U.S. patent application number 15/954789 was filed with the patent office on 2018-10-18 for protective glove with knitted palm covering.
The applicant listed for this patent is Warrior Sports, Inc.. Invention is credited to David K. Morrow.
Application Number | 20180296900 15/954789 |
Document ID | / |
Family ID | 63791908 |
Filed Date | 2018-10-18 |
United States Patent
Application |
20180296900 |
Kind Code |
A1 |
Morrow; David K. |
October 18, 2018 |
PROTECTIVE GLOVE WITH KNITTED PALM COVERING
Abstract
A protective glove includes a padded back portion and a palm
portion. The palm portion can include an engineered material, which
is knitted and/or weaved, including at least one of (a) a pattern
defining different sized openings, (b) a pattern formed from
threads of at least two different materials, and (c) a pattern
formed with three-dimensional contours. The protective glove
provides enhanced breathability and durability over existing gloves
having mesh palm coverings. The protective glove also offers
improvements in manufacturing, particularly along the edges of the
engineered palm covering. The use of different strands in different
portions of the palm covering provides improved strength in select
areas of the palm covering while not sacrificing flexibility in
other areas of the palm covering.
Inventors: |
Morrow; David K.; (Cherry
Hills Village, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Warrior Sports, Inc. |
Warren |
MI |
US |
|
|
Family ID: |
63791908 |
Appl. No.: |
15/954789 |
Filed: |
April 17, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62486658 |
Apr 18, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A63B 2102/22 20151001;
A63B 2102/24 20151001; A63B 71/143 20130101; A63B 2102/14
20151001 |
International
Class: |
A63B 71/14 20060101
A63B071/14 |
Claims
1. A protective glove, comprising: a padded back portion including
a plurality of pads; a palm portion including a finger portion, a
thumb portion, and a palm portion, the palm portion connected to
the padded back portion to form a finger sheath, a thumb sheath,
and an opening capable of receiving a human hand; and a gusset
joining the palm portion with the padded back portion; wherein the
palm portion includes an engineered material including at least one
of (a) a knitted pattern defining different sized openings, (b) a
knitted pattern formed from strands of at least two different
materials, and (c) a knitted pattern forming a three-dimensional
contour that withstands the force of gravity when placed on a
horizontal surface.
2. The protective glove of claim 1, wherein the palm portion
includes a first region having a first thread density and includes
a second region having a second thread density, the second thread
density being less than the first thread density.
3. The protective glove of claim 1, wherein the at least two
different materials are selected from a group consisting of:
cotton, polyester, acrylic, aramid, rayon, polyethylene, polyamide
and polypropylene.
4. The protective glove of claim 1, wherein the three-dimensional
contour includes a textured pattern having raised portions and/or
recessed portions.
5. The protective glove of claim 1, wherein the palm portion
includes a perimeter flange, wherein the perimeter flange is
constructed from at least one of an aromatic polyamide, a polyamide
and an ultra-high molecular weight polyethylene, wherein the
perimeter flange is joined with a wear resistant covering that
extends over a portion of the engineered material along an edge of
the engineered material.
6. The protective glove of claim 5, wherein the wear resistant
material is selected from the group consisting of natural leather,
synthetic leather, natural suede, and synthetic suede.
7. The protective glove of claim 1, wherein the finger portion and
the thumb portion of the palm portion include the engineered
material, which is a knitted material.
8. The protective glove of claim 1, wherein the engineered material
is a knitted textile including a plurality of interlooped strands;
wherein the palm portion includes a region comprising a plurality
of fusible strands that are fused to one another, wherein the
region including the fused plurality of fusible strands provides
support to the three-dimensional contour.
9. The protective glove of claim 1, wherein the palm portion
includes the knitted pattern defining the different sized openings,
wherein each of the different sized openings include a border that
comprises a plurality of interlooped strands that are uncut,
wherein the palm portion includes a perimeter flange, wherein the
perimeter flange is constructed from at least one of an aromatic
polyamide, a polyamide and an ultra-high molecular weight
polyethylene, wherein the perimeter flange is joined with a wear
resistant covering that extends over a portion of the engineered
material along an edge of the engineered material.
10. A protective glove, comprising: a padded back portion; a palm
covering including a finger portion, a thumb portion, and a central
palm portion, the palm covering joined with the padded back portion
to form a finger sheath, a thumb sheath, and an opening capable of
receiving a human hand; wherein the palm covering includes an
engineered material constructed from a single, unitary knitted
textile, the engineered material forming a three dimensional
contour corresponding to at least one of a palm, film and finger of
a wearer of the glove, the three-dimensional contour capable of
self-supporting itself against the force of gravity when placed on
a horizontal surface, wherein the palm covering includes a
perimeter flange surrounding an interior portion of the palm
covering, the perimeter flange constructed from a plurality of
strands of a first material that are different from a plurality of
strands of a second material from which the interior portion of the
palm covering is constructed.
