member so as to
not substantially penetrate all the way through to the interior
surface of the hollow member.
22. A glove as defined in claim 1, wherein the elastomeric coating
forms a continuous film on the hollow member.
23. A glove as defined in claim 1, wherein the elastomeric coating
forms a discontinuous film on the exterior surface of the hollow
member.
24. A process for producing a glove product comprising: forming a
hollow member defining an opening for receiving a hand therein, the
hollow member having an interior surface configured to be placed
adjacent to a hand when the glove product is donned and an opposite
exterior surface, the hollow member comprising an elastic laminate,
the elastic laminate including at least one nonwoven layer; and
dipping at least a portion of the hollow member into an elastomeric
coating composition containing a natural or synthetic polymer, the
elastomeric coating composition forming an elastomeric coating on
the exterior surface of the hollow member.
25. A process as defined in claim 24, wherein the hollow member is
placed on a former prior to being dipped into the elastomeric
coating composition.
26. A process as defined in claim 24, wherein the exterior surface
of the hollow member is only partially coated by the elastomeric
coating.
27. A process as defined in claim 24, further comprising the step
of first forming a precoat on the exterior surface of the hollow
member prior to dipping the hollow member into the elastomeric
coating composition.
28. A process as defined in claim 27, wherein the precoat comprises
a coagulant composition for the natural or synthetic polymer.
29. A process as defined in claim 24, wherein the natural or
synthetic polymer comprises natural rubber latex, a nitrile
polymer, polyvinyl chloride, a silicone polymer, an acrylic
polymer, a polyurethane, or a block copolymer.
30. A process as defined in claim 24, wherein the elastic laminate
comprises a spunbond laminate, a neck-bonded laminate, or mixtures
thereof.
31. A polymer-coated protective garment comprising: a hollow member
defining an opening, the hollow member having a shape configured to
receive a hand, a foot, an arm, or a leg of a wearer, the hollow
member having an interior surface configured to be placed adjacent
to a wearer's skin and an opposite exterior surface, the hollow
member comprising an elastic laminate, the elastic laminate
including at least one nonwoven layer; and an elastomeric coating
covering at least a portion of the exterior surface of the hollow
member, the elastomeric coating comprising a natural or synthetic
polymer, the polymer comprising a natural rubber latex, a nitrile
polymer, a polyvinyl chloride, a polyurethane, a silicone polymer,
an acrylic polymer, or a block copolymer.
32. A polymer-coated protective garment as defined in claim 31,
wherein the elastic laminate comprises a stretch-bonded laminate, a
neck-bonded laminate, or mixtures thereof.
Description
BACKGROUND OF THE INVENTION
[0001] Many types and styles of protective gloves are known in the
art. Depending on the type of environment, nature of work, or
desired properties, these gloves are made from a variety of
materials, including woven cloth fabrics, leather, natural latex or
synthetic polymer elastomeric materials, or combinations of such
materials.
[0002] Gloves made of woven fabrics generally allow the user's skin
to breathe through the fabric such that perspiration from the hand
may be wicked away by the fabric. Knit gloves are often desirable
in that they allow for a relatively comfortable fit on the hand of
the user. Additionally, knit gloves demonstrate at least some
degree of inherent flexibility in order to accommodate movement of
the user's hands. Knitting processes used to create woven knit
gloves, however, are typically slow and expensive.
[0003] Gloves that require greater protection against fluids,
chemicals, or microscopic pathogens typically incorporate a barrier
layer that is impervious to the undesirable substances. For
example, surgical, examination, or work gloves typically are made
using natural or synthetic rubber latex or other elastic polymer
membranes.
[0004] In still other embodiments, gloves have been made in the
past that include a combination of textile materials with
elastomeric or film materials. For example, gloves have been made
in the past that include an elastomeric shell that includes an
internal lining composed of fibrous material, such as cotton flock.
For instance, the flock may be composed of finely divided, ground,
fibrous particles that are applied as a lining by spraying the
flock particles onto an adhesive covered shell. The cotton flock
lining is intended to provide a smooth, comfortable feel that
cushions the hands and absorbs perspiration. The cotton flock
lining may also insulate against hot and cold temperatures and may
facilitate donning of the glove.
[0005] The cotton flock lining, however, may have various
disadvantages and drawbacks. For instance, the flock particles and
fibers may become detached from the internal lining and can migrate
out of the glove. The cotton flock lining, in some applications,
may also be difficult to attach to the inside surface of an
elastomeric article. Further, in order to attach the cotton
flocking to the inside surface of the article, a glue or adhesive
is used that adds complexity to the process for making the
glove.
[0006] In still other embodiments, multi-layered gloves have been
produced that include a woven interior layer coated with a
rubber-like material. Such gloves, however, generally have little
elasticity and are typically reserved for heavy duty uses.
[0007] In view of the above, a need currently exists for an
improved composite garment, such as a glove, that includes a
cloth-like glove body that is at least partially coated with an
elastomeric material. Specifically, a need exists for a composite
glove that is relatively inexpensive to manufacture, that possesses
both the benefits of a cloth-like lining and an elastomeric coating
and that still has relatively good tactile properties such as
elasticity and feel.
Definitions
[0008] As used herein, the term "nonwoven fabric or web" means a
web having a structure of individual fibers or threads which are
interlaid, but not in an identifiable manner as in a knitted
fabric. Nonwoven fabrics or webs have been formed from various
processes such as, for example, meltblowing processes, spunbonding
processes, and bonded carded web processes. The basis weight of
nonwoven fabrics is usually expressed in ounces of material per
square yard (osy) or grams per square meter (gsm) and the fiber
diameters are usually expressed in microns. (Note that to convert
from osy to gsm, multiply osy by 33.91).
[0009] As used herein, the term "spunbonded fibers" refers to small
diameter fibers that are formed by extruding molten thermoplastic
material as filaments from a plurality of fine, usually circular
capillaries of a spinneret with the diameter of the extruded
filaments then being rapidly reduced to fibers as by, for example,
in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No.
3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki
et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat.
No. 3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo et
al., the entire contents of which are incorporated herein by
reference in their entirety for all purposes. Spunbond fibers can
be continuous and have diameters generally greater than about 7
microns, more particularly, between about 10 and about 20
microns.
[0010] As used herein, the term "meltblown fibers" means fibers
formed by extruding a molten thermoplastic material through a
plurality of fine, usually circular, die capillaries as molten
threads or filaments into converging high velocity, usually hot,
gas (e.g. air) streams which attenuate the filaments of molten
thermoplastic material to reduce their diameter, which may be to
microfiber diameter. Thereafter, the meltblown fibers are carried
by the high velocity gas stream and are deposited on a collecting
surface to form a web of randomly disbursed meltblown fibers. Such
a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to
Butin et al., the entire contents of which are incorporated herein
by reference in their entirety for all purposes. Meltblown fibers
are microfibers that may be continuous or discontinuous with
diameters generally less than 10 microns.
[0011] As used herein, the term "stretch-bonded laminate" refers to
a composite material having at least two layers in which one layer
is a gatherable layer and the other layer is an elastic layer. The
layers are joined together when the elastic layer is extended from
its original condition so that upon relaxing the layers, the
gatherable layer is gathered. Such a multilayer composite elastic
material may be stretched to the extent that the material gathered
between the bond locations allows the elastic material to elongate.
One type of stretch-bonded laminate is disclosed, for example, by
U.S. Pat. No. 4,720,415 to Vander Wielen et al., the entire
contents of which are incorporated herein by reference in its
entirety for all purposes. Other composite elastic materials are
disclosed in U.S. Pat. No. 4,789,699 to Kieffer et al., U.S. Pat.
