U.S. patent application number 14/933319 was filed with the patent office on 2016-05-05 for glove having two-dimensional injection molded components.
The applicant listed for this patent is Ansell Limited. Invention is credited to Miguel Angel Sanchez Gonzalez, Alvin Jerome Jenkins, JR., Agustin Portillo Mercado, Eric M. Thompson.
Application Number | 20160120242 14/933319 |
Document ID | / |
Family ID | 55851230 |
Filed Date | 2016-05-05 |
United States Patent
Application |
20160120242 |
Kind Code |
A1 |
Thompson; Eric M. ; et
al. |
May 5, 2016 |
GLOVE HAVING TWO-DIMENSIONAL INJECTION MOLDED COMPONENTS
Abstract
A glove, including a fabric liner having a thumb, an index
finger, a middle finger, a ring finger, a pinky finger, a palm
area, an upper knuckle area, a back of a hand area, and optionally
a cuff; at least one two-dimensional injection molded component
disposed on at least one planar region of the fabric liner.
Inventors: |
Thompson; Eric M.; (Central,
SC) ; Mercado; Agustin Portillo; (Ciudad Juarez,
MX) ; Jenkins, JR.; Alvin Jerome; (Greenville,
SC) ; Gonzalez; Miguel Angel Sanchez; (Ciudad Juarez,
MX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ansell Limited |
Richmond |
|
AU |
|
|
Family ID: |
55851230 |
Appl. No.: |
14/933319 |
Filed: |
November 5, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62075666 |
Nov 5, 2014 |
|
|
|
Current U.S.
Class: |
2/161.6 ;
2/169 |
Current CPC
Class: |
A41D 19/001 20130101;
A41D 19/01523 20130101; A41D 19/0065 20130101 |
International
Class: |
A41D 19/00 20060101
A41D019/00; A41D 19/015 20060101 A41D019/015 |
Claims
1. A glove, comprising: a fabric liner having a thumb, an index
finger, a middle finger, a ring finger, a pinky finger, a palm
area, an upper knuckle area, a back of a hand area, and optionally
a cuff; and at least one two-dimensional injection molded component
disposed on at least one planar region of the fabric liner, wherein
the two-dimensional molded component is molded onto the at least
one planar region of the fabric liner.
2. The glove of claim 1, wherein the at least one two-dimensional
injection molded component disposed on at least one planar region
of the fabric liner comprises a silicone, thermoplastic
vulcanizate, thermoplastic rubber, thermoplastic elastomer,
thermoplastic polyolefin, a shear-thickening polymer, aliphatic
nylons, aromatic nylons, vinyls, polyesters, modified-styrenics,
SEBS, SEPS, or styrene block copolymers polymeric material, and
blends or alloys thereof.
3. The glove of claim 1, wherein the at least one two-dimensional
injection molded component is disposed on at least one planar
region of a finger, fingertip, thumb, thumbtip, upper knuckle area,
palm area or back hand area of the fabric liner.
4. The glove of claim 1, wherein the at least one two-dimensional
injection molded component comprises 50% or less than at least one
of a palm side or a back hand side of the fabric liner.
5. The glove of claim 1, wherein the at least one two-dimensional
injection molded component, disposed on at least one planar region
of the fabric liner, comprises at least one of a blind hole or a
through hole.
6. The glove of claim 1 wherein the fabric liner is a knitted
fabric liner.
7. The glove of claim 6, wherein the knitted fabric liner comprises
cotton, rayon, elastane, HPPE, a composite yarn, ultra-high
molecular weight polyethylene, nylon 6, nylon 66, carbon fibers,
oxidized polyacrylonitrile, para-aramid, or meta-aramid fibers or
filaments, steel wire, glass fibers, filaments, and the like or any
blend of the fibers, filaments and the materials.
8. The glove of claim 2, wherein the polymeric material comprising
the at least one two-dimensional injection molded component is
foamed.
9. The glove of claim 2, wherein a melting point temperature of the
fabric liner is complementary with a melting point temperature of
the polymeric material of the at least one two-dimensional
injection molded component to promote adhesion thereto.
10. The glove of claim 2, wherein a melting point temperature of
the elastomeric coating is complementary with a melting point
temperature of the polymeric material of the at least one
two-dimensional injection molded component to promote adhesion
thereto.
11. The glove of claim 1, wherein an elastomeric coating is
disposed on the fabric liner in one of a palm dip, a knuckle dip, a
3/4 dip, or a full dip.
12. The glove of claim 11, wherein the at least one two-dimensional
injection molded component is disposed on the fabric liner, the
elastomeric coating, or on a part of the fabric liner and the
elastomeric coating.
13. A method for producing a glove, comprising: dressing a knitted
fabric liner on a hand-shaped former having at least one planar
surface to maintain regions of the knitted fabric liner in a planar
manner; injecting a polymeric material, specified to enhance
abrasion resistance, impact resistance, grip, antimicrobial
properties, biostatic properties, or anti-vibration
characteristics, via an injection molding process onto at least one
planar region of the knitted fabric liner, wherein the polymeric
material forms at least one two-dimensional injection molded
component; and dipping the fabric liner having the at least one
two-dimensional injection molded component disposed thereon into an
elastomeric composition, forming an elastomeric coating on the
knitted fabric liner.
14. The method of claim 13, wherein the two-dimensional injection
molded component comprises an elastomeric material such as
silicone, thermoplastic vulcanizate, thermoplastic rubber,
thermoplastic polyolefin, aliphatic nylon, aromatic nylon, vinyls,
polyesters, modified styrenics, and styrene block copolymers, and
blends or alloys thereof.
15. The method of claim 13, wherein the at least one
two-dimensional injection molded component is molded on a planar
region of the elastomeric coating.
16. The method of claim 13, wherein the knitted fabric liner
comprises cotton, rayon, elastomerics, HPPE, a composite yarn,
ultra-high molecular weight polyethylene, nylon 6, nylon 66, carbon
fibers, oxidized polyacrylonitrile, p-aramids, or m-aramids, steel
wire, glass fibers, filaments, and the like or any blend of the
fibers, filaments, and the materials.
17. The method of claim 13, wherein a melting point temperature of
the elastomeric coating is complementary with a melting point
temperature of the polymeric material of the at least one
two-dimensional injection molded component to promote adhesion
thereto.
18. A method for producing a glove, comprising: dressing a knitted
fabric liner on a hand-shaped former having at least one planar
surface to maintain regions of the knitted fabric liner in a planar
manner; dipping the fabric liner having the at least one
two-dimensional injection molded component disposed thereon into an
elastomeric composition, forming an elastomeric coating on the
knitted fabric liner; and injecting a polymeric material, specified
to enhance abrasion resistance, impact resistance, grip,
antimicrobial properties, biostatic properties, or anti-vibration
characteristics, via an injection molding process onto at least one
planar region of at least one of the knitted fabric liner or the
elastomeric coating, wherein the polymeric material forms at least
one two-dimensional injection molded component.
19. The method of claim 18, wherein a melting point temperature of
the elastomeric coating is complementary with a melting point
temperature of the polymeric material of the at least one
two-dimensional injection molded component to promote adhesion
thereto.
