Utility glove

Abstract

A utility glove comprising a three dimensional molded portion formed of an elastomeric material molded onto a fabric material, wherein the molded portion has a thickness of from about 0.8 to about 10.8 mm with the elastomeric material including two or more areas of differing thicknesses within the range of from about 0.4 to about 10.0 mm. The molded portion of the utility glove has a concave palm, with the middle of the palm being set in from the edges to form a concave configuration. The utility glove is manufactured by placing a glove blank comprising a fabric material over a first mold part in the form of at least a portion of a hand and bringing at least one second mold part into molding engagement with the first mold part to create a cavity with the glove blank on the first mold part. The elastomeric material is then injected into the cavity to form a molded portion, wherein the elastomeric material is injected on the side of the fabric material opposite the first mold part.

Claims

1. A method of manufacturing a utility glove having a thumb, four fingers and a main body, said glove comprising a three dimensional molded portion, the molded portion comprising an elastomeric material bonded to a fabric material in a three dimensional configuration substantially conforming to three dimensional contours of at least a portion of a hand exclusive of any variations in thickness or features on the surface of the molded portion, comprising the steps of: a. placing a glove blank comprising a fabric material over a first mold part in the form of at least a portion of a hand; b. bringing a second mold part into molding engagement with the first mold part to create a cavity with only a portion of the glove blank on the first mold part; and c. injecting an elastomeric material into the cavity to form a molded portion, said molded portion having a thickness of from about 0.8 mm to about 10.8 mm with the elastomeric material on the fabric of the molded portion having a thickness of from about 0.4 mm to about 10.0 mm, wherein the elastomeric material of the molded portion is integrally formed to continuously extend up to and including 360 about the main body of the glove while leaving a portion of the fabric material of the glove blank without elastomeric material entirely surrounded by the molded portion.

2. The method of claim 1 further comprising the steps of: d. disengaging the second mold part from the first mold part; and e. removing the fully formed utility glove from the first mold part.

3. The method of claim 1 wherein the second mold part includes elements for forming a molded portion with two or more adjacent elastomeric areas of differing thicknesses.

4. The method of claim 1 wherein the second mold part includes elements for forming a molded portion with one or more textured gripping portions taken from the group consisting of gnarled portions, dimples, bumps, w-shaped members, v-shaped members, textured loops, perforations and embossed gripping details.

5. The method of claim 1 wherein the elastomeric material of the molded portion is integrally formed to continuously extend 360 about the main body of the glove.

6. The method of claim 1 wherein the molded portion covers greater than 50% of the circumference of each finger and the thumb of the glove but not 100% of each finger and the thumb.

7. The method of claim 1 wherein the molded portion includes a saddle between the thumb and a first finger that extends continuously from a palm side to a back side of the glove.

8. The method of claim 1 wherein the second mold part in step (b) comprises a plurality of mold parts which create the cavity with the glove blank on the first mold part.

9. The method of claim 1 wherein the utility glove includes at least one area of fabric without elastomeric material entirely surrounded by a molded portion.

10. The method of claim 9 wherein the at least one area of fabric without elastomeric material entirely surrounded by a molded portion is on at least one of a thumb and one or more fingers of the glove.

11. The method of claim 1 wherein the molded portion covers greater than 50% but less than 100% of the circumference of each finger, the thumb and the main body of the glove.

12. The method of claim 1 wherein the ratio of thickness of the fabric material to the thickness of the elastomeric material forming the molded portion is from about 0.4% to about 100%.

13. The method of claim 1 wherein elastomeric material comprises a material is taken from the group consisting of a thermoplastic vulcanite (TPV) and a thermoplastic rubber (TPR) having a shore durometer of from about 10 to about 25.

14. The method of claim 13 wherein the elastomeric material is a TPR having a shore durometer of about 15.

15. The method of claim 1 wherein the fabric material is a knit hydrophilic material having a thickness of from about 0.4 to about 1.8 mm.

16. The method of claim 15 wherein the knit hydrophilic material comprises a nylon material and has a thickness of from about 0.5 to about 0.8 mm.

17. The method of claim 1 further comprising the step of dipping the glove in a material after the molded portion is formed.

18. The method of claim 1 further comprising the step of dipping the glove in a material before the molded portion is formed.

19. The method of claim 1 wherein the molded portion covers a palm area on a palm side of the main body of the glove, wherein the molded palm is formed in a pre-curved configuration where the middle of the palm is set in from the edges of the palm to form a concave shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will be better understood when considered in view of the attached drawings, in which like reference characters indicate like parts. The drawings, however, are presented merely to illustrate the preferred embodiment of the invention without limiting the invention in any manner whatsoever.