No. 4,781,966 to Taylor and U.S. Pat. Nos. 4,657,802 and 4,652,487
to Morman and U.S. Pat. No. 4,655,760 to Morman et al., the
contents of which are incorporated herein by reference in their
entirety.
[0012] As used herein, the terms "necking" or "neck stretching"
interchangeably refer to a method of elongating a nonwoven fabric,
generally in the machine direction, to reduce its width
(cross-machine direction) in a controlled manner to a desired
amount. The controlled stretching may take place under cool, room
temperature or greater temperatures and is limited to an increase
in overall dimension in the direction being stretched up to the
elongation required to break the fabric, which in most cases is
about 1.2 to 1.6 times. When relaxed, the web retracts toward, but
does not return to, its original dimensions. Such a process is
disclosed, for example, in U.S. Pat. No. 4,443,513 to Meitner and
Notheis, U.S. Pat. Nos. 4,965,122, 4,981,747 and 5,114,781 to
Morman and U.S. Pat. No. 5,244,482 to Hassenboehier Jr. et al., the
entire contents of which are incorporated herein by reference in
their entirety for all purposes.
[0013] As used herein, the term "reversibly necked material" refers
to a material that possesses stretch and recovery characteristics
formed by necking a material, then heating the necked material, and
cooling the material. Such a process is disclosed in U.S. Pat. No.
4,965,122 to Morman, commonly assigned to the assignee of the
present invention, the entire contents of which are incorporated by
reference herein in its entirety for all purposes.
[0014] As used herein, the term "neck bonded laminate" refers to a
composite material having at least two layers in which one layer is
a necked, non-elastic layer and the other layer is an elastic
layer. The layers are joined together when the non-elastic layer is
in an extended (necked) condition. Examples of neck-bonded
laminates are such as those described in U.S. Pat. Nos. 5,226,992,
4,981,747, 4,965,122 and 5,336,545 to Morman, the entire contents
of which are incorporated herein by reference in their entirety for
all purposes.
[0015] As used herein, the term "coform" means a meltblown material
to which at least one other material is added during the meltblown
material formation. The meltblown material may be made of various
polymers, including elastomeric polymers. Various additional
materials may be added to the meltblown fibers during formation,
including, for example, pulp, superabsorbent particles, cellulose
or staple fibers. Coform processes are illustrated in commonly
assigned U.S. Pat. No. 4,818,464 to Lau and U.S. Pat. No. 4,100,324
to Anderson et al., the entire contents of which are incorporated
herein by reference in their entirety for all purposes.
[0016] As used herein, the term "ultrasonic bonding" refers to a
process in which materials (fibers, webs, films, etc.) are joined
by passing the materials between a sonic horn and anvil surface,
such as a roll. An example of such a process is illustrated in U.S.
Pat. No. 4,374,888 to Bornslaeger, the entire contents of which are
incorporated herein by reference in their entirety for all
purposes.
[0017] As used herein, the term "elastic" refers to any material,
including a film, fiber, nonwoven web, or combination thereof,
which upon application of a biasing force, is stretchable to a
stretched, biased length which is at least about 150 percent, or
one and a half times, its relaxed, unstretched length, and which
will recover at least 15 percent of its elongation upon release of
the stretching, biasing force.
[0018] As used herein, the terms "elastomer" or "elastomeric" refer
to polymeric materials that have properties of stretchability and
recovery.
[0019] As used herein, the term "stretch" refers to the ability of
a material to extend upon application of a biasing force. Percent
stretch is the difference between the initial dimension of a
material and that same dimension after the material has been
stretched or extended following the application of a biasing force.
Percent stretch may be expressed as [(stretched length +initial
sample length)/initial sample length].times.100. For example, if a
material having an initial length of one (1) inch is stretched 0.50
inch, that is, to an extended length of 1.50 inches, the material
can be said to have a stretch of 50 percent.
[0020] As used herein, the term "recover" or "recovery" refers to a
contraction of a stretched material upon termination of a biasing
force following stretching of the material by application of the
biasing force. For example, if a material having a relaxed,
unbiased length of one (1) inch is elongated 50 percent by
stretching to a length of one and one half (1.5) inches the
material would have a stretched length that is 150 percent of its
relaxed length. If this exemplary stretched material contracted,
that is recovered to a length of one and one tenth (1.1) inches
after release of the biasing and stretching force, the material
would have recovered 80 percent (0.4 inch) of its elongation.
[0021] As used herein, the term "polymer" generally includes but is
not limited to, homopolymers, copolymers, such as for example,
block, graft, random and alternating copolymers, terpolymers, etc.
and blends and modifications thereof. Furthermore, unless otherwise
specifically limited, the term "polymer" shall include all possible
geometrical configurations of the molecule. These configurations
include, but are not limited to isotactic, syndiotactic and random
symmetries.
SUMMARY OF THE INVENTION
[0022] In general, the present disclosure is directed to
polymer-coated garments that are not only relatively inexpensive to
produce but also can have elastic properties. The garment can have
a shape to fit over an extremity such as a hand, an arm, a foot, or
a leg. In one particular embodiment, for instance, the
polymer-coated garment comprises a glove.
[0023] For instance, in one particular embodiment, the glove
comprises a hollow member defining an opening for receiving a hand
therein. The hollow member has an interior surface configured to be
placed adjacent to a hand when the glove is donned and an opposite
exterior surface. In accordance with the present disclosure, the
hollow member comprises an elastic laminate including at least one
nonwoven layer.
[0024] A polymeric coating, such as an elastomeric coating covers
at least a portion of the exterior surface of the hollow member.
The elastomeric coating comprises a natural or synthetic polymer.
The elastomeric coating may form a film on the exterior surface of
the hollow member. The film may be continuous or may be
discontinuous. For instance, the elastomeric coating may form a
pattern on the exterior surface of the hollow member.
[0025] The elastomeric coating may penetrate through the hollow
member so as to not only reside on the exterior surface of the
hollow member but may also be present on the interior surface of
the hollow member. Alternatively, the elastomeric coating may be
present on the exterior surface so as to not substantially
penetrate all the way through to the interior surface of the hollow
member.
[0026] As described above, the hollow member is generally formed
from an elastic laminate. The elastic laminate may comprise, for
instance, a spunbond laminate, a neck-bonded laminate, and mixtures
thereof. In one embodiment, for instance, the elastic laminate may
have at least three layers. The three layers may include two outer
nonwoven layers and a middle layer comprising elastic filaments, an
elastic film, or an elastic nonwoven. If desired, the outer layers
may be attached to the middle layer while the middle layer is in a
stretched state such that the outer layers gather when the middle
layer is in a relaxed state. The outer layers may comprise the same
or different materials. For example, the outer layers may comprise
spunbond webs, meltblown webs, coform webs and laminates thereof.
In one embodiment, the outer layer forming the exterior surface of
the hollow member may comprise a meltblown web, while the outer
layer of the elastic laminate forming the interior surface of the
hollow member may comprise a spunbond web.
[0027] In one embodiment, the hollow member may comprise a first
panel attached to a second panel along a seam. The seam, for
instance, may have a thickness of less than 1 mm and may have been
formed by ultrasonically bonding the first panel to the second
panel. Each panel may comprise a similar elastic laminate or
different elastic laminates. For example, in one embodiment, one
panel may comprise a neck-bonded laminate, while the second panel
may comprise a spunbond laminate. For instance, in this embodiment,
the neck-bonded laminate having one dimensional stretch
characteristics may comprise a palm portion of the glove while a
stretch-bonded laminate having two dimensional stretch
characteristics may form a back portion of the glove.