20. The method of claim 18, wherein a melting point temperature of
the knitted fabric liner is complementary with a melting point
temperature of the polymeric material of the at least one
two-dimensional injection molded component to promote adhesion
thereto.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Ser. No. 62/075,666,
which is incorporated in its entirety herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to
gloves and, more specifically, to gloves comprising a fabric liner
having two-dimensional injection molded components adhered to the
fabric liner and, optionally, an elastomeric coating adhered to the
fabric liner.
[0004] 2. Description of the Related Art
[0005] Gloves for the skilled trades have typically been made of
leathers, which are expensive and offer little design choices for
manufacturers. In addition, leather does not breathe adequately.
Therefore, gloves having an injection molded component adhered to a
fabric liner were developed. Molded components provide a
three-dimensional molded palm portion to enable the glove to fit
users. The molded components are typically fabricated from
thermoplastic elastomers (TPEs), thermoplastic vulcanizates (TPVs),
or thermoplastic rubbers (TPRs). Such fabric liners generally
consist of fabrics that can withstand temperatures encountered
during injection molding processes, e.g., 450.degree. F.
[0006] Previously, gloves having injection-molded components have
typically found use as gloves for which the injection molded
components are curved and traverse, for example, the circumference
of a finger, fingertip, or palm and backhand region and are not
easily permanently adhered thereto unless the injection molded
components further consist of a large contact area with the
underlying substrate to promote adhesion. However, such gloves are
very stiff and suffer from a lack of grip and flexibility and,
therefore, dexterity characteristics. Furthermore, gloves having
three-dimensional molded portions, which cover most of a liner
and/or traverse from a palm to a backhand area, require complex
molds, which are expensive. For the purposes of this disclosure, as
apparent to one skilled in the art, the use of the phrase "three
dimensional" when referring to a molded portion means that the
molded portion is applied to a curved surface of a former or mold,
i.e., the plastic is injected onto a surface that is curved or
non-planar. Therefore, the three dimensional characteristic is not
merely a bending or flexing of a two dimensional material but the
formation of the molded portion into a three dimensional shape by
injection molding the elastomeric material onto a surface
approximating the shape of a human hand.
[0007] Therefore, the inventors have invented a method for applying
two-dimensional injection molded components onto a planar fabric
glove liner and gloves comprising a fabric glove liner and
two-dimensional injection molded components.
SUMMARY
[0008] Embodiments according to the present invention comprise a
variety of gloves having a fabric liner further comprising one or
more two-dimensional injection-molded component(s) molded onto the
fabric liner and/or onto an elastomeric coating disposed on at
least part of the fabric liner, substantially as shown in and/or
described in connection with at least one of the figures, as set
forth more completely in the claims, are disclosed. Various
advantages, aspects, and novel features of the present disclosure,
as well as details of an exemplary embodiment thereof, will be more
fully understood from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] So that the manner in which the above recited features of
the present invention can be understood in detail, a more
particular description of the invention, briefly summarized above,
may be had by reference to embodiments, some of which are
illustrated in the appended drawings. It is to be noted, however,
that the appended drawings illustrate only typical embodiments of
this invention and are therefore not to be considered limiting of
its scope, for the invention may admit to other equally effective
embodiments.
[0010] FIG. 1A is a back of the hand view of a fabric liner,
according to embodiments of the invention;
[0011] FIG. 1B is a back of the hand view of the fabric liner of
FIG. 1A having two-dimensional injection molded components disposed
thereon, according to embodiments of the present invention;
[0012] FIG. 2A is a back of the hand view of a glove comprising the
fabric liner having two-dimensional injection molded components of
FIG. 1B, and further comprising an elastomeric coating disposed on
the fabric liner, according to embodiments of the present
invention;
[0013] FIG. 2B is a palm view of the glove of FIG. 2A showing the
elastomeric coating disposed on the fabric liner, according to
embodiments of the invention;
[0014] FIG. 3A is a cross-sectional view of a glove having
two-dimensional injection molded components disposed on the fabric
liner of FIG. 2A taken along line 3A-3A, according to embodiments
of the invention;
[0015] FIG. 3B is a cross-sectional view of a glove having
two-dimensional injection molded components and the coating
disposed on the fabric liner of FIG. 2A taken along line 3B-3B,
according to embodiments of the invention;
[0016] FIG. 4 depicts a palm view of a glove having two-dimensional
injection molded components, according to embodiments of the
invention;
[0017] FIG. 5 depicts a back hand view of a glove having a
plurality of two-dimensional, injection molded components and a
coating disposed thereon, according to embodiments of the
invention;
[0018] FIG. 6A depicts a perspective view of an "A" side of an
injection mold, according to embodiments of the invention;
[0019] FIG. 6B depicts a perspective view of a "B" side of an
injection mold, according to embodiments of the invention;
[0020] FIG. 6C depicts a perspective view of a flat former for use
in conjunction with the "A" and "B" sides of an injection mold,
according to embodiments of the invention;
[0021] FIG. 6D depicts an assembled perspective view of the "A"
side of the injection mold of FIG. 6A, the "B" side of the
injection mold of FIG. 6B, and the flat former of FIG. 6C,
according to embodiments of the invention; and
[0022] FIG. 7 depicts a process for forming a glove, according to
embodiments of the invention.
DETAILED DESCRIPTION
[0023] Embodiments of the invention comprise at least one
two-dimensional injection molded component that is molded onto a
fabric liner. The at least one two-dimensional injection molded
component is adhered, for example, to a flat planar region of a
fabric liner. Embodiments according to the invention include a
fabric liner, dressed on a flat former capable of maintaining the
planarity of the knitted fabric liner and, therefore, the
two-dimensional injection molded component(s) during the molding
process.
[0024] Embodiments according to the invention further comprise a
polymeric coating disposed on a fabric liner having at least one
two-dimensional injection molded component adhered or attached to a
planar region of the fabric liner via an injection molding process,
i.e., injection molded directly onto the fabric liner and further
comprising a polymeric, elastomeric, or latex coating disposed
thereon, for example, by a dipping process known to those in the
art, to form a hybrid glove comprising at least one two-dimensional
polymeric injection molded component and a polymeric coating
disposed on the fabric liner. Also, embodiments according to the
invention comprise at least one two-dimensional injection molded
onto a polymeric, elastomeric, or latex coating that is disposed on
a fabric liner.
[0025] FIG. 1A is a back of the hand view of a fabric liner 102,
according to embodiments of the invention. The fabric liner 102
comprises a thumb portion 110, index finger portion 112, a middle
finger portion 114, ring finger portion 116, a pinky finger portion
118, upper knuckle area 128, back of the hand portion 130, and a
cuff portion 122. A cuff ring 109 is also optionally knitted within
the fabric liner 102. Fabrication of knitted liners for gloves is
well-known in the art, for example, as described in commonly
assigned U.S. Pat. No. 7,246,509, incorporated herein by reference
in its entirety. The fabric liner 102, which may be, for example,
knitted or woven, comprises a material that is heat resistant to
facilitate attachment of the at least one two-dimensional injection
molded component (discussed further below). For example, the
melting or processing temperature for the material of which the
two-dimensional injection-molded component is comprised, may be
350.degree.-500.degree. F. and approximately the same for the
fabric liner 102 yarn. In some embodiments, irrespective of the
melting or processing temperature of the base material or resin for
the injection molded component, the material or resin will comprise
additives, such as low molecular weight additives and/or
plasticizers, which depresses the melting or processing temperature
to below 400.degree. F., so that the melting temperature of the
material of a fabric liner, e.g., the fabric liner 102, is
approximately the same or complementary with that of the material
of which the injection molded component(s) is comprised, which can
promote adhesion of the two-dimensional injection molded
component(s) to the fabric liner 102. For example, HPPE, elastane
yarns, e.g., SPANDEX.RTM., rayon, nylon 6 and/or the like have
melting points less than 400.degree. F.