11. A method of making a protective glove comprising: mechanically
manipulating a plurality of first and second strands with an
automated pocket assembly machine during an automated process to
form a palm covering during the automated process, the palm
covering including predefined three dimensional concave contours as
a direct result of the automated process, the palm covering
including a palm portion integrally formed with at least one of a
finger portion and a thumb portion; heating the plurality of first
strands so that the plurality of first strands at least partially
melt to form a first molten material that fuses individual ones of
the first plurality of strands with one another; cooling the
plurality of first strands so that the first molten material
solidifies, thereby forming a fused region of the palm covering;
and coupling the palm covering to a padded back portion, wherein
the palm covering and padded back portion cooperatively define a
pocket for a human hand.
12. The method of claim 11, wherein the palm covering includes a
knit pattern includes a first region having a first thread density
and includes a second region having a second thread density, the
second thread density being less than the first thread density.
13. The method of claim 11 comprising: forming a perimeter flange
around at least a portion of a perimeter of the palm covering,
wherein the perimeter flange is constructed from a plurality of
strands of a material that is at least one of an aromatic
polyamide, a polyamide and an ultrahigh molecular weight
polyethylene.
14. The method of claim 11, comprising: forming a perimeter flange
around at least a portion of a perimeter of the palm covering,
wherein the fused region is located at these partially within the
perimeter flange.
15. The method of claim 11, comprising: knitting the palm covering
with the assembly machine during a knitting process.
16. The method of claim 11, wherein the plurality of second strands
are constructed from a non-melting material, wherein the plurality
of second strands do not melt during the heating step.
17. The method of claim 11 comprising: joining a wear resistant
covering with a portion of the palm covering.
18. The method of claim 17, wherein the wear resistant material is
selected from the group consisting of natural leather, synthetic
leather, natural suede, and synthetic suede.
19. A method of manufacturing a protective glove comprising:
mechanically manipulating a plurality of strands with an automated
pocket assembly machine during an automated process to form a
unitary textile material that is an engineered palm covering
including a first region and a second region joined with one
another as integral parts of the same unitary textile material, the
first region having a first set of physical properties, the second
region having a second set of physical properties different from
the first set of physical properties, wherein the engineered palm
covering forms a predefined, three dimensional concave contour
produced during the mechanically manipulating step, the concave
contour configured to correspond to a contour of a hand of a wearer
of the glove, the concave contour constructed via the automated
process so that the concave contour retains a three dimensional
shape that withstands a force of gravity when placed on a
horizontal surface.
20. The method of claim 19 comprising: joining a backhand portion
to the palm covering, and joining a cuff to the backhand portion,
wherein the automated process is a knitting process.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a protective glove having a
knitted palm covering and a related method of manufacture.
[0002] In many contact sports, such as lacrosse and hockey, sticks
are elements of the game. In these sports, a player's wrists, hands
and fingers are vulnerable to injury from another player's stick or
when hit with a ball or puck. For this reason, players typically
wear padded gloves to protect their wrists, hands and fingers.
[0003] To provide improved control of the stick, and to provide
breathability, padded gloves are known to include a mesh fabric of
a uniform single mesh pattern, exposed in holes defined by a
leather or suede covering. One example of a padded glove having
both a mesh fabric insert and a natural or synthetic leather
covering is presented in U.S. Pat. No. 7,117,540 to Morrow. The
mesh fabric is constructed to include a large number of closely and
uniformly spaced holes to provide a screen like porosity for
ventilation, and the leather covering is located in regions of the
palm intended to contact the wearer's stick.
[0004] While conventional mesh fabrics can be utilized in lacrosse,
hockey and other gloves to provide certain functional
characteristics, they suffer a number of shortcomings. For example,
mesh fabrics typically are of a single uniform thickness, which can
prevent the mesh from effectively conforming to a user's palm, or
otherwise can make the glove feel too rigid or too soft. Mesh
fabric inserts also are typically die cut from a larger sheet of
mesh fabric, which can produce waste. In addition, the resultant
edges can be unfinished, having been formed from a simple die cut
operation. In turn, these edges are less durable for stitching the
insert to another element of the glove. In addition, mesh inserts
are typically constructed from flat, planar pieces of mesh fabric.
Thus, the flat, planar configuration of the mesh does not readily
conform to the contours of a human hand. In turn, the palm of the
resulting glove can feel uncomfortable and/or can bunch unevenly,
which can make it difficult to grasp a lacrosse stick or other
implement. Further, most conventional mesh fabrics have a low
coefficient of friction. Thus, when large portions of the palm
include such mesh fabrics, the wearer's ability to effectively grip
a stick or other implement can decrease, which can impair the
player's ability to play well.
[0005] Accordingly, there remains room for improvement in the field
of protective gloves.
SUMMARY OF THE INVENTION
[0006] A protective glove including a palm covering including an
engineered material and a method of manufacture are provided. The
palm covering is opposite a padded back portion of the protective
glove, and can provide improved control, durability, grip and
ventilation as compared to conventional mesh palms.
[0007] In one embodiment, the palm covering includes a palm area
surface formed partially or completely from a knitted or woven
material, fabric, textile or cloth, any and all of which is
considered an engineered material. Generally, this palm covering
can be formed from a unitary, single piece textile that optionally
includes no seams, stitches or joints to join the various portions
of the palm covering with one another.