[0028] The elastic laminate may have any suitable basis weight
depending upon the glove being produced and its intended uses. The
basis weight of the elastic laminate may vary, for instance, from
about 20 gsm to about 400 gsm or greater.
[0029] The elastomeric coating may be made from any suitable
film-forming polymer. For instance, the polymer used to form the
elastomeric coating may comprise a natural rubber latex, a nitrile
polymer, a polyurethane polymer, polyvinyl chloride, a silicone
polymer, an acrylic polymer, a block copolymer, and the like. When
using a block copolymer, the block copolymer may comprise a
styrenic block copolymer such as a styrene-ethylene
butylene-styrene block copolymer.
[0030] In one embodiment, a precoat may be present in the glove
positioned between the elastomeric coating and the hollow member.
The precoat may be added in order to facilitate bonding between the
elastomeric coating and the hollow member, may be used to
polymerize the elastomeric coating material, or may be used to
control penetration of the elastomeric coating into the hollow
member. In one embodiment, for instance, the precoat may comprise a
coagulant composition for the natural or synthetic polymer.
Alternatively, the precoat may comprise a hydrophobic composition
that does not form a film on the exterior surface of the hollow
member, but does serve to prevent penetration of the elastomeric
material into the hollow member.
[0031] The elastomeric coating may cover the entire exterior
surface of the hollow member or may only cover a portion of the
exterior surface. For example, in one embodiment, the hollow member
may include a palm portion, finger portions, and a back side
portion. The elastomeric coating may be applied so as to only cover
the palm portion and the finger portions. When the hollow member is
made from first and second panels that are joined along a seam, in
one embodiment, the elastomeric coating may at least cover the seam
in order to reinforce the attachment between the panels.
[0032] In various embodiments, the finger portions of the glove may
be configured to enclose the fingers of a wearer or may have open
ends for allowing the fingers of a wearer to remain exposed.
Further, the glove may include a cuff portion that extends only a
relatively small amount past the hand of a wearer or may extend to
the elbow of the wearer.
[0033] In forming the glove product, any suitable process may be
used in order to coat the hollow member with the elastomeric
material. In one embodiment, for instance, the hollow member may be
dipped into an elastomeric coating composition that contains the
natural or synthetic polymer. The natural or synthetic polymer may
be present in an aqueous dispersion or in a solvent dispersion.
After being coated on the hollow member, the glove may be subjected
to heat in order to cause the elastomeric material to dry, cure
and/or crosslink.
[0034] When contacted with the elastomeric coating composition, the
hollow member may be dipped into the composition so that the
elastomeric coating completely covers the hollow member or only
covers the hollow member in certain areas. For example, in one
embodiment, the elastomeric coating may be applied to the hollow
member so as to only cover the palm portion and the finger portions
of the glove.
[0035] In one embodiment, the hollow member may be placed on a
former prior to being dipped into the elastomeric composition. The
former may comprise, for instance, a ceramic or metal mold in the
shape of a hand. By placing the hollow member on a former prior to
applying the elastomeric coating, the resulting glove may assume a
three-dimensional configuration after the elastomeric coating is
dried and/or cured.
[0036] Other features and aspects of the present invention are
discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth more particularly in the remainder of the
specification, which makes reference to the appended figures in
which:
[0038] FIGS. 1A and 1B are perspective views of a glove made in
accordance with one embodiment of the present disclosure;
[0039] FIG. 2 is an exploded perspective view of one embodiment of
a stretch-bonded laminate that may be used in accordance with the
present disclosure;
[0040] FIG. 3 is an exploded perspective view of another embodiment
of a stretch-bonded laminate that may be used in accordance with
the present disclosure;
[0041] FIG. 4 is an exploded perspective view of still another
embodiment of a stretch-bonded laminate that may be used in
accordance with the present disclosure;
[0042] FIG. 5 is a perspective view of the stretch-bonded laminate
illustrated in FIG. 2;
[0043] FIG. 6 is a perspective view with cutaway portions of a seam
formed according to one embodiment of the present disclosure;
[0044] FIG. 7 is a perspective view of an alternative embodiment of
a seam formed in accordance with the present disclosure;
[0045] FIG. 8 is a perspective view of one embodiment of a process
for producing glove liners in accordance with the present
disclosure;
[0046] FIG. 9 is a perspective view of one embodiment of a process
for dipping glove liners into an elastomeric coating
composition;
[0047] FIG. 10A is a perspective view of one embodiment of a glove
made in accordance with the present disclosure;
[0048] FIG. 10B is a perspective view of an alternative embodiment
of a glove made in accordance with the present disclosure;
[0049] FIG. 11 is a cross-sectional view of one embodiment of a
glove layer made in accordance with the present disclosure;
[0050] FIG. 12 is a cross-sectional view of an alternative
embodiment of a glove layer made in accordance with the present
disclosure;
[0051] FIG. 13 is a perspective view of another embodiment of a
glove made in accordance with the present disclosure;
[0052] FIG. 14 is a perspective view of still another embodiment of
a glove made in accordance with the present disclosure; and
[0053] FIG. 15 is a perspective view of yet another embodiment of a
glove made in accordance with the present disclosure.
[0054] Repeat use of reference characters in the present
specification and drawings is intended to represent the same or
analogous features or elements of the invention.
DETAILED DESCRIPTION
[0055] Reference will now be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, and not meant as a limitation of the invention. For
example, features illustrated or described as part of one
embodiment can be used with another embodiment to yield still a
third embodiment. It is intended that the present invention include
these and other modifications and variations.
[0056] It is to be understood that the ranges mentioned herein
include all ranges located within the prescribed range. As such,
all ranges mentioned herein include all sub-ranges included in the
mentioned ranges. For instance, a range from 100-200 also includes
ranges from 110-150, 170-190, and 153-162. Further, all limits
mentioned herein include all other limits included in the mentioned
limits. For instance, a limit of up to 7 also includes a limit of
up to 5, up to 3, and up to 4.5.
[0057] In general, the present disclosure is directed to a
polymer-coated protective garment. The protective garment includes
a hollow member that is shaped to receive an arm, a leg, a foot, or
a hand of a wearer. For example, in one embodiment, the protective
garment comprises a glove for receiving a hand. The glove can be
used in numerous applications, such as for industrial applications,
sports applications, medical applications, and the like.
[0058] The following description for exemplary purposes only is
generally directed to a polymer-coated glove. It should be
understood, however, that similar articles and garments can be
constructed in accordance with the present disclosure.
[0059] Referring to FIGS. 1A and 1B, one embodiment of a glove 10
made in accordance with the present disclosure is illustrated. FIG.
1A illustrates the palm side of the glove, while FIG. 1B
illustrates the back side of the glove. In general, gloves made
according to the present disclosure include a hollow member made
from an elastic laminate. The elastic laminate, for instance, may
comprise at least one nonwoven material. In accordance with the
present disclosure, the hollow member is then at least partially
coated with an elastomeric material.
[0060] For instance, as shown in FIGS. 1A and 1B, the glove 10
includes a hollow member 12 formed from an elastic laminate. The
glove 10 further includes a polymeric coating, such as an
elastomeric coating 14 that, in this embodiment, only partially
covers the hollow member 12. In particular, in this embodiment, the
elastomeric coating 14 covers a palm portion of the glove 10 along
with the finger portions. In this manner, the back side of the
hollow member remains uncoated for allowing optimum stretch and
breathability.