[0026] The fabric liner 102 may be knitted from a monofilament or a
yarn comprising many fibers and/or filaments, such as cottons,
rayons, nylons, polyesters, and the like and may further comprise
elastomeric materials (e.g., natural or synthetic rubber), such as
SPANDEX.RTM.. The fabric liner 102 may be knitted using a main
yarn, i.e., a single layer, or with a plaited yarn knitted with the
main yarn, i.e., a multi-layer liner. Additionally, the knitted
fabric liner may comprise high performance yarns, such as
high-performance polyethylene (HPPE). In some embodiments, yarns
comprise cut resistant yarns, such as, but not limited to, steel
wire, glass fibers, carbon fibers and filaments, ultra-high
molecular weight polyethylenes, nylons, p-aramids, m-aramids,
aliphatic nylons, aromatic nylons, NOMEX.RTM., TWARON.RTM.,
KEVLAR.RTM., DYNEEMA.RTM., SPECTRA.RTM., VECTRAN.RTM., and the like
or any composite or blend of the fibers and materials. Furthermore,
fabric liners comprise, for example, a composite yarn including at
least one core yarn and at least one wrapping yarn as disclosed in
commonly-assigned U.S. Pat. No. 8,074,436, which is herein
incorporated by reference in its entirety. At least one exemplary
blended yarn according to the invention comprises a cut-resistant
composite yarn comprising 90% HPPE and 10% glass fiber, which is
gel, wet, or dry spun into a core yarn and is subsequently wrapped
with, for example, 2X-50 denier polyamide wrapping yarns (such as
nylon 66). Similarly, a blended yarn according to the invention
comprises a composite yarn that includes, for example, a 140, 150,
or 160 denier filament of 90% HPPE, which may be stretch-broken and
10% mineral fibers, e.g., basalt and/or glass fibers that are gel,
wet, or dry spun to form a core yarn and wrapped with a 2X-50
denier polyamide wrapping yarn, resulting in an, e.g., 257-289 dtex
composite yarn. In at least one embodiment according to the
invention, the HPPE fibers are the same length as the mineral
fibers, for example, 90-150 mm. Furthermore, any wrapping yarn may
be, for example, 30 denier to 140 denier or any denier
therebetween. Therefore, a core yarn or filament comprising 90%
HPPE and 10% glass fibers having, for example, 140-221 denier, and
wrapped with a 2X-40, 2X-50, 2X-60, or 2X-70 to 2X-140 denier
polyamide and/or polyester wrapping yarns are contemplated
herein.
[0027] At least one exemplary embodiment comprises one or more
flame-resistant yarns, which can be via a chemical treatment or an
inherent property of the base engineering resin, for example,
modacrylics, polybenzimidazole (PBI), polysulphonamide (PSA),
oxidized acrylics, partially oxidized acrylic, and combinations
thereof. Additionally, any fabric liner, such as the fabric liner
102, comprises yarns that melt and/or degrade at very high
temperatures, for example, oxidized polyacrylonitrile or carbon
fiber yarns, which can be especially appropriate for a glove
specified for an oil and gas worker. The fabric liner 102 may also
comprise hydrophobic and/or hydrophilic yarns, which can provide a
push-pull effect to wick moisture from one area of the glove to
another, as is disclosed in commonly-assigned U.S. Pat. No.
9,127,382, which is herein incorporated by reference in its
entirety.
[0028] The fabric liner 102 may be knitted, for example, using one
or more 13-gauge, 15-gauge, or 18-gauge needles. In general,
13-gauge needles are capable of knitting 600 denier yarns, 15-gauge
needles are capable of knitting 260-400 denier yarns, and 18-gauge
needles are capable of knitting 40-221 denier yarns, wherein a 40
denier yarn has a smaller diameter than a 221 denier yarn, which,
in turn, has a smaller diameter than a 260-400 denier yarn, etc.
Therefore, 18-gauge knitted liners comprise thinner yarns, which
are commensurately more flexible than 15-gauge knitted liners.
Similarly, 15-gauge knitted liners are thinner than 13-gauge
knitted liners. In at least one exemplary embodiment of the
invention, the fabric liner 102 is a 15 gauge knitted liner that
comprises a p-aramid yarn, such as KEVLAR.RTM., a polyamide, such
as nylon 6 or nylon 66, and an elastane yarn, such as
SPANDEX.RTM..
[0029] FIG. 1B is a back of the hand view of the fabric liner 102
of FIG. 1A having two-dimensional injection molded components
disposed thereon, according to embodiments of the present
invention. The fabric liner 102 comprises two-dimensional injection
molded components 140 and 142 on the index finger 112 and the upper
knuckle area 128 respectively. The two-dimensional injection molded
components 140 and 142 comprise polymeric resins injected,
transferred, or cast onto the fabric liner 102 via an injection
molding process or, in some embodiments, cast, transfer molded, or
compression molded onto the fabric liner 102. The two-dimensional
injection molded component 140, for example, is disposed as a
bumper for impact resistance of the index finger 112 as described
above on glove 160. The two-dimensional injection molded component
140 comprises a first end 202 and a second end 204 with one or more
middle portions 206 disposed therebetween. Disposed between each
middle portion 206 and an adjacent middle portion 206 are windows
as discussed more fully below. The two-dimensional injection molded
component 142 comprises lateral holes 150 and 152 on a first
portion 146 and a second portion 148 respectively and a plurality
of longitudinal holes 154 on a third portion 147 disposed
therebetween, as described more fully below.
[0030] The at least one injection molded component may be
fabricated from a polymeric material such as thermoplastic
vulcanizates, thermoplastic rubbers, thermoplastic elastomers, and
the like, and/or blends and/or alloys thereof. Some embodiments
according to the invention include injection molded components,
such as two dimensional injection molded components, that are
non-Newtonian, i.e., the material of which the injection molded
components are comprised are shear-thinning or shear-thickening
materials. For example, a dimethyl siloxane hydroxyterminated
polymer, sold by Dow Corning Inc. or any of several shear
thickening polymers sold by D3O of London, UK, all of which can be
injection molded, for example, onto a fabric liner or other
substrate. In some embodiments, the injection molded components
comprise thermoplastic polyolefins, such as polyethylene,
polypropylene, and the like. In some embodiments, the
two-dimensional injection molded components comprise engineering
resins, such as aliphatic or aromatic nylons,
acrylonitrile-butadiene-styrene, nitrile-butadiene rubbers, vinyls,
polyesters, saturated styrene block copolymer thermoplastic
elastomers (SEBS), polyurethanes, thermoplastic polyurethane
alloys, modified-styrenics, styrene-butadiene-styrene, and
polybutylene terephthalate resins, other thermoplastics, and/or
blends and/or alloys thereof. In some exemplary embodiments, the
injection molded components comprise silicon resins, which can be
applied via liquid injection molding, or poly(vinyl chloride)
plastisols, which can be applied by injection molding, compression
molding, transfer molding, and/or casting. Silicones, which are
generally soft, provide excellent dimensional stability and
chemical resistance over a wide range of temperatures while
providing impact resistance. Additionally, the viscosity of
silicones, approximately 1500-2500 centipoises, and low processing
pressures, e.g., 500-5000 psi, helps prevent strikethrough of the
silicone through the fabric liner, thereby providing a larger
processing window and, in turn, more comfortable gloves. It is to
be understood that any of the foregoing polymeric materials can be
adhered to a fabric liner without using glues, epoxies, or
adhesives, or via sewing or stitching, i.e., can be injection
molded, transfer molded, compression molded, and or applied via
casting methods to a fabric liner or a polymeric coating on a
fabric liner.
