Cooling Material for Protective Garment

Abstract

A yarn having a plurality of filaments in which the filaments are made of a polymer having a moisture regain of 5 w/w % or less. The plurality of filaments is composed of individual filaments each having a linear density in a range of 1 to 3 denier, and the individual filaments have a multilobed cross-sectional shape. The yarn can be incorporated into fabrics, in particular for protective garments.

Claims

1. A yarn, comprising: a plurality of filaments, the filaments comprising a polymer having a moisture regain of 5 w/w % or less; wherein the plurality of filaments is comprised of individual filaments each having a linear density in a range of 1 to 3 denier; and wherein the individual filaments comprise a multilobed cross-sectional shape.

2. The yarn of claim 1, wherein the polymer comprises polyamide, polyester, or a blend of polyamide and polyester.

3. The yarn of claim 1, wherein the multilobed cross-sectional shape is a star.

4. The yarn of claim 1, wherein the yarn comprises a powder configured to enhance a thermal effusivity of the yarn.

5. The yarn of claim 4, wherein the powder is a pyroxene mineral.

6. The powder of claim 5, wherein the pyroxene mineral is jadeite.

7. The yarn of claim 1, further comprising a core filament comprised of an elastic material, wherein the plurality of filaments form a sheath around the core filament.

8. The yarn of claim 7, wherein the elastic material comprises elastane.

9. The yarn of claim 7, wherein the core filament has a linear mass density in a range from 10 denier to 60 denier.

10. The yarn of claim 1, wherein the plurality of filaments is from 50 to 150 filaments.

11. A fabric comprising the yarn according to claim 1.

12. A garment comprising the fabric of claim 11, the garment being selected from a group consisting of a gaiter, a sleeve, a balaclava, a t-shirt, a glove, a helmet liner, or a cooling towel.

13. A cut-resistant fabric, comprising: a first yarn, the first yarn comprising the yarn according to claim 1, and a cut-resistant yarn.

14. The cut-resistant fabric of claim 13, wherein the polymer of the first yarn is polyamide and wherein the multilobed cross-sectional shape is a star.

15. The cut-resistant fabric of claim 13, comprising a single jersey knit pattern.

16. A glove comprising the cut-resistant fabric of claim 13.

17. The glove of claim 16, comprising an ANSI/ISEA 105-2016 cut level of at least 2.

18. The glove of claim 16, comprising a rating of at least level B according to EN 388:2016.

19. A protective sleeve comprising the cut-resistant fabric of claim 13, the protective sleeve comprising an ANSI/ISEA 105-2016 cut level of at least 1.

20. A protective sleeve comprising the cut-resistant fabric of claim 13, the protective sleeve comprising a rating of at least level A according to EN 388:2016.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

[0028] FIG. 1 depicts personal protective equipment (PPE) in the form of a glove prepared from the disclosed cut-resistant, cooling fabric, according to an exemplary embodiment;

[0029] FIG. 2 depicts PPE in the form of a sleeve prepared from the disclosed cut-resistant, cooling fabric, according to an exemplary embodiment;

[0030] FIG. 3 depicts the sleeve of FIG. 2 on a wearer's arm, according to an exemplary embodiment;

[0031] FIG. 4 depicts PPE in the form of a gaiter prepared from the disclosed cut-resistant fabric, according to an exemplary embodiment;

[0032] FIG. 5 depicts a cross-section of a filler yarn of the cut-resistant, cooling fabric, according to an embodiment of the present disclosure;

[0033] FIG. 6 is a table showing various sheath filament cross-sectional shapes, according to exemplary embodiments of the present disclosure; and

[0034] FIG. 7 is a schematic representation of a filament forming process, according to an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

[0035] Referring generally to the figures, various embodiments of a yarn configured for use in personal protective equipment is provided. In embodiments, the yarn is a cooling material designed to provide improved cooling, thermal transfer, and/or moisture wicking. In specific embodiments, the yarn is incorporated into fabrics, alone or in combination with at least one other yarn, that are utilized in protective garments, such as gloves, cut resistant gloves, cut resistant sleeves, etc.