[0061] Gloves and garments made in accordance with the present
disclosure provide various advantages. For instance, the hollow
member 12 made from an elastic laminate not only provides
form-fitting properties but can also be made so as to be
breathable. The hollow member 12 also has a lower coefficient of
friction relative to the elastomeric material, thus facilitating
donning or doffing of the glove. As will be described in more
detail below, the hollow member 12 can also be made from elastic
laminates that can be mass produced at a relatively low cost making
the gloves disposable after one or two uses.
[0062] The elastomeric coating 14 as shown in FIGS. 1A and 1B may
comprise any suitable rubber-like material. For example, the
elastomeric coating 14 may comprise natural rubber latex, a nitrile
polymer, polyvinyl chloride, a block copolymer, a polyurethane, a
silicone polymer, an acrylic polymer, and the like. The elastomeric
coating 14 provides a liquid impermeable barrier that provides
protection to the wearer from the environment in which the glove is
used. The elastomeric material, in some applications, may also have
good elastic properties that can work well in combination with the
hollow member 12.
[0063] In the embodiments shown in FIGS. 1A and 1B, the elastomeric
coating 14 only partially covers the hollow member 12. It should be
understood, however, that the elastomeric coating may be applied to
other locations on the glove or to the entire glove body depending
upon the particular application and the desired result.
[0064] As described above, the hollow member 12 is generally formed
from an elastic laminate. The elastic laminate may include at least
one nonwoven web and at least one elastic layer. In general, the
elastic laminate contains at least two layers of material but can
also contain three layers, four layers, five layers, six layers or
more. The elastic laminate as shown in FIGS. 1A and 1B forms a
hollow member with an opening that fits snuggly without bunching at
flex points, such as along the curves of the fingers or between
individual digits of the glove 10, and without either slipping or
binding too tightly against, for example, a wrist of a wearer.
[0065] In one embodiment, the elastic laminate used to form the
hollow member 12 comprises a stretch-bonded laminate. The
stretch-bonded laminate, for example, may be capable of stretching
from about 50% to 400% or greater. For example, in one embodiment,
the stretch-bonded laminate may be capable of stretching 200 to
300%. The above amount of stretch not only provides comfort to the
wearer but also works well in conjunction with the elastomeric
coating 14.
[0066] The stretch-bonded laminate may be made in various different
ways and may include various different layers. In one embodiment,
the stretch-bonded layer may be liquid and gas permeable, only gas
permeable, or impermeable to liquid and gases. In one embodiment,
the stretch-bonded laminate can be made so as to be breathable. For
instance, the stretch-bonded laminate may include pores or openings
that permit liquids and gases to pass through.
[0067] Referring to FIGS. 2 through 5, various embodiments of
elastic laminates, namely stretch-bonded laminates that may be used
in accordance with the present disclosure are shown. In the
illustrated embodiments, the stretch-bonded laminates include three
layers. It should be understood, however, that fewer or more layers
may be used.
[0068] Referring to FIG. 2, an elastic laminate or stretch-bonded
laminate 16 is illustrated. The stretch-bonded laminate 16 includes
an elastic layer 18 positioned in between a first outer layer 20
and a second outer layer 22. In this embodiment, the middle elastic
layer comprises a plurality of elastic filaments or strands 24. The
elastic strands 24 may be made from any suitable elastomeric
material. For example, the elastic strands may be made from LYCRA
that is manufactured by E.I. DuPont of Wilmington, Del.
Alternatively, the elastic strands 24 may be made from various
other elastomeric materials such as styrenic block copolymers. For
instance, in an alternative embodiment, the elastic strands 24 may
be made from a styrene-ethylene butylene-styrene copolymer, such as
KRATON G2740 available from the Kraton Polymer Company. In still
other embodiments, the elastomeric strands 24 may be made from
elastomeric polyolefins, such as a polypropylene, a polyethylene,
which includes copolymers thereof.
[0069] The elastic strands 24 are attached to the outer layers 20
and 22 using any suitable method or technique. For instance, the
elastic strands may be attached to the outer layers using an
adhesive. The adhesive, for instance, may be sprayed on the outer
layers and then attached to the elastic strands. Alternatively, the
elastic strands may be thermally, chemically, or ultrasonically
bonded to the outer layers.
[0070] When forming a stretch-bonded laminate, the elastic strands
are attached to the outer layers 20 and 22 while the elastic
strands 24 are in a stretched state. Once the strands are attached
to the outer layers and relaxed, the outer layers gather together
to form gatherable layers. In this manner, the stretch-bonded
laminate 16 has inherent stretch properties in at least one
direction.
[0071] The outer layers 20 and 22 may be made from any suitable
material. For example, in one embodiment, the outer layers comprise
nonwoven webs. The nonwoven webs may be elastic or non-elastic.
[0072] In general, the first and second non-woven webs 20 and 22
may be flexible sheet materials that can provide desired skin-like
barrier and elastic properties, while also improving the overall
tactile aesthetics or feeling for the wearer, by reducing stiffness
often found with nonwoven fabrics and the tackiness and difficult
donning properties associated with latex-based substrates. Given
the particular structure of certain nonwoven fabrics, corrugation
of the contact surface especially when gathered helps reduce the
amount of surface area that actually contacts the wearer's skin,
making the article 10 easier to don or doff. The physical structure
of nonwoven materials also can produce capillary action to wick
moisture away from the wearer's skin, hence reducing any sense of
wetness or clamminess and keeping the wearer feeling dry and
comfortable. The wrinkles may also act to enhance air flow between
the glove 10 and the skin of the user.
[0073] In one embodiment, the outer layers 20 and 22 can be made
from polymer-based nonwoven materials that have various cloth-like
properties. A foundational substrate or a base nonwoven fiber web
can be formed, for instance, from materials that may include
synthetic fibers, pulp fibers, thermo-mechanical pulp, or mixtures
of such materials. Non-woven web materials suitable for use in the
present disclosure may include spunbond webs, meltblown webs,
spunbond-meltblown-spunbond laminates, coform webs,
spunbond-film-spunbond laminates, bicomponent spunbond webs,
bicomponent meltblown webs, biconstituent spunbond webs,
biconstituent meltblown webs, bonded carded webs, airlaid webs, and
the like.
[0074] In one particular embodiment, for instance, the outer layers
20 and 22 may comprise spunbond webs that may be thermally bonded
or through-air bonded. In one embodiment, for instance, the
spunbond webs may contain bicomponent polyethylene/polypropylene
filaments in a side-by-side arrangement.
[0075] The basis weight of the outer layers 20 and 22 can vary
dramatically depending upon the particular application. For
exemplary purposes only, the basis weight of the outer layers may
generally be from about 10 gsm to about 300 gsm, such as from about
15 gsm to about 200 gsm. In various embodiments, for instance, the
basis weight of the outer layers may be relatively low, such as
from about 12 gsm to about 20 gsm. Alternatively, the outer layers
may have a basis weight of from about 35 gsm to 175 gsm, such as
from about 65 gsm to about 140 gsm. Further, the basis weight of
the outer layers 20 and 22 may be similar or may be very
different.
[0076] In one embodiment, one or both of the outer layers 20 and 22
may comprise elastic nonwoven webs. For instance, the webs may be
formed from a block copolymer, such as a KRATON polymer
manufactured by Kraton Polymers of Houston, Tex. The elastic
nonwoven webs may comprise, for instance, spunbond webs or
meltblown webs.