(2) FIG. 1 shows a front view, palm side, of a utility glove according to the invention;

(3) FIG. 2 shows a back view of the glove of FIG. 1;

(4) FIG. 3 shows the back of the palm side gripping portion of the glove of FIG. 1;

(5) FIG. 4 shows the palm side of the palm gripping portion of the glove of FIG. 1 with embossed grip details;

(6) FIG. 5 shows the inside of the palm gripping portion of the gardening glove embodiment;

(7) FIG. 6 shows the palm side of the gardening glove with the gripping portions of FIG. 5;

(8) FIG. 7 shows the back side of the glove of FIG. 6; and

(9) FIG. 8 shows the palm side of the palm gripping portion of FIG. 5.

(10) FIG. 9 shows a front view, palm side, of a preferred embodiment of a utility glove according to the invention.

(11) FIG. 10 shows a back view of the glove of FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(12) FIG. 1 shows the palm side of a utility glove 2 with a molded portion 4 formed of an elastomeric material bonded to a fabric material. The palm side of the utility glove 2 shown in FIG. 1 also includes a fabric material 12 in the area beyond the molded portion 4, although such a fabric material 12 is not required as a visible element of the palm side of the glove 2 of the present invention. Notwithstanding, it is preferred that the fabric material 12 beyond the molded portion 4 is the continuation of the fabric material forming the adjacent molded portion 4.

(13) FIG. 2 shows the back side of the glove 2, including a fabric material 12 and having independent molded areas 14 applied with raised perforated protective shapes. Of course, any molded portion can be formed on the back side of the glove 2, including a molded portion 4 or 14 that covers the knuckles where the fingers join the back of the hand or even the back of the hand itself. The fabric material 12 on the back side of the glove 2 is preferably formed as part of a glove blank including the fabric material 12 on the palm side of the glove. Alternatively, the fabric 12 on the back side of the glove 2 may be sewn to the palm side of the glove 2, either to the molded palm portion 4 or the fabric material 12 of the palm side. A closure element, shown as a molded wrist strap 16, may be provided to afford a better fit and help keep the glove 2 securely on the user's hand while in use.

(14) The molded portion 4 of the glove 2 of the present invention preferably has embossed gripping details 6, as shown in FIGS. 6, 8 and 9, debossed flex grooves 8, shown in FIGS. 4 and 9, and raised textured grip areas 10, shown in FIGS. 4, 6 and 10. In this regard, the molded portion 4 of the embodiment of FIGS. 3-10 preferably includes raised textured grip areas 10 shown as a raised or thickened textured index finger tip and thumb tip for better gripping, durability and reinforcement.

(15) The molded portion 4 of the glove 2, or any molded portion 4 and/or 14 of the glove 2, is preferably manufactured by using a heat resistant knit hydrophilic fabric that can withstand heat of approximately 400 degrees Fahrenheit onto which an elastomeric material is injection molded. Preferably, a mold that comprises a first mold part in the shape of at least a portion of a hand and at least one corresponding second mold part create a mold cavity with the fabric therein. Although any suitable knit hydrophilic heat resistant fabric can be used for the fabric, it has been found that fabric material comprising a nylon material is the most suitable for the invention as presently contemplated. Such a nylon knit hydrophilic material comprises a porous structure for the elastomeric material to bond with the fabric 12 by penetrating and being drawn into the pores of the fabric 12.

(16) As set out above, a mold part in the shape of at least a portion of a hand may be in the three dimensional shape of at least a portion of a hand, not merely a two dimensional silhouette of a portion of a hand. The heat resistant fabric 12 is preferably in the form of a glove blank, i.e., at least a portion of a glove structure which can receive at least a portion of a hand. Alternatively, albeit less preferred, the heat resistant fabric 12 can be cut in the shape of the outlined elastomeric material that forms the molded portion 4 of the glove 2, as shown in FIGS. 3-4 and/or FIGS. 5 and 8, that is sewn to a fabric material 12, illustrating an alternative embodiment of the molded portion 4.

(17) The utility glove 2 of the present invention, however, is most preferably manufactured by placing a glove blank comprising a fabric material 12 over a first mold part in the form of at least a portion of a hand and bringing at least one second mold part into molding engagement with the first mold part to create a cavity with the glove blank on the first mold part. The elastomeric material is then injected into the cavity to form a molded portion 4, wherein the elastomeric material is injected on the side of the fabric material 12 opposite the first mold part. Once the molded portion 4 is formed, the second mold part is disengaged from the first mold part and the fully formed utility glove 2 is removed from the first mold part.