[0031] In some embodiments, the rubbers, elastomers, vulcanizates,
olefins, and other thermoplastic resins, etc., of which the
two-dimensional injection molded components are comprised, further
comprise fillers and/or reinforcements, such as silica, metallic
and ceramic powders, glass-fibers, and the like to provide grip,
texture, strength, and other physical properties. Such fillers and
reinforcements can, for example, comprise between 1-60% of a
material by weight, tailored to end properties for various
applications. Other additives are added as needed, such as for
flame- and arc-retardance, adhesion promoters, ultra-violet
stabilization, hardness, pigments, and the like. Also, any
two-dimensional injection molded component may be foamed, using
chemical blowing agents and/or physical blowing processes, for
example, MuCELL.RTM. technology as sold by Trexel, Inc.
[0032] FIG. 2A is a back of the hand view of a glove 160 comprising
the fabric liner 102 having two-dimensional injection molded
components 140 and 142 of FIG. 1B, and further comprising an
elastomeric coating 162 disposed on the fabric liner 102, according
to embodiments of the present invention. The coating 162 comprises
a palm dip as shown. The palm dip of the coating 162 is
characterized in that it covers the crotches between the fingers
112, 114, 116, and 118 and the thumb 110. As can be seen, the
coating 162 optionally extends to a border 207 formed by the
coating 162 and an edge of the two dimensional injection component
140. As discussed more fully below, a two-dimensional injection
molded component may be molded onto other areas of the glove 160,
such as any finger, thumb, and/or palm. Also, embodiments according
to the invention comprise dips other than a palm dip, e.g., a
knuckle dip, a 3/4 dip, or a full dip, etc. In general, the less
the fabric liner is covered by a coating or the fewer
two-dimensional injection molded component(s), the more ventilated
and flexible the glove formed therewith will be.
[0033] FIG. 2B is a palm view of the glove 160 of FIG. 2A showing
the elastomeric coating 162 disposed on the fabric liner 102,
according to embodiments of the invention. For a palm dip, the
coating 162 covers the thumb 110 and the fingers 112, 114, 116, and
118, as well as part of the cuff 122, terminating at a palm-cuff
border 164. The elastomeric coating 162 comprises, for example, an
elastomeric, polymeric, or latex composition, such as a natural
rubber, synthetic polyisoprene composition, polyurethane, or the
like. The elastomeric composition 162, for at least one exemplary
embodiment according to the invention, comprises a
nitrile-butadiene composition, such as at least one of KRATON.RTM.
nitrile-butadiene resins, which have melting points between
approximately 400 to 490.degree. F. Also, at least one
two-dimensional injection molded component may also be disposed on
the cuff 122 for use as, for example, a pull tab 166, a
donning/doffing aid, additional protection, decoration, indicia of
the type of glove, or to depict a logo or trademark.
[0034] The glove 160 therefore has excellent impact-resistant
properties from the two-dimensional injection molded components 140
and 142, on either or both of the palm side region and back hand
side region as well as being chemical resistant because of the
coating 162 without sacrificing the dexterity and flexibility of
the glove because the coating 162 is not as stiff as would be a
three-dimensional injection molded component that would traverse an
area in which a glove needs to flex, i.e., from a knuckle on the
back hand region to the corresponding area on the palm side of a
finger or palm. Furthermore, gloves having two-dimensional
injection molded components that need to flex in at least one
direction, i.e., laterally and/or longitudinally, are inherently
more flexible, as compared with gloves having three-dimensional
injection molded components, which typically need to flex both
laterally and longitudinally at the same time.
[0035] The two-dimensional injection molded components 140 and 142
protect the wearer from impacts using a resilient material such as
flexible thermoplastic. Also two-dimensional injection molded
components 140 and 142 are positioned in high wear regions of the
glove 160 to provide reinforcement and extend the life of the glove
160. Also, by leaving the back of the glove 160 uncoated (as with a
palm dip), the glove 160 is flexible and remains ventilated.
Workers and all other glove wearers, including construction
workers, industrial workers, and other laborers may find such a
glove useful in protecting their hands as well as for comfort. At
least one exemplary embodiment according to the invention comprises
a two dimensional injection molded component injection molded
directly onto the coating 162 (not shown). Adhesion of the
two-dimensional injection molded components to the coating 162,
such as the two-dimensional injection molded components 140 and
142, comprise one or more primers, for example, a flexible primer.
Primers include chemical primers for adhering, for example,
polyolefins to nitrile-butadiene, polyurethane, polychloroprene, or
any combination thereof and/or two-dimensional nitrile-butadiene,
polyurethane, polychloroprene injection molded components to
nitrile-butadiene, polyurethane, polychloroprene coatings, or any
combination thereof as are known to those in the art.
[0036] Additionally, embodiments of the invention comprise adhering
two-dimensional injection molded components to a polymeric,
elastomeric, or latex coating by partially curing the coating and
subsequently directly injection molding the two-dimensional
injection molded components thereon. Also, some embodiments
comprise a polymeric, elastomeric, or latex material for the
coating having a melting point or processing temperature that is
complementary with the temperature of the TPRs, TPVs, or TPEs
injected into the mold that form the two-dimensional injection
molded component discussed herein. Complementary in this context
indicates that melting and/or processing temperatures for materials
comprising injection molded components and coatings are
approximately the same, which is defined as being within
approximately 50-100.degree. F. of each other for the purpose that
adhesion is promoted without burning or destroying features.
Without intending to be bound by theory, it is believed that at
least some of the fibers and/or filaments comprising the knitted
fabric liner is impregnated with the polymer of the injection
molded component, promoting a strong adhesion between the injection
molded component and the knitted fabric liner. The combination of
appropriate melting or processing temperatures, injection, clamp,
and mold cavity pressures, generally, low pressure, in some
embodiments, less than 1000 psi, and in some embodiments, less than
500 psi, and inherent and processing viscosities of the engineered
materials, along with the tightness of the knit structure and a
complementary function regarding the melt temperature of the
knitted fabric liner and the injection molded component, allows the
design of a glove having optimum flexibility, dexterity, and
tactility balanced with other desirable protective properties, such
as grip, abrasion-, impact-, flash-, and arc-resistance, and the
like. In other words, at least one knitted liner, e.g., the knitted
liner 102, comprises fibers or filaments or monofilaments or yarns
or core yarns or wrapping yarns, or the like, having a melting
point that is complementary with the melting point of the injection
molded component(s) adhered thereto to promote adhesion, according
to at least one exemplary embodiment of the invention.