[0077] Various different types of stretch-bonded laminates are also
disclosed in U.S. Pat. No. 5,385,775, U.S. Pat. No. 4,720,415, and
U.S. Patent Application No. 2002/0104608, all of which are
incorporated herein by reference.
[0078] As described above, after attachment of the first outer
layer 20 and/or the second outer layer 22 to the elastic layer 18,
the stretch-bonded laminate 16 may be released so that the elastic
strands 24 return to their normal length, thus causing the first
and second outer layers 20 and 22 to wrinkle. FIG. 5 shows the
stretch-bonded laminate 16 in a relaxed position in which wrinkles
26 are formed in the first and second outer layers. The wrinkles 26
may extend through the entire outer layers so that they are
essentially on both sides of the layers. The stretch-bonded
laminate 16 thus has a certain degree of hidden stretchability that
allows for the stretch-bonded laminate 16 to function as a glove 10
or other protective article so that movement of a portion of the
user's body causes a stretching in the stretch-bonded laminate 16
while still maintaining a comfortable fit onto the user. The
stretch-bonded laminate 16 may fit tightly onto the skin of the
user in both a relaxed state and then in a stretched state where
the user moves a portion of his or her body.
[0079] In the embodiment illustrated in FIG. 2, the elastic strands
24 are arranged so as to be parallel. An alternative arrangement of
a stretch-bonded laminate 16, however, is shown in FIG. 3. Like
reference numerals have been used to indicate similar elements. In
the embodiment illustrated in FIG. 3, the elastic filaments or
strands 24 are formed into a grid-like or mesh-type shape.
[0080] For parallel strands, the elasticity may be one dimensional,
but second dimensional elasticity can come from elastic fibers if
present in the first and second nonwoven webs 20 and 22. If elastic
fiber webs can be formed by spraying fibers perpendicular to the
parallel strands, a knit-like microstructure is formed and may be
vapor or liquid permeable. The grid type of arrangement of FIG. 3
may allow for the stretch-bonded laminate 16 to stretch in various
directions and may also incorporate additional stretching from the
outer layers 20 and 22. As such, the elastic strands 24 may be
viewed as mesh frames that are equivalent to mesh structures formed
in woven products during the knitting process but with improved
surface flexibility and structural variations. However, in
accordance with other exemplary embodiments the elastic strands 24
may be arranged in any desired direction so as to accommodate
stretching in various directions.
[0081] Referring to FIG. 4, still another embodiment of a
stretch-bonded laminate 16 that may be used in accordance with the
present disclosure is illustrated. Again, like reference numerals
have been used to indicate similar elements. As shown, the
spunbonded laminate 16 includes an elastic layer 18 positioned in
between a first outer layer 20 and a second outer layer 22. In this
embodiment, the elastic layer 18 comprises an elastic film. The
film, for instance, may be made from any suitable elastomeric
material, such as a styrenic block copolymer, an elastomeric
polyethylene, an elastomeric polypropylene, or any other suitable
elastomeric material. For instance, the film 18 can be made from
any of the same materials described above with respect to the
elastic filaments 24.
[0082] Similar to the above embodiments, the elastic film layer 18
may be stretched and then attached to the outer layers 20 and 22
for forming the laminate material. The use of an elastic film layer
18 may be desirable in some applications. For example, the film
layer 18 may provide further protection to the hand of the wearer
by serving as a barrier layer to the hand. The use of a film layer,
for instance, may be incorporated into the glove 10 where the
elastomeric coating 14 is not present. In addition, as will be
described in greater detail below, the film layer 18 may prevent
penetration of the elastomeric coating which may provide the glove
with a higher degree of flexibility and comfort.
[0083] It should be understood that in addition to spunbond
laminates, the glove of the present disclosure may be constructed
from various other types of elastic laminates. In one particular
embodiment, for instance, a neck-bonded laminate including reverse
neck-bonded laminates may be used.
[0084] When incorporated into a glove, the elastic laminate may
have uniform stretch properties or may have non-uniform stretch
properties in one or more directions. For example, in one
embodiment, the elastic laminate may be formed so that greater
stretch and/or elasticity may be built into the laminate in
particular areas, such as where the glove is expected to undergo
greater tension. For example, greater amounts of stretch or
elasticity may be incorporated into the hollow member in the palm
area, in the cuff area, in the back side of the glove, or on the
finger portions where the knuckles are located. The greater stretch
or elastic areas, for instance, may comprise bands that extend
across the elastic laminate.
[0085] For example, in one embodiment, the elastic laminate may
comprise a stretch-bonded laminate containing outer layers made
from a nonwoven web, such as a spunbond web. The spunbond webs may
be formed on a forming surface containing cavities where greater
amounts of fibers may deposit. These cavities, for instance, can
have a rectangular shape that extends in the machine direction or
the cross-machine direction. When laminated to an elastic layer,
such as elastic filaments, the higher basis weight areas formed in
the cavities on the forming surface may provide greater inherent
stretch in those areas. For instance, the stretch or elasticity in
those areas may be from about 5% to about 20% greater than the
remainder of the laminate, such as from about 5% to about 10%
greater.
[0086] The basis weight of the elastic laminate used to construct
the hollow member 12 as shown in FIGS. 1A and 1B may vary depending
upon the particular application and the desired results. For
instance, lower basis weights may be used where tactile properties
are more desirable. Higher basis weights, however, may be used
where greater protection is needed. In general, the basis weight of
the elastic laminate may vary from about 25 gsm or lower to 400 gsm
and greater. For instance, the basis weight of the elastic laminate
may vary from about 30 gsm to about 200 gsm, such as from about 50
gsm to about 100 gsm.
[0087] When constructing the hollow member 12 as shown in FIGS. 1A
and 1B, a single piece of elastic laminate may be used to form the
glove or multiple panels may be used. For example, in one
embodiment, a first panel may be attached to a second panel in
forming the hollow member. Of particular advantage in a two panel
construction is that the panels may be made from different
materials. For instance, different types of elastic laminates or
elastic laminates having different properties can be used to form
the palm portion of the glove and the back side of the glove.
[0088] For example, in one embodiment, an elastic laminate having
stretch in generally one direction may be used for the palm side of
the glove while an elastic laminate having stretch in multiple
directions may be used for the back side, where greater stretch is
typically needed. In one particular embodiment, for instance, a
neck-bonded laminate may be used to form the palm side of the glove
containing a film layer while a stretch-bonded laminate containing
elastic filaments may be used to construct the back side of the
glove. In this embodiment, the spunbonded laminate has better
elasticity which may be desirable on the back side of the glove
since more flexibility is needed when the hand bends to form a
fist. Also, the stretch-bonded laminate may allow gas flow
therethrough so that the glove can be breathable, especially in
applications where the back side of the glove is not coated with
the elastomeric coating.
[0089] The neck-bonded laminate, on the other hand, may contain a
polymer film layer so as to provide further barrier protection to
the palm side of the hand where substances are more prone to
contact the glove. The film layer also will maintain the
elastomeric coating on the outside layer of the laminate.
[0090] In other embodiments, the elastic laminate used to form the
palm side of the glove may be thicker and have a greater basis
weight than the elastic laminate used to form the back side of the
glove. In this embodiment, both elastic laminates may have a
similar or different construction. The palm side, however, may be
thicker and have a greater basis weight for providing greater
protection against objects that are held with the glove.