(18) With respect to the embossed gripping details 6, debossed flex grooves 8, and raised textured grip areas 10, as well as perforations 24, dimples, bumps and the like, it is preferred that the second mold part is adapted to form these elements in the molded portion 4.

(19) In one of the most preferred embodiments, where the molded portion 4 extends up to and including 360 about the glove 2 without a seam, a second mold part and a third mold part may be brought into molding engagement with the first mold part to create a mold cavity, with a glove blank in the form of at least a portion of a glove on the first mold part. It is here contemplated that the second mold part is adapted to mold at least a portion of one of the palm side or the back side of the glove 2 and the third mold part is adapted to mold a portion of the other of the palm side or the back side of the glove 2.

(20) The method of injection molding of the elastomeric material in the present invention permits the application of the elastomeric material on both sides of the glove 2, i.e., the palm side and the back side, while selectively leaving areas on the back of the glove 2 without an elastomeric material. This ensures breathability of the glove 2, where the open portions without an elastomeric material may have a mesh or other fabric in the opening for user comfort. Preferably, as shown in FIGS. 9 and 10, the elastomeric material of the molded portion 4 continues seamlessly around to the back of the glove 2, and most preferably seamlessly 360 around at least a portion of the glove 2.

(21) For the three dimensional portion of the mold, namely the thumb and index finger in the embodiment of FIGS. 3 and 4 and each of the fingers in the embodiment of FIGS. 5 and 8-10, a stay can be inserted that ensures the fingers, including the index finger and thumb, to help keep their shape. However, the shaped molded portions of the glove 2, including the fingers and the palm of the molded portion 4 adapted to take a pre-curved concave configuration, are preferably formed by corresponding mold parts, where a first mold part is the three dimensional shape or form of at least part of a hand. When using the preferred corresponding mold parts, the elastomeric material is injected on the side of the fabric 12 opposite the first mold part in the shape of at least a portion of the hand to form the molded part or parts 4 and/or 14 of the glove 2.

(22) In either event, the molded elastomeric material is intended to adhere to all areas of the fabric within the mold, preferably including the cap for covering the entire tip of the thumb and index finger or fingers, as well as the majority of the circumference of the thumb and fingers to be covered, that is at least, and preferably greater than, 50% of the circumference of the user's thumb and fingers, as desired.

(23) Optionally, a thin lining material can be inserted between the fabric and the first mold part or as the fabric prior to shooting the elastomeric material, so that whatever portion that would be in contact with the palm, thumb and fingers of the user would be lined. The glove fabric 12 could then be stitched onto the contour of each finger and reinforcement area of the glove 2, if desired.

(24) If the fabric in the molded palm portion 4 is not in the form of a glove blank which comprises the entire area of the glove 2, the molded portion 4 is then attached to the balance of the glove 2. Preferably, however, the fabric 12 that is visible on the back of the molded fingers, including the back of the thumb and the back of the index finger in FIGS. 1-4 and all fingers in FIGS. 5-8, is not stitched, but is a continuation of the fabric 12 bonded to the elastomeric material in the molding process.

(25) In the embodiment of FIGS. 1-4, 9 and 10, the molded portion 4 is molded about the tip of the thumb and index finger, to form a cap over the tip of the thumb and index finger, and across the palm in the area below the fingers, including up onto a lower portion of the fingers adjacent the fourchettes for the purposes of creating as much of a waterproof construction as possible. The mold would also rise in between the index finger and the thumb, forming a saddle 28 from at least about the base of the thumb to at least about the base of the forefinger and extending from the palm side of the glove 2 to the back side of the glove 2 as part of the molded palm portion 4, for enhanced grip to enable the user to grip trowels, rakes, etc. more effectively. Flex grooves 8 are preferably placed in the areas of at least some of the joints of the hand on the molded palm portion 4, including in the palm area and at the fingers to provide improved flexibility. Raised portions 10, for abrasion resistance or padding, are included at the tips of the thumb and index finger as well as in the area of the saddle 28.