[0037] FIG. 3A is a cross-sectional view of the glove 160 having
the two-dimensional injection molded component 140 disposed on the
fabric liner 102 of FIG. 2A taken along line 3A-3A, according to
embodiments of the invention. The two-dimensional injection molded
component 140, for example, is disposed as a bumper for impact
resistance of the index finger 112 as described above on the glove
160. The two-dimensional injection molded component 140 comprises a
first end 202 and a second end 204 with one or more middle portions
206 disposed therebetween. Disposed between each middle portion 206
and an adjacent middle portion 206 are windows 208, which provide
flexibility. It is to be noted that the two-dimensional injection
molded component 140, as well as all other two-dimensional
injection molded components, has a flat side 220. The flat side 220
is adhered to, in this example, the finger 112 of the fabric liner
102 while the liner is on a flat former (discussed below) to create
a planar region on the fabric liner 102 for adherence to
two-dimensional injection molded component 140. The two-dimensional
injection molded component 140 is molded flat because the former to
which the fabric liner 102 is dressed, as discussed in more detail
below, is flat.
[0038] In practice, any two-dimensional injection molded component
disclosed herein, and not limited to 140, 142 may have a plurality
of middle portions 206, which are spaced apart to define at least
one window 208 disposed therebetween, and the windows 208, as
shown, may comprise different widths. Additionally, the first end
202, the second end 204, and the middle portion 206 may further
comprise tapered (or chamfered) surfaces 210, which will further
promote impact resistance because the tapered surfaces 210 promote
any impact to be a glancing impact. To enhance usefulness, such as
for gripping, tactility, flexibility, dexterity, impact-resistance,
abrasion-resistance, as well as for comfort, the two-dimensional
injection-molded components 140 and 142, and others (not shown) may
be contoured to provide additional application specific
functionality as described below.
[0039] The two-dimensional injection molded components may have
varied thicknesses across a cross-section of one area, for example,
a finger area, knuckle area, palm area, and the like. Additionally,
the two-dimensional injection molded components may have one or
more surface textures (i.e., Electric Discharge Machining (EDM)
finishes 1-9 or SPI finishes A-1 through D-3), and the like.
Rougher finishes enhance gripping properties (for example, for
two-dimensional injection molded components molded to a palm side
of a glove) while smoother finishes allow glancing impacts to
deflect more easily and therefore absorb less energy, i.e., better
impact resistance, promoting safety. At least one exemplary
embodiment according to the invention comprises a surface texture
comprising multi-faceted cavities/indentations, as disclosed in
commonly assigned U.S. Pat. Nos. 7,771,644 and/or 8,522,363, each
of which is incorporated herein by reference in its entirety.
[0040] Different thicknesses and different topographies, as
discussed further below, of the two-dimensional injection molded
components, such as the two-dimensional injection molded components
140 and 142 are also contemplated herein for any embodiment in
accordance with the invention, such as ranging from approximately
0.010 to 0.500 of an inch (0.025-1.25 cm), which are designed for
application-specific purposes. Any two-dimensional injection molded
component according to embodiments of the invention may have a
varied thickness or for embodiments having more than one injection
molded component, even where one component has a non-varied
thickness, other components may have different thicknesses. For
example, a cut resistant fabric liner may have further protection
provided by injection-molded components located on an index finger
and thumb for a carpenter's glove; for a mason's glove, the finger
tips may have two dimensional injection molded components for
abrasion resistance, impact resistance, and gripping properties;
while for a sheet metal worker's glove, only the palm and finger
tips may have the two-dimensional injection-molded components,
further comprising two-dimensional injection molded in the finger
crotches to protect against cuts.
[0041] The two-dimensional injection molded components 140,142 (as
well as any other two-dimensional injection molded component
described herein) may have a specific composition commensurate with
a particular application. For example, particles may be added to
the elastomeric material, of which the two-dimensional injection
molded component 140 is comprised, to facilitate abrasion
resistance, surface grip, antimicrobial properties, enhanced
anti-vibration characteristics, enhanced impact characteristics,
and/or enhanced flexibility or visibility. The addition of such
materials to achieve these characteristics may be added in various
amounts to tailor the desired characteristic to the application of
the glove. To enhance abrasion resistance the elastomeric material
of the component may be selected for hardness or inorganic
additives such as boron nitride may be mixed in the elastomeric
material. Additives for flame resistance, such as for a welder's
glove, such as metal hydroxides and/or fumed silicas, may be
compounded into the elastomeric material(s).
[0042] The hybrid gloves, i.e., gloves comprising a knitted liner,
a polymeric coating, and at least one injection molded component
discussed herein may be customized to provide only the
characteristics and properties for specific service applications.
For example, a glove for an oil and gas worker requires exceptional
grip under oily conditions, cut-resistance, impact-resistance,
flame-resistance as well as dexterity, a glove for an electrician
requires high dexterity and puncture-resistance in the fingertips
and breathability (so that moisture and sweat are not an issue),
and a glove for a carpenter requires thin fingertips for dexterity
and impact-resistance features to protect the back of hands. A
glove for a mason requires abrasion resistance and superior grip
for fingertips, as well as impact-resistance on both the palm and
backhand area, a glove for a plumber requires grip, breathability,
and liquid-resistance, and a glove for a laborer requires
durability, impact-resistance, breathability, all while being
appropriate for winter and summer use. Gloves for more general
uses, i.e., for use for many different tasks, e.g., digging,
welding, using hand tools, etc., e.g., an HVAC worker, are also
contemplated according to embodiments of the invention.
[0043] For example, and not by way of limitation, a glove for use
by masons can comprise a composition such as the following. At
least one exemplary embodiment according to the invention comprises
two dimensional injection molded components that include resins
such as styrene-ethylene/butylene-styrene (SEBS) and/or
styrene-ethylene/propylene-styrene (SEPS). At least one suitable
saturated styrene block copolymer (SEBS), providing good abrasion
resistance and hardness properties (for example, a Shore A
durometer hardness of 25), is grade RTP 2799SX 127556 A TPE, sold
by the RTP Co. Additives for SEBS or SEPS can comprise sand,
silica, ultraviolet additives, pigments, and the like. In some
embodiments, the TPE grade by weight is approximately 95 percent or
more. A material for the injection molded components for an oil and
gas glove can comprise thermoplastic vulcanizate elastomer, such as
grade RTP 2899 X 128802 B by the RTP Co. and further comprise flame
retardance and ultraviolet stabilizers. Embodiments for an oil and
gas glove may comprise between 80-100 percent by weight material
grade RTP 2099 E X 117792 C, a thermoplastic urethane alloy (TPU),
a flame retardant, and an adhesion promoter, increasing the
adherence of the material to, for instance, polycarbonate, ABS, and
polyesters. In at least one exemplary embodiment of the invention,
the 2D injection molded components comprise a TPU blended with
TPE-SEBS resin and/or a TPE supplied by Allod Werkstoff GmbH &
Co.
[0044] To enhance surface grip, the surface of the two-dimensional
injection molded components may be roughened using a chemical
treatment, the mold for the injection molded component may emboss a
surface texture onto the component (EDM finishes, as described
above), particles may be embedded in the surface (e.g., sand,
silica) or the like for grip and durability.