[0008] In another embodiment, the palm covering includes a knit or
weave pattern defining different sized openings. Portions of the
palm covering having smaller openings can include a greater thread
density than portions of the engineered palm covering having larger
openings. The different size openings can differ in area by a
factor of two or more, for example, alternatively by a factor of
ten or more. Portions of the palm covering having smaller openings
can be located in regions intended to primarily contact the stick,
and portions of the palm covering having larger openings can be
located in regions where improved ventilation is desired.
[0009] In another embodiment, the palm covering and in particular
its engineered material is formed from at least two different
materials. The materials can be selected from cotton, polyester,
nylon, acrylic, aramid, rayon, polyethylene, and polypropylene, for
example. A first portion of the palm covering can include a first
material and a second portion of the palm covering can include a
second material different from the first material. The first
material can include a higher tensile strength and/or coefficient
of friction in regions intended to primarily contact the stick, and
the second material can include a lesser tensile strength and/or
coefficient of friction in regions not in primary contact with the
stick.
[0010] In yet another embodiment, the palm covering, and in
particular its engineered material, can be formed with relief
effects, such as three-dimensional contours. For example, the palm
covering can be knitted or woven on a special automated machine and
formed with a textured pattern having raised portions and/or
recessed portions, or contours following a user's hand in general.
The textured pattern or contours can correspond to the curvature of
the wearer's palm. In other embodiments, the textured pattern can
include an engineered material that is thicker in some areas than
in other areas.
[0011] In still another embodiment, the palm covering, and in
particular its engineered material, can be constructed on an
automated machine, such as a knitting and/or weaving machine, so
that the resultant palm facing surface of the covering is contoured
to conform to surfaces of a user's palm, from and/or fingers. For
example, the material can be knitted so that it includes a concave
and/or convex configuration so as to conform to a corresponding
concave and/or convex surface of a wearer's palm, finger and/or
thumb. In this way, when the engineered palm covering can be placed
adjacent the wearer's palm in use; and it readily conforms to the
corresponding contours to provide an exceptional fit.
[0012] In even another embodiment, the engineered palm covering and
in particular its engineered material can be constructed on an
automated machine, such as a knitting and/or weaving machine, so
that a perimeter flange is formed to surround all or a portion of
an outer perimeter of the engineered palm covering. This perimeter
flange can be constructed from strands of a first material and can
surround an interior region of the palm covering, which is
constructed from strands of a second material. The first and second
strands can be different from one another. For example, the strands
of the perimeter flange first material can be constructed from a
durable, tear and rip resistant material, such as an aromatic
polyamide, an ultrahigh molecular weight polyethylene and/or Nylon
66 thermoplastic resin, such as PA66. The second material can be a
thermoplastic polymer, for example high density or high strength
polyethylene, polypropylene and/or a polyethylene multifiber yarn.
With the durable perimeter flange, the engineered palm covering can
be durably and reliably stitched, sewn, glued, adhered or otherwise
attached to an adjacent component of the glove without significant
concern of detachment or tearing of the covering from that
component. The interior portion can remain supple and
comfortable.
[0013] In still yet another embodiment, the palm covering and in
particular its engineered material can be constructed to include
one or more fusible strands, knitted or weaved into the engineered
palm covering. These fusible strands can include a fusible
thermoplastic polymer material, non-limiting examples of which
include polyurethane, nylon, polyester, polyolefin and polyamide.
These fusible strands can be fused in certain areas corresponding
to the palm, fingers and/or thumb that are intended for repeated
engagement with surfaces of an object, such as a stick, handle
and/or grip of an implement. The fusible strands also can be fused
in certain areas to impart a particular rigid contour to the
engineered palm covering in a preselected area. The fusible strands
further can be fused along a perimeter flange of a piece of
engineered material so that the perimeter flange can be durably and
reliably stitched, sewn, glued or otherwise attached to an adjacent
component of the glove.
[0014] In another embodiment, a method of assembling a protective
glove is provided. The method includes forming an palm covering
including an engineered material and coupling the palm covering to
a padded back portion, wherein the palm covering extends over the
padded back portion to define a pocket for a human hand, wherein
the knitted material includes at least one of (a) a knit or weave
pattern defining different sized openings, (b) a knit or weave
pattern formed from at least two different materials, and (c) a
knit or weave pattern formed with three-dimensional relief effects
and/or contours that are self-supporting under the force of
gravity. With the latter construction, the pattern can maintain a
three dimensional form or shape immediately after manufacture and
can be resistant to completely flattening out to a two dimensional
form upon placement on a horizontal surface. The method can further
include joining a wear resistant covering over a portion of the
palm covering and/or adjacent a portion of the palm covering, the
wear resistant covering being natural leather, synthetic leather,
natural suede, or synthetic suede, for example. The method can
still further include forming a wrist guard and/or a cuff and
joining the same to the protective glove.
[0015] The protective glove of the current embodiments, with its
palm covering and engineered material, provides enhanced
breathability and durability over gloves having conventional mesh
inserts. The protective glove also offers improvements in
manufacturing, particularly along the seams of the palm covering
where it joined with other components of the glove. The use of
different strands in different portions of a knitted palm covering
also can provide improved strength and functionality in select
areas of the palm covering while not sacrificing flexibility in
other areas of the palm covering.