(26) With respect to the elastomeric materials used, different compositions of elastomeric material can be used in the formation of the molded portion(s) 4 and/or 14 or parts thereof. For example, an elastomeric material that is less slippery when wet may be used at the tips of the thumb and one or more fingers, as well as the saddle 28, allowing the glove 2 to be more versatile in wet conditions. Moreover, if abrasion resistance is of particular importance in an area of the molded portion 4, a denser material can be used in that area. Similarly, where impact resistance is of particular importance in an area, such as a padded area 10, a less dense elastomeric material may be preferred. The proper applications of such variations will be well within the design preferences of one skilled in the art.

(27) Notwithstanding, it has been found that thermoplastic vulcanite (TPV) and thermoplastic rubber (TPR) are preferred materials for forming and serving as the elastomeric material used for the molded portion(s) 4 and/or 14 of the glove 2 of the present invention. It has been found that the balance between durability and flexibility of the elastomeric material can be tilted toward flexibility when using the present invention. As such, an elastomeric material with a shore durometer of from about 15 to about 25, and most preferably about 15, can be used at very thin thicknesses when bonded to the fabric in areas where flexibility is more desirable than durability.

(28) In the embodiments shown in FIGS. 5-10, molded portion 4 preferably covers at least, and preferably greater than, 50% of the circumference of the fingers including the entire palm side and the majority of the sides of the fingers. The palm portion 4 of the embodiment shown in FIGS. 9 and 10 is preferably pre-curved in a concave configuration to minimize bunching when the wearer's hand closes. The molded portion 4 also preferably contains embossed gripping details 6, such as textured loops, a gnarled surface, dimples bumps and/or the like, to increase gripping and enhance the protection of the user. The back portion of the glove 2 may include a closure element, shown in the form of a stretchable material 18 rather than a wrist strap 16, to provide a snug and comfortable fit while permitting easy insertion and removal of the wearer's hand.

(29) Of course, the molded portion 4 of the glove 2 of FIGS. 5-10 is also amenable to molding with any variety of different patterns shapes and designs, including padded or raised portions 10, greater or lesser pre-curving of the palm portion 4 to create a predetermined cupped shape, flex grooves 8 or textured areas 6. The benefits of these features would similarly be the comfort, cosmetic value, waterproofing, which may be important for some uses such as gardening, as well as providing padding in critical impact areas, and additional grip and or abrasion resistance in critical areas of the glove 2.

(30) The glove 2 of the present invention can be manufactured with different fabric and elastomeric materials, as described above. In addition to the different materials, the glove 2 of the present invention can have different thicknesses, both overall and in different areas of the molded portion.

(31) More particularly, the fabric material used to form the glove of the present invention, preferably a knit hydrophilic fabric, can have any suitable thickness, but is preferably from about 0.4 to about 1.8 mm thick and most preferably about 0.5 to about 0.8 mm thick. Similarly, the elastomeric material can be molded onto the fabric material at any suitable thickness, however, it is preferred that the elastomeric material have a thickness of from about 0.4 to about 10.0 mm. In this regard, the upper limit of the elastomeric material can correspond to the appropriate use, including thicknesses of up to about 4.0, about 5.0, about 6.0 about 7.0 and about 10.0 mm for uses requiring such characteristics as electrical insulation to vibration damping, for use with everything from power drills to jackhammers. As such, the thickness of the molded portion, with the elastomeric material boded to the fabric material, would have a preferred thickness of from about 0.8 to about 10.8 mm.

(32) Notwithstanding, for more common utility uses, it is preferred that the thickness of the elastomeric material in the molded portion 4 be from about 0.5 to about 3.0 mm thick, with from about 0.5 to about 1.7 being most preferred. Using these thicknesses, the overall thickness of the preferred glove 2 in the molded portion 4, including the elastomeric material bonded to the fabric material, is from about 0.8 to about 3.1 mm thick and most preferably from about 1.0 to about 2.3 mm thick.

(33) In the preferred embodiment of FIGS. 9 and 10, the molded pre-curved palm portion 4 continues to the fingers to form an overall cupped shape including the fingers, again to minimize bunching when the hand is closed. Also incorporated in this embodiment are raised portions 10 and flex grooves 8 having stepped thicknesses to maximize flexibility, wear and cushioning. Most preferably, the areas of the embodiment of FIG. 9 forming the molded first areas 20, shown as about and within the palm, between the fingertips and joint between the fingers and the palm, around the back of the glove and in the flex grooves 8, is formed of an elastomeric material that is from about 0.4 to about 1.0 mm, and preferably from about 0.5 to about 0.8 mm. Used with a fabric of about 0.5 to about 0.6 mm, the total thickness of the molded palm portion 4 in the molded first areas 20 is preferably from about 1.0 to about 1.6 mm. This provides maximum flexibility for the user in the molded first areas 20.

