Three dimensional glove with performance-enhancing layer laminated thereto

Abstract

A 3D hand-shaped glove includes a performance-enhancing layer laminated to a fabric glove shell. A flat, solid laminate preform can be prepared with printed graphics, fabric layers, oriented films, dense and/or concentrated fillers, and other features. The 3D hand-shaped glove shell is placed on a 3D laminating form, and the preform is laminated thereto while preserving the 3D shape. In embodiments, the laminating form includes opposing flat surfaces, and a platen or roller press is used. In other embodiments, a bladder or vacuum bag press is used to laminate the preform to a curved or otherwise shaped surface of the laminating form. In embodiments, edge peel resistance is enhanced by extending the perimeter of a low modulus upper layer beyond underlying layers and bonding it directly to the glove shell. Recovery of the glove shell after deformation by the laminating form can provide a warping deformation of the laminate preform.

What is claimed is: 
     
         1 . A glove having a three-dimensional shape that approximates the shape of a human hand, the glove comprising:
 a knit or woven glove shell having a three-dimensional shape that approximates the shape of a human hand, the glove shell having an interior surface and an exterior surface; and   a laminate preform bonded by a lamination adhesive layer to a portion of the exterior surface of the glove shell, the laminate preform including an enhancement feature that cannot be provided by dipping the glove shell into a liquid coating material.   
     
     
         2 . The glove of  claim 1 , wherein the enhancement feature is one of:
 a textile layer;   an oriented film;   a layer of graphics;   an elastomeric layer including a filler having a density that would cause the filler to settle if added to the liquid coating material; and   an elastomeric layer including a filler having a density that, if added to the liquid coating material, would increase a viscosity of the liquid coating material, thereby rendering the liquid coating material unsuitable for dip-coating the glove shell.   
     
     
         3 . The glove of  claim 1 , wherein the enhancement feature is an elastomeric layer including a filler having a density of between 2 and 14. 
     
     
         4 . The glove of  claim 1 , wherein the laminate preform includes a grip layer on an outer surface thereof. 
     
     
         5 . The glove of  claim 1 , wherein the lamination adhesive layer has a surface energy greater than 30 mJ/m 2 . 
     
     
         6 . The glove of  claim 1 , wherein the lamination adhesive layer includes at least one of a thermoplastic, a pressure sensitive adhesive, and a reactive adhesive. 
     
     
         7 . The glove of  claim 1 , wherein the lamination adhesive layer is one of SBR and urethane. 
     
     
         8 . The glove of  claim 1 , wherein the lamination adhesive layer is a film having a thickness of between 6 microns and 50 microns. 
     
     
         9 . The glove of  claim 1 , wherein the bonding of the laminate preform to the glove shell is such that a  1  inch ASTM T peel sample having the same bonding properties would have a  5  average peak peel forces of greater than 5 lbf/inch. 
     
     
         10 . The glove of  claim 1 , wherein the glove shell is knit or woven from a textile having a total surface energy of greater than 40 mJ/m 2 . 
     
     
         11 . The glove of  claim 1 , wherein the glove shell is knit or woven from one of cotton and nylon. 
     
     
         12 . The glove of  claim 1 , wherein the laminate preform includes an exposed upper layer, whereby the upper layer and the lamination adhesive layer extend beyond any intervening layers, so that the perimeter of the upper layer is bonded by the lamination adhesive layer directly to the glove shell. 
     
     
         13 . The glove of  claim 12 , wherein the upper layer is a thermoplastic urethane, and the glove shell is knit or woven from nylon. 
     
     
         14 . The glove of  claim 12 , wherein the upper layer is an elastomeric film of greater than 100% elongation. 
     
     
         15 . The glove of  claim 1 , further comprising an inner laminate preform bonded to an inner surface of the glove shell. 
     
     
         16 . The glove of  claim 1 , further comprising an inner cut-and-sew glove lining. 
     