[0016] These and other objects, advantages, and features of the
invention will be more fully understood and appreciated by
reference to the description of the current embodiment and the
drawings.
[0017] Before the embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited to
the details of operation or to the details of construction and the
arrangement of the components set forth in the following
description or illustrated in the drawings. The invention may be
implemented in various other embodiments and of being practiced or
being carried out in alternative ways not expressly disclosed
herein. Also, it is to be understood that the phraseology and
terminology used herein are for the purpose of description and
should not be regarded as limiting. The use of "including" and
"comprising" and variations thereof is meant to encompass the items
listed thereafter and equivalents thereof as well as additional
items and equivalents thereof. Further, enumeration may be used in
the description of various embodiments. Unless otherwise expressly
stated, the use of enumeration should not be construed as limiting
the invention to any specific order or number of components. Nor
should the use of enumeration be construed as excluding from the
scope of the invention any additional steps or components that
might be combined with or into the enumerated steps or
components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a top view of a dorsal side of a glove including a
palm covering according to a current embodiment;
[0019] FIG. 2 is a bottom view of a palm side of the glove of FIG.
1;
[0020] FIG. 3 is a side view of a medial side of the glove of FIG.
1;
[0021] FIG. 4 is side view of a lateral side of the glove of FIG.
1; and
[0022] FIG. 5 is a palm side view of an alternative of the palm
covering before installation relative to a glove.
DESCRIPTION OF THE CURRENT EMBODIMENTS
[0023] A protective glove in accordance with a current embodiment
is illustrated in FIGS. 1-4 and generally designated 10. While the
drawings are illustrative of a left hand glove, the current
embodiments can be incorporated into a right hand glove, which is
generally a mirrored version of the left hand glove. Additionally,
the glove 10 as illustrated is designed for use in the game of
lacrosse; however, the glove can be used in a variety of other
sports or other activities, such as ice hockey or field hockey.
[0024] As shown in FIGS. 1 and 2, the protective glove 10 includes
a padded back portion 12 and a palm side portion 14, between which
an interior space adapted to receive a wearer's hand, fingers, and
thumb is defined. The glove 10 also includes a hand portion 16, a
plurality of finger portions 18 and a thumb portion 20 extending
from the hand portion 16, a wrist roll 22, and cuff portion 24.
[0025] As best shown in FIG. 1, the padded back portion 12 includes
multiple protective elements 26, which can be constructed of one or
more layers of foam, polyurethane, polymers or other suitable
padding that are covered with a covering such as a nylon mesh. Each
of the protective elements 26 can define one or more flex lines
therebetween, which allow the padded back portion 12 to move to
provide a better fit and comfort during play. Flex lines could take
on a variety of different configurations and placements as
desired.
[0026] The hand portion 16 is joined with the cuff portion 24. The
cuff portion 24 can include one or more cuff panels 28 joined with
the hand portion 16, generally being joined with the hand portion
rearward edge. The cuff panels 28 can be similar in size,
connection and dimension. In some embodiments, the cuff portion 24
can include a floating cuff 30. The floating cuff 30 can be
disposed immediately under the cuff panels 28. Optionally, the
floating cuff 30 can be similar to that described in U.S. Pat. No.
7,636,951 to Morrow et al, which is hereby incorporated by
reference in its entirety. The floating cuff can be interposed on a
wrist of the wearer, located generally between the cuff portion and
the wearer's wrist. Optionally, the floating cuff can extend under
the cuff opening, as well as the cuff panels and secondary wrist
guard cuff.
[0027] As shown in FIG. 2, the palm side portion 14 includes a palm
covering 32, finger coverings 34, and a thumb covering 36. The
engineered palm covering 32 includes a wear resistant material 38
in combination with an engineered material 40. In other embodiments
the palm covering 32 includes only an engineered material 40, or
like the embodiment shown in FIG. 5, the engineered palm covering
includes and covers the palm, the fingers and the thumb.
[0028] In the embodiment shown in FIGS. 1-4, the engineered
material 40 can be formed partially or completely from a knitted or
woven material, fabric, textile or cloth, again referred to herein
as an engineered material. Various processes for example, knitting
and/or weaving processes, can be used to form the engineered
material. Generally, the engineered palm covering can be
constructed from a unitary textile material and is manufactured
from strands, which can be in the form of threads, cables, yarn,
fibers, filaments, cords and other strand-like elongated
structures, all referred to herein as strands. Certain conventional
strands have an indefinite length and can be combined with other
strands to produce a yarn for use in textile materials. The strands
used in this embodiment can be constructed from materials such as
thermoplastic polymers, such as nylon, polypropylene, high density
polyethylene, ultra-high molecular weight polyethylene, polyamides,
as well as aromatic polyamide and other polymeric materials. Other
abrasion resistant and durable material likewise can be
implemented. As explained below, the forgoing materials can be
mixed and matched within a single unitary textile material, making
up an engineered palm covering to provide different mechanical and
physical properties in different regions of the engineered palm
covering as desired. As mentioned above, the engineered palm
covering is a unitary textile material. Unitary textile materials
can be produced via machine implemented mechanical manipulation of
the strands, thereby producing a weaved or knitted material, or
some other type of engineered material. The engineered material can
be constructed automatically, by manipulating strands using various
techniques implemented on a machine (rather than performed manually
by a human). The various techniques include knitting, weaving,
intertwining and/or twisting, the latter two of which are generally
encompassed by knitting.