[0091] When forming the hollow member 12 from a first elastic
laminate and a second elastic laminate, the two panels may be
attached together using any suitable method or technique. For
instance, the panels may be adhesively bonded together, thermally
bonded together, or ultrasonically bonded together. In still
another embodiment, the panels may be sewn together to form the
seam. For example, FIG. 6 shows a cut away portion of the inside of
a glove 10 in accordance with one exemplary embodiment. Here, a
first stretch-bonded laminate 28 is attached to a second
stretch-bonded laminate 30 thus forming a seam 32. The seam 32 may
have a height 34 that is up to 5 mm in length in accordance with
certain exemplary embodiments. Alternatively, the height 34 of the
seam 32 may be up to three millimeters, up to two millimeters, or
less than one millimeter in accordance with certain exemplary
embodiments. The height 34 of the seam 32 may impact the comfort of
the user during wearing of the glove 10. For example, if the height
34 of the seam 32 is relatively large, the user will feel the seam
32 if the hollow member is inverted and may experience discomfort
therefrom. Additionally, the height 34 of the seam 32 may also
hinder removal of the glove 10 from the user or may interfere with
donning of the glove 10. If the hollow member is not inverted and
the seam remains on the exterior surface of the hollow member, a
relatively large seam may interfere with use of the glove.
[0092] In accordance with one exemplary embodiment of the present
disclosure, the first and second stretch-bonded laminates 28 and 30
may be connected to one another through one or more "flush" seam
bonds 36 as shown in FIG. 7. For example, flush seam bonds can be
formed through a single step ultrasonic bonding and cutting
process. Here, the seams are formed between the first and second
stretch-bonded laminates so as to have a height of generally equal
to or less than 1 mm. The flush seam bond 36 allows for a greater
degree of user comfort of the glove 10 as the user will not be able
to feel discomfort from any seams during wearing of the glove 10.
Additionally, flush seam bonding may allow for the glove 10 to be
more easily donned and removed from the hand of the user as seams
32 will not be present to interfere with donning and removal. The
flush seam bonds 36 may be desirable in that they result in a glove
10 that can have the same quality as woven knit gloves with respect
to wearing feel and comfort. Additionally, the stretchability of
the glove 10 may also provide for desired hand fitting properties
and allow for easy donning and removal of the glove 10.
[0093] In a particular embodiment, the flush seam bonds 36 may be
less than about 500 micrometers (.mu.m) in width and about 500
.mu.m in height. The flush seam bond 36 may also be less than 400
or 300 .mu.m in width and 400 or 300 .mu.m in height. Preferably,
the flush seam bond 36 is less than 100 .mu.m in width and 100
.mu.m in height. In certain exemplary embodiments, the flush seam
bond 36 width can be as narrow as about 50 .mu.m. The width and
height of the flush seam bond may be controlled, for instance, by
varying the width, height and the cutting angle of the glove
pattern on the bonding horn or bonding anvil, or ultrasonic sewing
die.
[0094] With respect to ultrasonic bonding of the elastic laminates,
the bonding seam 36 along the edges further functions as an anchor
for the strands to prevent the strands from becoming loose when the
seam 36 lines are formed. In one embodiment, a seam 36 line may be
formed by employing an ultrasonic glove cut/seal fixture in which a
flat top is present for cutting within an angle slope for
simultaneous sealing. The slope part of the fixture may only melt
the laminates so that the strands will be intimately bonded
together for preventing the formation of loose strands. Preferably,
the loose strands may be less than 50% after cut/seal, and in some
embodiments, less than 75%, and in some embodiments, less than 85%,
and in some embodiments, less than 90%.
[0095] When forming the seam 36, the seam may have a relatively
uniform width or may have a non-uniform width. For example, in one
embodiment, the seam may be wider or may include additional bonding
points in high stress areas. The high stress areas may include
between the thumb and the palm, between the fingers, and
surrounding the opening of the glove.
[0096] Since gloves 10 may be in a variety of sizes and shapes,
ultrasonic bonding installations, such as a plunge bonder, may not
be able to place a whole hand glove facial onto a horn. For
example, a glove 10 at 7.times.10 inches in size cannot be
fabricated by a bonder that can only support a 6.times.9 inch horn.
This is particularly true for large size gloves when the size is
beyond the limit of a given ultrasonic bonder. In this case, it is
possible to have more than one horn to make a hollow member 12. In
some embodiments, two horns may be needed to make a hollow member
12. In other embodiments, four horns may be needed. Each horn can
have a facial for bonding one area of the hollow member.
Alternatively, the glove facial can be placed onto a large anvil
and use a smaller horn to bond the glove in one or more successive
plunge bonds. Rotary ultrasonic bonding can also be used with a
pattern located on a cylindrical anvil.
[0097] It is also possible that three-dimensional shaped gloves or
other garments can be made by stretching one laminate during
bonding. In this case, the stretched laminate retracts to its
normal length and causes the glove 10 to have a three-dimensional
shape. Such a bonding process is especially useful for forming a
glove that has open finger tips, as shown in FIG. 13.
[0098] In certain embodiments, the hollow member can also be formed
so as to include a hemline surrounding the opening for receiving
the hand. The hem can be formed by either forming a cut/seal edge
by ultrasonic sewing or employing a traditional hem-forming
machine. The hem can be used to reinforce the strength of the cuff
of the glove.
[0099] FIG. 8 shows a process of manufacturing the hollow member 12
as shown in FIGS. 1A and 1B in accordance with one exemplary
embodiment. Here, first and second stretch-bonded laminates 28 and
30 are drawn towards one another and formed into the hollow member
through an ultrasonic bonding step 48. The ultrasonic bonding step
48 and related manufacturing steps may be performed as that shown
and described in U.S. application Ser. No. 11/118,078 filed Apr.
29, 2005, the entire contents of which are incorporated by
reference herein in their entirety for all purposes. The ultrasonic
bonding step 48 in FIG. 8 may employ a blade horn 52 positioned on
one side of the first stretch-bonded laminate 28 while an anvil 54,
in this case a cylindrical anvil having a pattern of gloves
thereon, is located adjacent the second stretch-bonded laminate 30.
The blade horn 52 may be moved into engagement with the laminates
to simultaneously bond and cut the laminates in order to form the
flush seam bond 36 thereon. The rotary anvil 54 may be configured
to have an edge that is flat for cutting and an angled side for the
sealing function as shown and described in the above-mentioned U.S.
application Ser. No. 11/118,078.
[0100] The hollow members may be arranged so that the opening for
the hand of the user is located on an edge of the laminates. Once
formed, the hollow members may be removed and collected. The
process shown in FIG. 8 may be a continuous rotary process so that
the hollow members may be manufactured at a high rate of speed.
Alternatively, an intermittent process for the formation of the
hollow members may also be employed, if desired, in accordance with
other exemplary embodiments.
[0101] An inverting step may be employed to turn the hollow member
so that the flush seam bonds 36 that have any height thereto are
then located on the inside of the hollow member. However, the
inverting step is not necessary in accordance with other exemplary
embodiments. For example, the hollow member may be constructed and
arranged so that the height of the flush seam bonds 36 are located
on the outside of the hollow member. Additionally, the flush seam
bonds 36 may be formed so that a height is negligible.
[0102] After the hollow member 12 is formed, the hollow member is
then contacted with an elastomeric composition for forming a
coating at least on a portion of the hollow member. For instance,
as shown in FIGS. 1A and 1B, the elastomeric coating may cover the
palm portion and the finger portions of the glove 10. The
elastomeric coating composition may contain any suitable natural or
synthetic film-forming polymer. The elastic coating composition may
comprise an aqueous-based dispersion or a solvent-based dispersion.