     
         17 . A method of manufacturing a glove having a three-dimensional shape approximating the shape of a human hand, the glove including a laminate preform attached by a lamination adhesive to a portion of an underlying glove shell, the method comprising:
 providing a glove shell having a three-dimensional shape that approximates the shape of a human hand;   preparing a flat, solid laminate preform, the laminate preform including an exposed layer of lamination adhesive;   providing a three dimensional laminating form having a hand-shaped region, the hand-shaped region including a smooth laminating surface;   placing the glove shell on the laminating form so that the glove shell surrounds the hand-shaped region, and so that a portion of the glove shell conforms closely to the laminating surface without any seam or wrinkle;   placing the laminate preform on the glove shell above the laminating surface, the exposed layer of lamination adhesive being in direct contact with the glove shell;   applying a pressure above ambient pressure at a temperature above ambient temperature to the assembled laminate preform, glove shell, and laminating form, thereby causing the lamination adhesive to bond the laminate preform to the glove shell; and   removing the glove shell with the laminate preform bonded thereto from the laminating form.   
     
     
         18 . The method of  claim 17 , wherein the hand-shaped region of the laminating form includes a pair of opposing areas that are overlapping, substantially flat, and substantially parallel to each other, the laminating surface being included in one of the opposing areas. 
     
     
         19 . The method of  claim 17 , wherein applying pressure to the assembled lamination preform, glove shell, and laminating form includes applying pressure using at least one of a platen press, a roll press, a belt press, and a nip roll press. 
     
     
         20 . The method of  claim 17 , wherein the laminating surface is a non-flat, smooth surface. 
     
     
         21 . The method of  claim 20 , wherein applying pressure to the assembled lamination preform, glove shell, and laminating form includes applying pressure using at least one of a bladder press and a vacuum bag press. 
     
     
         22 . The method of  claim 17 , wherein
 the glove shell is reversibly deformable;   placing the glove shell on the laminating form includes deforming the glove shell; and   removing the glove shell with the laminate preform bonded thereto from the laminating form includes allowing the glove shell with laminate preform bonded thereto to recover substantially to the pre-deformation shape of the glove shell.   
     
     
         23 . The method of  claim 22 , wherein the shape recovery of the glove shell is disproportionately located in regions of the glove shell to which the laminate preform is not bonded, thereby causing a warping deformation of the laminate preform. 
     
     
         24 . The method of  claim 22 , wherein placing the glove shell on the laminating form includes increasing the circumferences of the glove shell fingers by a factor of between 10% and 60%. 
     
     
         25 . The method of  claim 17 , further comprising, before placing the lamination preform on the glove shell, removing substantially all spin finish and lubricants from the portion of the glove shell that conforms closely to the laminating surface, such that a Soxhlet extraction with acetone yields less than 1.5% by weight of the textile. 
     
     
         26 . The method of  claim 17 , further comprising, before placing the lamination preform on the glove shell, removing substantially all spin finish and lubricants from the portion of the glove shell that conforms closely to the laminating surface, such that a Soxhlet extraction with acetone yields less than 0.5% by weight of the textile. 
     
     
         27 . The method of  claim 17 , wherein the laminate preform includes at least one of:
 a textile layer;   an oriented film;   a layer of graphics;   a filler having a density that would cause the filler to settle if added to the liquid coating material; and   a filler having a density that, if added to the liquid coating material, would increase a viscosity of the liquid coating material, thereby rendering the liquid coating material unsuitable for dip-coating the glove shell.   
     
     
         28 . The method of  claim 17 , wherein preparing the flat, solid laminate preform includes at least one of printing, roll-to-roll coating, extrusion, stenting, blown extrusion, weaving, and knitting. 
     
     
         29 . The method of  claim 17 , wherein the pressure above ambient pressure is between 5 psi and 150 psi above ambient pressure. 
     
     
         30 . The method of  claim 17 , wherein the temperature above ambient temperature is between 200 degrees Fahrenheit and 375 degrees Fahrenheit. 
     
     
         31 . The method of  claim 17 , further comprising:
 preparing a flat, solid inner laminate preform, the inner laminate preform including an exposed layer of inner lamination adhesive;   placing the inner laminate preform on the laminating form before placing the glove shell on the laminating form, so that the inner lamination adhesive is in direct contact with the inner surface of the glove shell; and wherein   applying pressure to the assembled laminate preform, glove shell, inner laminate preform, and laminating form causes the inner lamination adhesive to bond the inner laminate preform to the inner surface of the glove shell.   
     
     
         32 . The method of  claim 17 , further comprising attaching a cut-and-sew inner liner inside of the glove shell before placing the inner lining and glove shell on the laminating form.