[0045] To enhance antimicrobial properties, antimicrobial materials
such as iodine, silver, zinc, silane quaternary ammonia salt, or
the like may be incorporated into the two-dimensional
injection-molded component or in the knitted fabric liner. Such
materials neutralize or kill any microbes that contact the surface
of the component and/or are active for biostatic properties.
Antimicrobial gloves may be used by food/health workers and/or
medical personnel.
[0046] To enhance anti-vibration characteristics, the surface of
the glove 160 must mitigate mechanical stresses that physically
deform the glove material. Such deformation may arise from a motor
(continuous vibration), an impact (single event vibration),
electrical (piezo-electric effect), water flow, and the like. Upon
deformation, both longitudinal and shear waves components (a
mechanical wave) is imparted into the glove surface and propagates
thru the glove material. The wave continues propagating until
attenuated by imperfections and features in the glove material.
Imperfections and features selected to attenuate waves may include
porosity, reinforcing materials, laminations, differing material
phases, and the like.
[0047] In other applications for the glove 160, impact resistance
may be selectively enhanced by utilizing zonal application of
thickened regions within the injection molded component, or using
particular materials for the component such as shear thickening
fluids as part of the component. As such, a glove may be designed
to improve hand protection for users.
[0048] Also, at least one finger of the fabric liner 102 may
comprise a conductive yarn that contacts the finger of a wearer. If
the elastomeric composition of which the coating 162 is comprised
has a conductive material admixed therein, a user can operate a
capacitive touchscreen without removing the glove 160. Similarly,
if at least one two-dimensional injection molded component disposed
on at least one palm side fingertip of an electrically conductive
fabric liner 102, i.e., an index finger, is comprised of a material
doped with an electrically conductive material, a user could
operate a capacitive touchscreen with removing the glove. In other
embodiments, the injection-molded components comprise elastomers or
other polymers that are fire- and/or heat resistant or
arc-resistant. Such gloves find use with oil and gas workers,
chefs, first responders, electricians, welders or any application
where heated or electrically enabled articles are moved or
touched.
[0049] FIG. 3B is a cross-sectional view of the glove 160 having
the two-dimensional injection molded component 142 and the coating
162 disposed on the fabric liner 102 of FIG. 2A taken along line
3B-3B, according to embodiments of the invention. The
two-dimensional injection molded component 142 comprises a first
portion 146, a second portion 148, and a third portion 147 disposed
therebetween. As shown, the first portion 146 comprises a through
hole 150, which traverses the first portion 146 laterally. The
second portion 148 comprises a blind hole 152, which traverses the
second portion 148 laterally. The third portion 147 comprises three
through holes 154, traversing the third portion 147 longitudinally.
In practice, the glove 160, as any other glove according to
embodiments of the invention, may comprise a plurality of the
longitudinal through holes 154, the lateral blind hole 152, and the
lateral through hole 150 on any portion of any two-dimensional
injection molded component or, for example, the third portion 147
may comprise one, two, three, or any reasonable number of through
holes or blind holes, or being oriented in any direction, laterally
or longitudinally. Some embodiments may comprise one or more
two-dimensional injection molded components in which the through
holes criss-cross for additional flexibility.
[0050] FIG. 4 depicts a palm view of a glove 300 having
two-dimensional injection molded components 304 and 306, according
to embodiments of the invention. The glove 300 comprises a fabric
liner 302, e.g., knitted or woven, and at least one injection
molded component 304. The fabric liner 302 comprises a thumb 310,
an index finger 312, a middle finger 314, a ring finger 316, a
little finger 318, and a cuff 322. As shown, the glove 300 has a
first injection molded component 304, which ranges, for example,
from 0.010 to 0.500 inches (0.01-0.5 cm) in thickness, and covers
the palm of the fabric liner 302 extending to an upper palm area
330, a lower palm area 332, and a portion of the thumb 310 and is,
as shown, one contiguous injection molded component. Additionally,
a second injection molded component 306 covers a lower right palm
area 334 and is not contiguous with the two-dimensional injection
molded component 304. A thinner two-dimensional injection molded
component, having a textured surface (not shown), provides
additional gripping capability. The glove 300, having two or more
two-dimensional injection molded components 304, 306, which are
separated from each other, are inherently more flexible. Also, by
incorporating molded components having varied thicknesses onto a
fabric liner, more impact resistance, flexibility, dexterity, and
tactility can be imparted only where needed. For example, the glove
300 comprises two-dimensional injection molded components disposed
as a plurality of finger grips 328, ranging in thickness from, for
example, 0.050 to 0.100 inches (0.125-0.25 cm) and may be textured
for enhanced grip on the palm side of the index finger 312.
Furthermore, as shown on the ring finger 316, the finger grips 328
may have a bridge 330 (which may be thinner than the finger grips
328 for added flexibility). The bridge 330, because it joins the
finger grips 328, aids in simplifying the runner system used to
injection polymeric materials onto the fabric liner 302 (as
discussed herein) as is known to those of skill in the art.
[0051] FIG. 5 depicts a back hand view of a glove 400 having a
plurality of two-dimensional, injection molded components 404, 406,
and 442, and a coating 462 disposed thereon, according to
embodiments of the invention. The glove 400 is at least one
exemplary embodiment of the invention and comprises a fabric liner
402 in the shape of a glove having fingers 312, 314, 316, and 318
and a thumb 310 and further comprises a two-dimensional injection
molded component 404, having a thickness ranging from approximately
0.050-0.500 inches (0.125-1.25 cm). The two dimensional injection
molded component 404 comprises a plurality of longitudinal slits
408 and a plurality of lateral slits 410. The fabric liner 402
further comprises a cuff portion 422, a cuff ring 426, and a lower
right portion 434, which comprises a two-dimensional injection
molded component 406 having a longitudinal slit 410, promoting
flexibility. At least one exemplary embodiment according to the
invention comprises a glove 400 having the thumb 310 in a bent
configuration. Furthermore, the thumb 310 may comprise a plurality
of injection molded components molded thereon. By way of
explanation, where the thumb 310 is in a bent configuration, it
embodies two planar areas, i.e., on each side of a knuckle, either
or both of which could have an injection molded component molded
thereon. For example, two-dimensional molded components, such as
the finger grips 328, may be molded onto the palm side or the back
hand side of the thumb 310.
[0052] Specifically, FIG. 6A depicts a side view of a
two-dimensional injection molded component 500 having holes 510
disposed on the fabric liner 102, according to embodiments of the
invention. The two-dimensional injection molded component 500 also
comprises a flat side 220, which is the side that is adhered to a
planar region of the fabric liner 102, by an injection molding
process. Where a two-dimensional injection molded component, e.g.,
the two-dimensional injection molded component 500, is molded onto
the knitted fabric liner 102 directly, polymeric molecules of the
two-dimensional injection molded component penetrate and become
intertwined on and within interstices of the knitted fabric liner
102, promoting its adherence thereto, such that the two-dimensional
injection molded component 500 could not be removed from the
knitted fabric liner 102 without destroying the knitted fabric
liner 102.
[0053] As shown, the two-dimensional injection molded component 500
comprises three holes 510 that traverse the two-dimensional
injection molded component 500 in a lateral manner. In practice,
any reasonable number of holes 510 may be molded into the
two-dimensional injection molded component 500, for example, arrays
of holes 510 stacked or staggered in networks, having different
sizes, and other properties. Moreover, the two-dimensional
injection molded component 500 may have one or more holes 510
comprising through holes, blind holes, or combinations of through
holes and blind holes.