Polymers that may be present in the elastomeric coating composition
include natural rubber latex, nitrile polymers, polyvinyl chloride
polymers, polyurethane polymers, silicone polymers, acrylic
polymers, block copolymers such as styrenic block copolymers, and
the like. As used herein, a nitrile polymer refers to any
film-forming polymer that contains acrylonitrile.
[0103] Particular styrenic block copolymers that may be used
include styrene-ethylene butylene-styrene block copolymers,
styrene-isoprene-styrene block copolymers,
styrene-butadiene-styrene block copolymers, styrene-isoprene block
copolymers, styrene-butadiene block copolymers, and the like. Block
copolymers, for example, that may be used in the present disclosure
are disclosed, for instance, in U.S. Pat. No. 5,112,900, U.S. Pat.
No. 5,407,715, U.S. Pat. No. 5,900,452, and U.S. Pat. No.
6,288,159, which are all incorporated herein by reference.
[0104] In order to contact the hollow member 12 with the
elastomeric coating composition, in one embodiment, the hollow
member may be dipped into the composition. Once contacted with the
elastomeric composition, the resulting glove may be heated in order
to dry and/or cure the elastomeric coating.
[0105] The manner in which the elastomeric coating composition is
contacted with the hollow member 12 can vary depending upon the
particular application and the desired result. In one embodiment,
for instance, the hollow member may contact the coating composition
in a flat configuration. Alternatively, the hollow member may be
placed on a hand-shaped former and then dipped into the elastomeric
coating composition. It has been discovered that the above two
processes may produce gloves having different physical
characteristics.
[0106] For example, FIG. 10B is an exemplary drawing of a glove 10
in which the hollow member 12 has been dipped into an elastomeric
coating composition to form an elastomeric coating 14 while the
hollow member is in a flat state. As shown, the coated glove 10
also assumes a relatively flat configuration. This may be desirable
in order to more easily pack the gloves and ship them.
[0107] When the hollow member, however, is placed on a hand-shaped
former and dip coated a three-dimensional glove 10 as shown in FIG.
10A may result. Specifically, the present inventors have found that
when the hollow member is placed on a hand-shaped former and dip
coated, the glove 10 assumes a three-dimensional shape after
curing.
[0108] Referring to FIG. 9, one embodiment of a process for forming
the three-dimensional glove 10 as shown in FIG. 10A is illustrated.
As shown, the process includes a plurality of hand-shaped formers
40. The formers 40, for instance, may be made from ceramic and are
grouped in rows and moved along a conveyor line 42. In accordance
with the present disclosure, the hollow members 12 are placed upon
each of the formers 40. As the hand-shaped formers 40 move along
the conveyor line 42, the hollow members 12 are dipped into a
dipping composition 44 in order to form an elastomeric coating on
at least a portion of the hollow member. One example of a dip tank
46 is shown in the figure. As will be described in more detail
below, the process may include a plurality of dip tanks containing
different or the same compositions. The process line can also
include various heating devices for heating the elastomeric
composition being formed on the hollow members.
[0109] The process illustrated in FIG. 9 is intended to represent a
continuous process. In an alternative embodiment, however, the
hand-shaped formers 40 may be assembled into groups and processed
separately in a batch processing operation.
[0110] In the embodiment illustrated in FIG. 9, the entire hand
shape of the hollow member 12 is being coated with the elastomeric
composition. In order to coat only a portion of the hollow member,
the molds can be dipped only partially into the coating composition
as desired. Also, the formers 40 can be placed into the elastomeric
coating composition at an angle as needed in order to coat the
hollow member where desired.
[0111] As shown in FIGS. 1A and 1B, in one embodiment, only the
palm portion and the finger portions of the hollow members are
coated. In one embodiment, the coating can extend so as to surround
any seam contained within the hollow member. Coating the seam
further reinforces the strength of the seam and prevents against
rupture during use.
[0112] In addition to a dipping process as shown in FIG. 9, it
should be understood that the elastomeric coating composition may
also be applied to the hollow member in other ways. For example, in
one embodiment, the elastomeric coating composition can be sprayed
or extruded onto the hollow member. For instance, in one
embodiment, it may be desirable to apply the elastomeric coating
composition in a discontinuous manner. For instance, referring to
FIG. 15, one alternative embodiment of a glove 10 made in
accordance with the present disclosure is illustrated. In this
embodiment, the elastomeric coating 14 is applied to the hollow
member 12 in a discontinuous fashion. Specifically, the elastomeric
coating 14 comprises a pattern of discrete shapes or dots. In this
manner, it should be appreciated that any suitable pattern may be
applied to the hollow member.
[0113] The amount the elastomeric coating composition penetrates
through the thickness of the elastic member can also vary depending
upon the particular application and the desired results. In one
embodiment, for instance, it may be desirable to have the
elastomeric coating composition penetrate through to the inside
surface of the hollow member. In this embodiment, for instance, the
elastic laminates may be completely impregnated by the elastomeric
coating composition. In this manner, the elastic laminates that
form the hollow member create a reinforcing matrix for the
elastomeric coating.
[0114] In alternative embodiments, however, it may be desirable
only for the elastomeric coating composition to penetrate only a
portion of the thickness of the hollow member. For example,
sufficient penetration of the hollow member may be needed in order
for there to be suitable bonding between the elastomeric coating
and the outside surface of the hollow member. Too much penetration,
however, can increase the stiffness of the resulting article.
Further, preventing penetration to the inside surface of the hollow
member leaves, in one embodiment, a nonwoven material placed
adjacent to the hand which provides softness. and comfort to the
wearer. Further, as described above, when the nonwoven web forms
the interior surface of the glove, the glove can be easily donned
by the wearer.
[0115] In order to control penetration of the elastomeric coating
composition, various methods and techniques may be used to control
the coating process. For instance, in one embodiment, the hollow
member may be formed from an elastic laminate containing a film as
shown in FIG. 4. For example, referring to FIG. 11, an elastic
laminate 16 is shown including two outer nonwoven layers 20 and 22
and a middle elastic layer 18 formed from a film. As also shown,
the elastic laminate 16 further includes an elastomeric coating 14.
Presence of the film layer 18 prevents penetration of the
elastomeric coating composition into the outer layer 22.
[0116] In addition to using a film layer in the elastic laminate,
various other processing techniques may also be used to control
penetration. For example, penetration of the coating composition
can be controlled by varying the viscosity of the coating
composition. For instance, by increasing the viscosity, penetration
of the elastomeric coating composition into the hollow member can
be reduced.
[0117] In addition, penetration of the coating composition can also
be controlled by varying the pore size and/or the fiber size of the
outer layer of the elastic laminate. For instance, smaller fiber
sizes typically lead to smaller pore sizes which prevent
penetration of the coating composition. In one embodiment, for
instance, the elastic laminate may include an exterior surface
comprising a meltblown web containing relatively small fibers. The
meltblown web may be used to prevent the coating composition from
impregnating the entire layer. Depending upon whether a spunbond or
a meltblown web is used, the diameter of the fibers may range from
about 10 microns to less than 1 micron.
[0118] In still another embodiment, penetration of the elastomeric
coating can be controlled by controlling fiber packing density of
the elastic laminate. For example, increasing the fiber packing
density will generally inhibit the elastomeric coating composition
from penetrating through the layer. For exemplary purposes only,
when the elastic laminate contains nonwoven synthetic fibers, the
packing density may vary from about 0.05 g/cc to about 0.3
g/cc.