[0029] The engineered material 40 and optionally the palm covering
of this embodiment can be constructed on a textile manufacturing
machine, such as a knitting machine and/or a weaving machine. A
knitting machine can be utilized to construct one commercial
embodiment of the palm covering and other knitted components if
incorporated into the glove. Knitting includes interlooping strands
in a series of connected loops, optionally forming multiple columns
of loops. In weaving, multiple strands are crossed and interweaved
over and under one another at right or other transverse angles to
each other at intersections. Strands used in weaving are usually
characterized as warp and weft yarns. Intertwining and twisting can
include techniques such as knotting and braiding, where strands
intertwine with one another. Generally, knitting can encompass
intertwining and twisting herein. Such machines are capable of
producing knitted materials with a high degree of precision and
reproducibility. With a glove or engineered palm covering
constructed from a unitary textile material or engineered material
as described herein, its configuration can be reproduced or
replicated with extreme precision. For example, from one palm
covering to the next, the dimensions, elasticity, stretchability,
contours are virtually identical when the palm covering is secured
to other components of the glove.
[0030] Due to this leap forward in glove manufacturing capability,
customers also can obtain gloves having palm coverings with a high
degree of customization, in many cases, perfectly fitting the
contours of the wearer's hand. For example, a particular player can
have a palm with a three dimensional surface or profile. That
profile can be determined and/or digitally captured or three
dimensionally mapped into an automated assembly machine. The
automated assembly machine, such as a knitting or weaving machine
described in U.S. Published Patent Application 2017/0340934 to
Kohler et al., filed Aug. 21, 2017 and U.S. Published Patent
Application 2016/0206939 to Huffa et al., filed Mar. 28, 2016,
which are both hereby incorporated herein in their entirety, can be
programmed with data and/or code relating to or based on the
preferred profile. The machine can then precisely replicate the
engineered material in the form of an engineered palm covering.
Generally, with the embodiments herein, a high degree of
consistency can be achieved in manufacturing gloves.
[0031] Where knitted, the material 40 provides excellent
breathability due to its optional screen-like architecture and its
repeating pattern of openings through the knitted material 40. As
used herein, the "openings" in the material refer to the repeating
pattern of closely spaced holes between adjacent threads, and not
other apertures, e.g., apertures purposely sewn into or punched
from the material. The material 40 can be formed from strands of
any desired material, optionally cotton, polyester, nylon, acrylic,
aramid, rayon, polyethylene, polypropylene and combinations
thereof. The material 40 also can constitute the gussets 42 that
join the padded back portion 12 to the palm side portion 14. As
discussed below, the engineered material 40 can include at least
one of (a) a knit pattern defining different sized openings, (b) a
knit pattern formed from threads of at least two different
materials, and (c) a knit pattern formed with three-dimensional
relief effects. The wear resistant material 38, where used, can
include natural or synthetic leather, natural or synthetic suede,
or other material which provide abrasion resistance and grip.
[0032] As noted above, the engineered material 40 of the palm
covering 32 can include different sized openings. The different
sized openings can be various sizes to accommodate better feel and
durability where needed. For example, a first portion of the
material 40 can include a first opening size and a second portion
of the material 40 can include a second opening size different from
the first opening size. Portions of the material 40 having smaller
openings can include a greater strand density, and portions of the
material 40 having larger openings can include a lesser strand
density. The larger openings can define an area that is larger than
the area defined by the smaller openings, optionally by a factor of
two or more, still further optionally by a factor of ten or more.
Though two portions of the material having distinct openings are
discussed above, other embodiments can include a material having
three or more portions with different sized openings. The openings
can include a variety of configurations depending upon the knit
pattern, with a round knit pattern being shown in FIG. 2. Other
openings can be oblong, hex, square, diamond, elliptical, and
rectangular, for example.
[0033] The material 40 can also include a knit pattern formed from
threads of at least two different materials, effectively a
combination fabric. The threads can be used in different locations
of the knitted material 40 to create performance, durability, and
manufacturing advantages. The threads can include for example
cotton, polyester, nylon, acrylic, aramid, rayon, polyamide,
polyethylene, or polypropylene. A first portion of the knitted
material 40 can include a first material and a second portion of
the knitted material 40 can include a second material different
from the first material. The first material can include a higher
tensile strength and/or coefficient of friction in regions intended
to primarily contact the stick. The second material can include a
lesser tensile strength and/or coefficient of friction in regions
not in primary contact with the stick. Though two portions having
distinct threads are discussed above, other embodiments can include
a knitted material having three or more portions with different
threads.
[0034] Optionally, the material 40 can be formed with relief
effects and/or concave or convex contours, effectively being formed
with three-dimensional contours to accommodate better fit, feel and
durability. For example, the material 40 can be formed with a
textured pattern having raised portions or ridges and/or recessed
portions. The textured pattern can correspond to the curvature of
the wearer's palm, in some embodiments. In other embodiments, the
textured pattern can include material 40 that is thicker in some
areas than in other areas.