(34) The molded second areas 22 of the embodiment of FIGS. 9 and 10, being at the fingertips, on the saddle 28, between the forefinger and thumb and/or across the area between the palm and the fingers, comprises an intermediate raised area 10. The molded second areas 22 are formed of an elastomeric material that is from about 1.2 to about 1.6 mm, and preferably about 1.4 mm. Used with a fabric of about 0.5 to about 0.6 mm, the total thickness of the molded portion 4 in the molded second areas 22 is preferably from about 1.7 to about 2.2 mm. This provides additional durability for wear and extra protection without sacrificing feel.

(35) The molded third areas 24 of the embodiment of FIGS. 9 and 10, being within the palm and/or across the knuckles on the back of the glove 2, is comprised of an extra raised area 10. The molded third areas 24 are formed of an elastomeric material that is from about 1.6 to about 2.0 mm, and preferably about 1.8 mm. Used with a fabric of about 0.5 to about 0.6 mm, the total thickness of the molded portion 4 in the molded third areas 24 is preferably from about 2.1 to about 2.6 mm. This provides maximum protection for the portions of the users hand most likely to receive traumatic impact.

(36) Significantly, the present invention provides the heretofore unknown benefit of a glove with a molded palm portion 4 that can utilize a molded elastomeric material of down to about a 15 shore durometer at a thickness down to about 0.4 mm, and preferably about 0.5 mm, provided it is backed with a suitable fabric 12 used in the molding process. This advance in the formation and flexibility permits the use as a molded portion 4 of a glove, where the user requires excellent flexibility with good durability.

(37) Most preferably, the embodiment of FIGS. 9 and 10 provides a glove 2 with an molded portion 4 that seamlessly extends up to and including 360 about the glove 2, preferably having openings to permit airflow and, therefore, breathability to the glove 2. For example, as shown in FIG. 10, the molded portion 4 surrounds open fabric portions 12 on the back of the glove 2 for breathability in the finger area. Such fabric portions without elastomeric material encompassed by molded portion 4 can likewise be incorporated into the palm area of the glove 2, as desired.

(38) Of course, as described above, the elastomeric material that is used for the molded portion 4 in the various areas 20, 22 and 24 may have different physical characteristics. These include differences in density, tackiness, flexibility, etc.

(39) Also as shown in FIGS. 9 and 10, the elastomeric portions of the glove 2 may include perforations 24 that extend thorough the elastomeric material. These perforations 24 not only provide ventilation between the interior and exterior of the glove 2, enhancing user comfort, but may provide a vacuum grip where a vacuum is created between the user's finger sealing off the perforation 24 at the interior of the glove 2 and the article to be held at the exterior of the glove 2.

(40) Additionally, the molded portion 4 of the glove 2 of FIGS. 9 and 10 includes gripping details 6 in the form of a gnarled surface, dimples, bumps, v shaped members and/or w shaped members that displace moisture both horizontally and vertically to create improved grip in wet or slippery conditions. As shown in the drawings, but without limitation, the gripping details 6 may have dimples or perforations 24 thereon to further increase grip by the use of a vacuum effect, as described above.

(41) For example, the glove 2 of the present invention preferably includes a molded portion 4 with raised textured grip areas 10 at the fingertips and thumb tip for use in gloves for sports and athletics. The raised areas 10 create additional grip and resistance to catch a ball and/or hold a racket, bat, rope, paddle, etc. Most preferably, the textured surface on the raised textured grip areas 10 of the fingertips and thumb tip further improve the grip and resistance.

(42) Moreover, as will be apparent to those skilled in the art, the glove 2 of the present invention can be designed with different combinations of the components described above. For example, the glove 2 of FIGS. 1-2 could be fashioned with a stretchable material 18 rather than a wrist strap 16, or could include a molded portion 4 that covers the front and sides of all of the fingers. Similarly, although the illustrated embodiments include a molded portion 4 over only the index finger and thumb or all fingers and thumb, it is understood that any number or combination of thumb and fingers can be covered.

(43) It will thus be seen that the objects set forth above, those made apparent from the preceding description, and certain changes in the above constructions may be made without departing from the spirit and scope of the invention, such that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative, and not limiting. In this regard, and without limitation, the various features shown in the several embodiments described can be applied singularly or in any number of combinations without falling beyond the scope of the invention.

(44) It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.