[0119] In another embodiment, penetration of the elastomeric
coating can be controlled by controlling the surface energy of the
outside surface of the hollow member. For example, hydrophobic
surfaces may react differently to the elastomeric coating than
hydrophilic surfaces. For example, if the elastomeric coating
composition comprises an aqueous composition, for some
applications, a hydrophobic surface will prevent penetration of the
coating composition.
[0120] When varying fiber size and packing density, it should be
understood that such characteristics can change over the thickness
of the elastic laminate. For example, the exterior surface of the
laminate may be modified or otherwise constructed to control
penetration, while the interior surface may have different
characteristics. For example, in one embodiment, the elastic
laminate may include two outer layers in which the outer layer
forming the exterior surface of the hollow member has a small pore
size while the outer layer forming the interior surface of the
hollow member has a relatively large pore size. The same can hold
true for packing density, fiber diameters, and surface energy.
[0121] In still another embodiment of the present disclosure, a
precoat on the hollow member may be used in order to control
penetration of the elastomeric coating composition. The precoat,
for instance, may comprise a chemical composition applied to the
exterior surface of the hollow member. The chemical composition may
not form a film on the hollow member but may serve to control
penetration of the elastomeric coating.
[0122] For example, in one embodiment, the precoat may comprise a
coagulant composition for coagulating the natural or synthetic
polymer contained within the elastomeric coating composition.
[0123] For example, the precoat composition may contain a coagulant
which causes a film-forming polymer such as natural rubber latex or
nitrile polymer to coagulate and polymerize on the outside surface
of the hollow member. Coagulants that may be used may include, for
instance, a solution of a coagulant salt such as a metal salt.
Examples of coagulants include but are not limited to water soluble
salts of calcium, zinc, aluminum, and the like. For example, in one
embodiment, calcium nitrate in water or alcohol may be used as the
coagulant composition. The amount of coagulant present in the
solution may determine the amount of penetration of the elastomeric
composition.
[0124] In order to apply the coagulant composition to the hollow
member, the coagulant composition can be sprayed on the hollow
member or the hollow member may be dipped into the coagulant
composition. For instance, the hollow member may be applied to a
hand-shaped former and dipped into the coagulant composition prior
to being dipped into the elastomeric coating composition. Once
applied, the coagulant may air dry leaving a residual coating on
the hollow member.
[0125] Upon contact of the coating composition with the elastomeric
composition, the coagulant causes the polymer contained in the
elastomeric composition to become locally unstable and coagulate on
the surface of the hollow member. In many applications, the
coagulant itself does not form a separate layer on the article, but
rather becomes part of the resulting film.
[0126] In addition to a coagulant composition, the precoat may
comprise other chemical compositions. For example, in an
alternative embodiment, the hollow member may be treated with a
hydrophobic composition that controls and reduces penetration of
the elastomeric coating.
[0127] Once the elastomeric coating composition is applied to the
hollow member and dried and/or cured, the thickness of the
resulting coating may vary. The thickness of the film, for
instance, may be increased or decreased by increasing or decreasing
the dwell time during which the hollow member contacts the coating
composition. Total thickness of the elastomeric coating may also
depend on various other parameters as well.
[0128] In order to increase the thickness of the elastomeric
coating, in one embodiment, multiple layers of the elastomeric
coating composition may be applied to the hollow member. For
example, as shown in FIG. 12, an elastic laminate 16 is shown
including an elastomeric coating 14. Like reference numerals have
been used to indicate similar or corresponding elements. Similar to
FIG. 11, in this embodiment, the elastic laminate includes two
outer layers 20 and 22 and an elastic film middle layer 18. In this
embodiment, however, the elastomeric coating 14 includes two
layers, an interior layer 60 and an outer layer 62. It should be
understood that multiple layers applied to the hollow member may be
indistinguishable. FIG. 12, however, is provided for purposes of
illustration only.
[0129] When applying separate layers of an elastomeric coating
composition to the hollow member, it should be understood that the
layers can be made from the same material or from different
materials. The layers may also have different thicknesses depending
upon the particular application. Further, the second layer applied
to the hollow member may be applied in the same areas as the first
layer or may be applied in different areas. For example, in one
embodiment, the second layer may only be applied to portions of the
glove where further reinforcement is needed.
[0130] As described above, once the elastomeric coating is applied
to the hollow member, the natural or synthetic polymer contained
within the elastomeric coating may be dried, cured or vulcanized if
necessary. In one embodiment, the polymer may be cured by high
temperature reaction with a vulcanizing agent, such as sulfur, to
cause cross-linking of the polymer chains. Curing may generally
take place at temperatures of about 50.degree. C. to about
200.degree. C. although the temperature is dependent upon the
particular polymer used. In addition to curing the polymer, the
high temperature process may cause the evaporation of any volatile
components remaining in the glove, including any water remaining in
the layers. In other embodiments, the elastomeric coating may be
air dried or cured at room temperature.
[0131] In general, the thickness of the elastomeric coating can
vary from 3 mils or less to greater than 15 mils or less. For
example, in one embodiment, the thickness of the elastomeric
coating may be from about 3 mils to about 5.5 mils.
[0132] After the elastomeric coating is dried and/or cured, various
post-processing steps may occur if desired. For example, in one
embodiment, the gloves may be immersed into a leaching bath and
leached. In addition, the articles may be subjected to a
halogenation process, such as, for example, a chlorination process
to improve the surface characteristics of the elastomeric coating.
Halogenation, for instance, can control the tackiness of the
resulting layer.
[0133] If desired, various other treatments may also be applied to
the glove. For example, a skincare formulation or
antimicrobial/antiviral agents may be applied to the glove if
desired. In one embodiment, for instance, the inside surface of the
hollow member can be treated with a composition intended to protect
the skin of the wearer or to otherwise provide benefits to the
skin. The skincare formulation, for instance, may comprise a
moisturizer and various other therapeutic components. It should
also be understood that the gloves can be made in any size or any
suitable color.
[0134] The glove of the present disclosure may be used in all
different types of applications. Particular embodiments of gloves
in addition to the one illustrated in FIGS. 1A and 1B are shown in
FIGS. 13 and 14. In FIG. 13, a glove 10 is illustrated that may be
used for sports or recreational purposes. In this embodiment, the
glove 10 includes finger portions having open ends for allowing the
uppermost portion of the fingers to remain uncovered. As shown, the
glove 10 includes a hollow member 12 and an elastomeric coating 14.
In this embodiment, the elastomeric coating only covers the palm
portion of the glove 10. Such gloves as shown in FIG. 13 are well
suited for use in weightlifting, bicycling, climbing, and sailing
in addition to various other applications.
[0135] Referring to FIG. 14, still another embodiment of a glove 10
made in accordance with the present disclosure is illustrated. In
this embodiment, the hollow member of the glove 10 is completely
coated by the elastomeric coating. Further, the glove 10 includes
an extended cuff portion 70. For instance, the cuff portion 70 may
extend from the hand to an elbow of the wearer.
[0136] These and other modifications and variations to the present
invention may be practiced by those of ordinary skill in the art,
without departing from the spirit and scope of the present
invention, which is more particularly set forth in the appended
claims. In addition, it should be understood that aspects of the
various embodiments may be interchanged both in whole or in part.
Furthermore, those of ordinary skill in the art will appreciate
that the foregoing description is by way of example only, and is
not intended to limit the invention so further described in such
appended claims.
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