[0035] A method for assembling the protective glove 10 generally
includes forming a palm covering including a material and coupling
the palm covering to a padded back portion to define a pocket for a
human hand. The engineered material includes at least one of (a) a
knit pattern defining different sized openings, (b) a knit pattern
formed from threads of at least two different materials, and (c) a
knit pattern formed with three-dimensional relief effects. The step
of coupling the palm covering to a padded back portion can include
forming a border in the material and joining the material to the
padded back portion along a seam. The palm covering can include
primarily a wear resistant material in some embodiments, for
example as shown in FIG. 2, in which the material spans one or more
apertures or gaps in the wear resistant material. In other
embodiments, the palm covering can include substantially only an
engineered material. As noted above, the material can additionally
include a finished border to simplify and strengthen the joining of
the palm covering to the padded back portion and/or to the wear
resistant material. The method of assembling the protective glove
can additionally include forming a wrist roll and a protective cuff
in the protective glove.
[0036] An alternative embodiment of the glove, in particular a palm
covering 132, is illustrated in FIG. 5. The palm covering of this
embodiment is similar in structure, function and operation to the
engineered material and/or palm covering of the above embodiments,
with several exceptions. For example, in this construction, the
palm covering 132 includes both a palm portion 132 as well as
finger portions 134 and a thumb portion 136 all of these portions
are formed from a unitary contiguous piece of engineered material
140. This engineered material can include various features as
described below. Further, it will be appreciated that these
features may be incorporated into a smaller, independent and
separate palm covering components, finger portion and/or thumb
portion, depending on the application. Further, the components of
the palm covering 132 can be covered by other materials in the
preselected locations, such as wearable, more durable
materials.
[0037] The engineered material 140 optionally can be a unitary
knitted or woven textile material. This material can include
various knit patterns in different locations of the palm covering
132. These knit patterns can be selected to provide certain
properties characteristics to areas of the palm covering. For
example, the finger portions can include regions 134R. These
regions can be constructed from a first knit pattern that is
different from a second knit pattern 135 that is immediately
adjacent the regions 134R. These regions 134R, for example, can
include multiple ridges or recesses 134S in the first knit pattern
that are formed as a result of a knitting operation in that region,
performed by the automated assembly machine. These ridges or
recesses 134S can enhance the coefficient of friction of the palm
covering 132 in these regions. The second knit pattern 135 can
include a smoother, more compliant and flexible surface due to the
second knit pattern. This can provide more flexibility at the
joints of the fingers that a user can more easily grasped an
object. The thumb portion 136 can include a knit pattern in region
136 similar to that of the first knit pattern.
[0038] As another example, the palm region 132R which generally
overlies a portion of the palm can include a third knit pattern
that provides a plurality of large, visible 0.5 mm to 5.0 mm
openings 1320. These openings can provide enhanced ventilation to
the palm. Of course such openings can be distributed elsewhere, for
example in the finger portions and/or thumb portion depending on
the application. Optionally, the openings can be bounded by a
border. The border can comprise interlooped strands that are uncut,
that is, the openings are not cut by a device or process in order
to form the border and the associated interlooped strands in the
border remain intact and uncut.
[0039] The engineered material 140, and in particular the palm
covering 132 can be constructed with the different knit patterns as
mentioned above. In some cases, these knit patterns can
cooperatively form one or more contours 132C, 134C and/or 136C.
These contours can mimic the natural contours of corresponding
features of a wearer's hand. For example the contours 134C of the
finger portions 134 can be convex on the outside of the palm 132,
that is, they bulge out of the page of FIG. 5. Conversely, on the
back side of the palm covering 132, those contours 134C would
appear as concave contours. The same is true for the thumb contour
136C. The material covering the palm also can include a contour
132C which likewise can be convex, bulging out of the page of FIG.
5. These contours can be formed as a direct result of the knitting
and/or weaving or other automated process used to make the
engineered material 140. These various contours also can be
self-supporting under the force of gravity, for example when the
palm covering 132 is placed on a flat plane, the contours 134C with
project upwardly in a three-dimensional fashion from the support
plane. The same is true for the contours 136C and 132C. Of course,
other contours could be incorporated into the engineered material
140, such that recesses or reliefs are formed in the engineered
material 140.
[0040] The engineered material 140 optionally can include strands
of different materials. These materials can be distributed in
regions or areas of the palm covering 132 depending on the function
of the same. For example, the perimeter flange 150 that generally
extends along the lateral side of the hand, over the outline of the
fingers and thumb, and back along the medial side of the palm, as
well as other regions of the palm covering 132, depending on the
application, can be constructed from strands of a first material,
which can be less elastic, and/or more abrasion resistant and more
durable than strands of a second material that is disposed inwardly
from that perimeter flange 150. With such a construction, this
perimeter flange can be well-suited for sewing stitching, gluing,
adhering, welding or otherwise joining with a peripheral allowance
or gusset or other padding associated with other components of the
glove, such as the dorsal backhand or other gussets. In some cases,
the perimeter flange can be of a width W1 that is optionally at
least 2.0 mm, further optionally at least 2.5 mm, even further
optionally at least 5.0 mm. With this width, there can be adequate
surface area along the outer perimeter of the palm covering 132 to
stitch the perimeter flange to another glove component. Due to the
durability of this perimeter flange 150, the engineered material
140 in the regions where it is joined to other components can
withstand extensive pulling forces that might otherwise tear or
damage the material 140 along points of attachment.