[0054] The plurality of holes 510 disposed within the
two-dimensional injection molded component 500 may be formed by
cams of a mold having core pins (not shown) as are known to those
in the art. Additionally, the core pins may be attached to cams
that are actuated by angled cam fingers that slide the core pins
into and out of the injection mold as the injection mold is opened
and closed during typical injection molding processes, as is
discussed in U.S. Pat. No. 5,234,329, incorporated by reference in
its entirety and Plastics Engineering Handbook, pp. 190-192,
5.sup.th Ed., Michael L. Berins, .COPYRGT.1991, the technology of
which at pages 190-192 is incorporated herein by reference.
[0055] The two-dimensional injection molded component 500
comprising the holes 510 flex more easily than injection molded
components having no holes. Also, the holes 510 in the
two-dimensional injection molded component 500 will partially
"collapse" (and return to their original shape) during an impact
event, distributing the energy of the impact and resulting in a
more impact resistant glove. Furthermore, by providing holes that
run along one or more axes of two-dimensional injection molded
components and/or molding channels of differing sizes, gloves
having anisotropic physical properties can be balanced and
therefore designed for specific applications, i.e., more or less
flexibility in specific regions of a glove, more or less impact
resistance, and the like.
[0056] FIG. 6A depicts a perspective view of an "A" side 602 of an
injection mold 600; FIG. 6B depicts a perspective view of a "B"
side 622 of an injection mold 600; FIG. 6C depicts a perspective
view of a flat former 644 for use in conjunction with the "A" and
"B" sides of the injection mold 600; and FIG. 6D depicts an
assembled perspective view of the "A" side 602 of the injection
mold 600 of FIG. 6A, the "B" side 622 of the injection mold 600 of
FIG. 6B, and the flat former 644 of FIG. 6C, to create a glove
having two-dimensional injection components injection molded on a
fabric liner, according to embodiments of the invention.
[0057] Specifically, FIG. 6A depicts a perspective view of an "A"
side 602 of an injection mold 600, according to embodiments of the
invention. The "A" side 602 comprises cavities 604, 606, 608, 610,
and 620, correspond to similar cavities on a "B" side as discussed
below. The cavity 610 further comprises cores 612 and 614, which
can be used to mold features such as the two-dimensional injection
molded components discussed above, for example, the first end 202,
the second end 204 and the middle portion 206 discussed above. The
cores 612 and 614 are the "negative" of the molded features of the
two-dimensional injection molded components. Also, the "A" side 602
further comprises a cavity 616, which can be used to mold a
two-dimensional injection molded component on, for example, the
back hand area of a glove. The "A" side 602 also comprises half of
a sprue bushing 646a (for receiving the nozzle of a barrel of an
injection molding machine, not shown) and guide holes 660, which
are capable of receiving guide pins located on the "B" side 622,
when the injection mold 600 is closed, as discussed below.
[0058] FIG. 6B depicts a perspective view of a "B" side 622 of an
injection mold 600, according to embodiments of the invention. The
"B" side 622 comprises cavities 624, 626, 628, 630, and 632 which
correspond to cavities 604, 606, 608, 610, and 620 respectively on
the "A" side, as discussed above. The cavities 624, 626, 628, 630,
and 632 can further comprise cores, similar to the cores 612, 614,
or cavity 616, as discussed above, which would dispose a
two-dimensional injection molded component on the palm side of a
glove. The "B" side 622 also comprises half of a sprue bushing
646b, which, when the "A" side 602 and the "B" side 622 are
assembled, form a sprue bushing, discussed below. Also, the "B"
side 622 comprises guide pins 662, which, when the "A" side 602 and
the "B" side 622 are assembled, are received into the guide holes
660, discussed above.
[0059] FIG. 6C depicts a perspective view of a flat former 644 for
use in conjunction with the "A" side 602 and the "B side 622 of the
injection mold 600, according to embodiments of the invention. The
flat former 644 is in the general shape of a hand and comprises a
little finger portion 634 having an end 674, a ring finger portion
636 having an end 676, a middle finger portion 638 having an end
678, an index finger portion 640 having an end 680, a thumb portion
642, and a handle 645. The flat former 644 comprises a palm side
625 as depicted and also comprises a corresponding backhand side
627. Embodiments according to the invention include a flat former
644 wherein at least one area, e.g., the little finger portion 634,
the end 674, the ring finger portion 636, the end 676, the middle
finger portion 638, the end 678, the index finger portion 640, the
end 680, the thumb portion 642, the palm side 625 or the backhand
side 627 is flat such that the flat former 644 can maintain the
planarity of the knitted fabric liner during the injection molding
of a two-dimensional molded component to a respective area of a
glove.
[0060] It is to be noted that at least one of the little finger
portion 634, the ring finger portion 636, the middle finger portion
638, the index finger portion 640, a thumb portion 642 palm side
625 and the corresponding backhand side 627 of the flat former 644
is flat. A two-dimensional injection molded component is to be
molded to a fabric liner on a flat side of the flat former 644. In
other words, the flat former 644 comprises a flat surface on the
side to which the two-dimensional injection molded component will
be molded, whether on the palm side 625 or the back hand side 627
because the flat former 644 maintains the flatness, i.e., planar
region of the fabric liner during molding in the region in which
the two-dimensional component will be molded to the fabric liner.
If a fabric liner will have two-dimensional injection molded
components molded on both the palm side 625 and the back hand side,
the flat former 644 will be flat on each of the palm side 625 and
the back hand side 627. Because the flat former 644 corresponds to
an area on a knitted liner on which the two-dimensional injection
molded components, will be disposed flat on a surface that adheres
the two-dimensional injection molded components to the fabric liner
dressed on the flat former 644 and, accordingly, the
two-dimensional injection molded components do not traverse any
edges, i.e., remain on either a palm side or a backhand side of the
fabric liner. The flat former 644 is typically placed in an
injection mold in a manner in which a longitudinal axis, i.e., an
axis running from a cuff to a fingertip, was parallel with the
parting line of the injection mold. In other words, if the fabric
liner were cut in half along the longitudinal axis, one half would
comprise part of each finger, thumb, and cuff of the back hand
while the other half would comprise part of each finger, thumb, and
cuff of the palm side. A parting line of an injection mold is
defined as the point at which two halves of an injection mold meet,
and, therefore, one half of the fabric liner discussed above would
be in a first half of the injection mold and the other half of the
fabric liner 102 would be in a second half of the injection mold.
Embodiments according to the invention comprise at least one
two-dimensional injection molded component, as discussed herein,
that is molded onto a fabric liner 102, and optionally disposed on
one or both sides of the injection mold parting line.
[0061] FIG. 6D depicts an assembled perspective view of the "A"
side 602 of the injection mold 600 of FIG. 6A, the "B" side 622 of
the injection mold 600 of FIG. 6B, and the flat former 644 of FIG.
6C, according to embodiments of the invention. As shown, the "A"
side 602 further comprises a first half of a sprue bushing 646
(along the parting line of the injection mold 600) and a second
half of a sprue bushing 630 (located solely on the "B" side 622).