[0041] Optionally, the first material can be at least one of an
aromatic polyamide, an ultra-high molecular weight polyethylene,
and a polyamide. One suitable aromatic polyamide is
poly-para-phenylene terephthalamide, sold under the commercial name
of KEVLAR.RTM. by DuPont of Wilmington, Del. The first material
optionally can have strands having: a tensile modulus of elasticity
of optionally 400-1000 g/d, further optionally 500-900 g/d, and
even further optionally at least 500 g/d; an elongation at break of
optionally 1.0% to 10.0%, further optionally of 3.0% to 2.4%,
further optionally 3.6%; a breaking tenacity of optionally 100-300
cN/tex, further optionally 150-250 cN/tex, even further optionally
203-208 cN/tex; and a tensile strength of optionally about
2,000-10,000 MPa, further optionally 3,000-6,000 MPa and even
further optionally about 3,600 MPa. This first material can be less
elastic and more abrasion resistant and durable and tear resistant
than the second material used in for example, inward from the
perimeter flange 150.
[0042] As mentioned above, the first material can be a polyamide,
such as polyamide 6,6, which is commonly known as Nylon 66
thermoplastic resin or PA66, having a CAS Number of 032131-17-2.
The polyamide can have a melting point in the range of 220.degree.
C.-250.degree. C. and a specific gravity relative to water of 1.15
g/cc measured using ASTM D792. The polyamide can have the molecular
formula (C12 H22 N2 O2)n, and a density optionally of 1.30
g/cm.sup.3-1.60 g/cm.sup.3, further optionally 0.90 g/cm.sup.3-1.2
g/cm.sup.3 at 20.degree. C. as measured using EN ISO 1183-1. The
polyamide can have a hardness of 80 Shore D measured using ASTM
D2240, a tensile strength of about 82.7 MPa, measured using ASTM
D638, and having a tensile modulus of optionally 2.0 GPa to 4.0
GPa, further optionally 2.5 GPa to 3.0 GPa using ASTM D638. The
polyamide, when in the form of a multifilament yarn, can exhibit
30%-50% elongation at break, further optionally 39%-42% elongation
at break, yet further optionally about 40% elongation at break
measured using ASTM D638. The polyamide can exhibit thermal
decomposition temperatures greater than 310.degree. C. Thus, when
the polyamide is used with the current embodiment, the molding
temperatures to mold a head over a portion of the pocket can be
optionally less than 350.degree. C., further optionally less than
325.degree. C., yet further optionally less than 310.degree. C.,
even further optionally less than 280.degree. C. Suitable
polyamides can be optionally ULTRAMID.RTM. A3X2G5 Uncolored
Polyamide commercially available from BASF of Florham Park, N.J.,
further optionally Emarex.TM. Polyamide Resin commercially
available from MRC Polymers Inc. of Chicago, Ill., yet further
optionally Polofil Nylon 66 commercially available from The Plastic
Group of America of Woonsocket, R.I. Of course a variety of other
polyamides can be suitable for the first material to construct the
first strands and associated yarns in the various edges as well as
other regions of the glove depending on the application.
[0043] Further optionally, inside the perimeter flange 150, the
engineered material 140 can include strands constructed from a
second material. The second material can be a thermoplastic
polymer, for example high density or high strength polyethylene,
polypropylene and/or a polyethylene multi-fiber yarn. The second
material optionally can have strands having: a modulus of
elasticity of optionally 0.1-2.0 GPa, further optionally 0.5-1.0
GPa; elongation at break of optionally greater than 50%, further
optionally greater than 100%, even further optionally greater than
500%; and a tenacity of optionally 20-350 kN/tex, further
optionally 30-320 kN/tex, and even further optionally 50-100
kN/tex, and even further optionally less than 150 kN/tex. The
second material can include strands optionally in a range of 100
Denier to 1000 Denier, further optionally 150 Denier to 840 Denier,
even further optionally 210 Denier to 750 Denier, yet further
optionally 300 Denier and/or 420 Denier. In some cases, the second
material can generally be more soft and flexible than the first
material, optionally due to the differences in their construction,
or due to different knitting or weaving processes used to make
these components.
[0044] If desired, the first and second materials can include a UV
inhibitor to protect the strands when the engineered material of
the palm covering is used in direct sunlight. Of course, the palm
covering can be constructed from the first material and second
material, only one of the two materials, and/or other additional
materials depending on the application.
[0045] It will also be appreciated that the perimeter flange 150
can form the outermost free edge of the engineered palm covering
132 of this embodiment. Via the automated processes disclosed
herein, the entire palm covering 132 can be constructed from the
engineer material 140 without producing any waste or other material
from which the palm covering 132 must be removed. In turn, this can
reduce waste and improve manufacturing of the subject palm covering
132.