Any injection mold can comprise one or multiple sprue bushings so
that a thermoplastic or other material can be injected into various
cavities of the mold. The sprue bushing 630 is capable of mating
with a nozzle 652, that is part of an injection molding barrel 656
that contains a plasticating screw 654 for melting and injecting a
plastic material, which when injected into an injection mold is
delivered via a runner and gate system (not shown), as is known to
those in the art, to at least one of the cavities 604, 606, 608,
610, 620, 624, 626, 628, 630, and 632 and becomes a two-dimensional
injection molded component, as discussed above. Also, the "A" side
602 comprises four mounting holes 666. In practice, the "A" side
602 may comprise any reasonable number of mounting holes for
mounting the injection mold 600 to an injection molding machine.
The "B" side 622 similarly comprises mounting holes (not shown).
Also, as is known to those in the art, an additional mounting plate
(not shown) having mounting holes may be assembled with each of the
"A" side 602 and "B" side 622.
[0062] As shown, the flat former 644 extends from the "A" side 602
and the "B" side 622 and can be seen when the injection mold 600 is
assembled and closed. In practice, the design of both the "A" side
602 and the "B" side 622 could be modified to enclose the ends 674,
676, 678, and 680 within the "A" side 602 and the "B" side 622, as
is known to one in the art.
[0063] To apply two-dimensional injection-molded components to the
knitted liner 102, the knitted liner 102 is dressed on the flat
former 644. The flat former 644, as shown and described above with
respect to FIG. 6C, is typically made of a metal, such as steel or
aluminum and is in the general shape of a hand, although the mold
may comprise any suitable material, such as aluminum, ceramics,
plastics (acrylics, epoxies, or other high-melting temperature
resins), wood, or the like. The flat former 644 having the knitted
liner 102 (or a knitted liner having a coating disposed thereon)
dressed thereon, is placed into the injection mold 600, as is known
in the injection molding industry, i.e., the "cavity" of a mold,
having an internal formed surface that inversely matches the
positioning and contour of the components. Accordingly, the flat
former 644 having the fabric liner 102 dressed thereon is a "core"
part of the injection mold 600. By using an injection molding
process, the two-dimensional injection molded components can be
positioned at any location on the knitted liner, i.e., wherever a
cavity, as described above, comprises a cavity having a desired
shape, depth, width, etc. And, as discussed above, two-dimensional
components are directly formed on a planar region of the fabric
liner 102 or planar region of the coating disposed on the fabric
liner 102, which is maintained by the flat former 644, as discussed
above.
[0064] The injection molding process comprises injecting molten
polymeric materials, such as TPRs, TPVs, or TPEs, under pressure
into the injection mold 600. Embodiments according to the invention
include dressing the knitted fabric liner 102 on the flat former
644, as discussed above, such that the TPRs, TPVs, or TPEs fills
the gaps between the knitted liner 602 and a surface of at least
one of the "A" side 602 or "B" side 622 of the injection mold 600.
Upon cooling, the injection mold 600 is opened and the flat former
644, with the knitted liner 102 now having the two-dimensional
injection-molded components disposed onto the knitted liner 102,
forming a glove having at least one two-dimensional injection
molded component, is removed from the injection mold 600. The glove
can now be stripped from the flat former 644, and the flat former
644 can then have another knitted liner dressed thereon and be used
in a subsequent injection molding cycle.
[0065] Typical injection molds comprise two mold halves, runner
systems, runner plates, knock-out plates, and other componentry as
is known to those in the art. Also, injection molds according to
the invention may further include slides, cams, cam fingers, and
the like to provide molded features within the injection molded
components of the gloves, such as undercuts, cantilevers, threads,
channels, and similar profiles, textures, and the like, which would
otherwise be difficult to eject from the mold without damaging the
molded features, i.e., the two-dimensional injection molded
components.
[0066] FIG. 7 depicts a process 700 for forming a glove, according
to embodiments of the invention. The process 700 starts at step 702
and proceeds to step 704, at which point a polymeric material is
injected onto a planar region of a fabric liner dressed on a flat
former (as discussed herein) displaced inside an injection mold.
The injection mold comprises cavities, as is known to those in the
art, in the shape of any two-dimensional injection molded component
as discussed herein.
[0067] At step 706, the flat former, having the fabric liner with
at least one two-dimensional injection molded component disposed
thereon, is removed from the injection mold and delivered and/or
dipped into a bath containing an elastomeric composition, such as a
synthetic polyisoprene, a natural rubber, an acrylonitrile
composition and/or the like. As discussed above, in some
embodiments according to the invention, the two-dimensional
injection molded components may be molded onto the fabric liner
before the dipping step. Also, as discussed above, in some
embodiments according to the invention, the two-dimensional
injection molded components may be molded directly onto the coating
disposed onto the fabric liner. The coating disposed thereon may
have a primer, such as a chemical primer, disposed thereon before
the injection molding step. Alternately, and/or additionally,
embodiments of the invention include wherein the coating is
partially cured for example, from 60-80.degree. C. for 10-20
minutes before the two-dimensional injection molded components are
molded directly onto the coating. In at least one exemplary
embodiment of the invention, the elastomeric composition comprises
a nitrile-butadiene material and/or a sandy nitrile-butadiene
material.
[0068] At step 708, the fabric liner having the at least one
two-dimensional injection molded component disposed thereon is
dipped into the bath, disposing an elastomeric coating on the
fabric liner (which may additionally cover the two dimensional
injection molded components). At step 710, the coating is cured,
such as by delivering the former having the at least one
two-dimensional injection molded component and coating disposed on
the fabric liner to an oven at an appropriate temperature as is
known to those in the art, for example, from 80-120.degree. C. for
30-50 minutes. At step 712, the process 700 ends.
[0069] With the materials for fabric liners, injection molded
components, and dipped coatings discussed herein in view, a custom
solution for each of the service specific applications is possible.
Embodiments according to the invention further include disposing
one or more two-dimensional injection molded components onto any of
the application specific gloves in commonly assigned patent
application, US Publ. No. 2010/0275342, which is herein
incorporated by reference in its entirety.
[0070] As discussed below, the polymeric, elastomeric or latex used
to make coatings disposed on the fabric liner comprises
polyisoprene, nitrile-butadiene, polyurethane, polychloroprene, or
any combination thereof. At least one exemplary embodiment includes
an elastomeric coating comprised of highly-carboxylated
acrylonitrile-butadiene rubber (NBR). Moreover, any polymeric,
elastomeric, or latex coating may be foamed as is known to those in
the art. Open-celled foams, generally comprising between 15-60% by
volumetric air content, comprise interconnected networks of cells
and are therefore breathable foams, allowing, for example, moisture
and perspiration to escape from inside a glove formed
therewith.
[0071] In various embodiments, a fabric liner may be knitted using
conventional knitting equipment and processes or, alternatively, a
Knitted Variable Stitch Design (KVSD) technology as disclosed in
commonly assigned U.S. Pat. No. 6,962,064, incorporated herein by
reference in its entirety. Also, the injection-molded components
may be applied for aesthetic purposes to add contour or color to a
glove or a labeling or logo.
[0072] While the foregoing is directed to embodiments of the
present invention, other and further embodiments of the invention
may be devised without departing from the basic scope thereof, and
the scope thereof is determined by the claims that follow.
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