[0046] Optionally, the engineered palm covering 132 can be knitted
or weaved from a engineered material, such as a textile material
having certain types of strands for example fusible strands
disposed in certain regions for certain functionality. For example
as shown in FIG. 5, region 132F can include a plurality of fusible
strands. These fusible strands can be fused together to make that
region generally more rigid and/or stiff. This can be suitable for
applications where the region 132F comes in contact with a stick or
other implement, or is otherwise a region of high wear. With the
fusible strands in this region, the wear can be reduced to prolong
the useful life of the palm covering 132.
[0047] One or more of the strands used to knit or weave the
engineered material may be a fusible strand that includes a fusible
thermoplastic polymer material, non-limiting examples of which
include polyurethane, nylon, polyester, polyolefin, and polyamide.
The fusible strands may be formed from a single, fusible material
or multiple layers of materials in which an outer layer is a
fusible material. For example, the fusible strands can include a
fusible material layer surrounding an interior strand material,
which may or may not be fusible, in a core-sheath type
configuration. In another example, a strand or strip of fusible
material may be applied to a strand made from a non-fusible
material. Following a fusing treatment, the fusible strand material
melts and/or softens to form a "molten" material that at least
partially surrounds the non-fusible material, forming a coated or
partially coated strand.
[0048] Optionally, the fusible strand may be formed entirely of a
thermoplastic polymer material or include a thermoplastic polymer
coating. The thermoplastic polymer coating may be applied using any
known technique, non-limiting examples of which include
co-extrusion, dip coating, and spray coating. The thermoplastic
polymer coating can be a reactive coating material that exhibits
thermoplastic properties prior to curing and thermosetting
properties after it has been exposed to curing conditions. Such a
reactive coating exhibits thermoplastic properties below a certain
temperature, allowing the material melt/soften and fuse with
adjacent strands. Following a curing treatment, the reactive
coating cures to a material with thermoset properties, such as by
forming cross links, for example. The curing treatment can include
heating the material to a second temperature, higher than the first
temperature at which the thermoplastic material melts and fuses.
Optionally, the curing treatment includes increased temperature and
pressure and/or the addition of a cross-linking agent. One
non-limiting example of a reactive coating includes an acrylic acid
copolymer and a cross-linking agent. Optionally, the reactive
coating is a material available from BASF Corporation under the
tradename ACRODUR.RTM.. In this manner, the fused area of the palm
covering 132 may be thermoset, which can increase the hardness
and/or stiffness of the fused area.
[0049] Optionally, the fusible strand may be constructed from a
first thermoplastic polymer with a first melting temperature and a
second thermoplastics polymer with a second melting temperature
that is less than the first melting temperature. The first and
second thermoplastic polymers may be configured in a core-sheath
type configuration or the second thermoplastic polymer may be
provided as a strand or strip applied to the first. A heat-based
fusing treatment can be applied to heat the fusible strand to a
temperature sufficient to melt the second thermoplastic polymer,
but below the melting temperature of the first thermoplastic
polymer. Further optionally, a fusible strand may be combined or
twisted with a non-fusible strand or yarn to form a fusible yarn
including such fusible strand.
[0050] Non-fusible material may include natural or synthetic
materials that are incapable of fusing or may include a fusible
material that is configured to not fuse during the prescribed
fusing treatment. For example, the non-fusible material may have a
higher melting point than the fusible material and thus not
melt/soften during the prescribed fusing treatment.
[0051] Directional terms, such as "vertical," "horizontal," "top,"
"bottom," "upper," "lower," "inner," "inwardly," "outer" and
"outwardly," are used to assist in describing the invention based
on the orientation of the embodiments shown in the illustrations.
The use of directional terms should not be interpreted to limit the
invention to any specific orientation(s).
[0052] The above description is that of current embodiments of the
invention. Various alterations and changes can be made without
departing from the spirit and broader aspects of the invention as
defined in the appended claims, which are to be interpreted in
accordance with the principles of patent law including the doctrine
of equivalents. This disclosure is presented for illustrative
purposes and should not be interpreted as an exhaustive description
of all embodiments of the invention or to limit the scope of the
claims to the specific elements illustrated or described in
connection with these embodiments. For example, and without
limitation, any individual element(s) of the described invention
may be replaced by alternative elements that provide substantially
similar functionality or otherwise provide adequate operation. This
includes, for example, presently known alternative elements, such
as those that might be currently known to one skilled in the art,
and alternative elements that may be developed in the future, such
as those that one skilled in the art might, upon development,
recognize as an alternative. Further, the disclosed embodiments
include a plurality of features that are described in concert and
that might cooperatively provide a collection of benefits. The
present invention is not limited to only those embodiments that
include all of these features or that provide all of the stated
benefits, except to the extent otherwise expressly set forth in the
issued claims. Any reference to claim elements in the singular, for
example, using the articles "a," "an," "the" or "said," is not to
be construed as limiting the element to the singular. Any reference
to claim elements as "at least one of X, Y and Z" is meant to
include any one of X, Y or Z individually, and any combination of
any number of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y,
Z.
* * * * *