[0036] Additional details are shown and described in the accompanying figures.

[0037] FIG. 1 depicts an example of personal protective equipment (PPE) in the form of a glove 100. As can be seen in the particular embodiment shown in FIG. 1, the glove 100 has a two-part construction with a first part of fabric 102 and a second part of a polymer coating 104. In one or more embodiments, the fabric 102 is a knitted fabric. In one or more embodiments, the fabric 102 provides cut protection as will be discussed more fully below, and the polymer coating 104 provides a gripping surface to enhance the ability of the wearer to manipulate objects while wearing the glove 100. In one or more embodiments, the polymer coating 104 is nitrile or polyurethane, for example.

[0038] In one or more embodiments, the glove 100 includes a front side 106 and a back side 108. As shown in FIG. 1, the polymer coating 104 of the glove 100 is disposed primarily on the front side 106 of the glove 100, covering substantially all of the palm 110 and fingers 112. In one or more embodiments, the polymer coating 104 may at least partially wrap around the fingers 112 to the back side 108. In one or more embodiments, the glove 100 includes a cuff 114. In one or more embodiments, the cuff 114 includes a color-coded band 116 to facilitate identification of the type of the glove 100, such as the level of cut protection, for example.

[0039] While the glove 100 depicted in the embodiment of FIG. 1 includes a polymer coating 104, other embodiments may not include a polymer coating 104 such that the glove 100 only includes the fabric 102. Further, the glove 100 may include other coatings or layers, and indeed, other glove constructions are within the scope of the present disclosure.

[0040] FIG. 2 depicts another example of PPE in the form of a sleeve 200. The sleeve 200 is formed from fabric 202 defining a tubular structure having a first end 204 and a second end 206. In one or more embodiments, the fabric 202 is a knitted fabric. In one or more embodiments, the tubular structure may include regions having various widths sized to fit different portions of a wearer's arm. For example, the tubular structure of the sleeve 200 includes a bicep portion 208, an elbow portion 210, a forearm portion 212, and a wrist cuff 214. In one or more embodiments, a thumb loop 216 is attached to the wrist cuff 214 at the first end 204 of the sleeve 200. In one or more embodiments, the sleeve 200 includes an elastic band 218 at the second end 206 of the sleeve 200. The elastic band 218 is configured to hold the sleeve 200 in place on the wearer's bicep at the second end 206, and the thumb loop 216 is configured to hold the sleeve 200 in place at the first end 204. The foregoing description of the sleeve 200 is merely exemplary, and other sleeve constructions are within the scope of the present disclosure.

[0041] FIG. 3 depicts a user 300 wearing the sleeve 200. As can be seen, the tubular structure of the sleeve 200 surrounds a substantial portion of the arm 302 of the user 300, including the bicep 304, elbow 306, forearm 308, and wrist 310. The elastic band 218 contracts around the user's bicep 304, and the thumb loop 216 is wrapped around a thumb 312 of the user 300. In this way, the sleeve 200 provides some level of protection against lacerations and abrasions for the area of the arm 302 of the user 300 covered by sleeve 200.

[0042] FIG. 4 depicts still another example of PPE in the form of a face covering, in particular a gaiter 320. Like the sleeve 200, the gaiter 320 is formed from fabric 322 defining a tubular structure having a first end 324 and a second end 326. In one or more embodiments, the fabric 322 is a knitted fabric. In contrast to certain embodiments of the sleeve 200, the gaiter 320 has a generally tubular structure with a substantially constant width along its length between the first end 324 and the second end 326. In one or more embodiments, the gaiter 320 includes at least one elastic band 328 at at least one of the first end 324 or the second end 326. The gaiter 320 can be worn in a variety of ways. In the embodiment shown in FIG. 4, the gaiter 320 is worn covering a nose and mouth of a user 300. In other embodiments, the gaiter 320 can instead be worn around the neck of the user 300, below the nose of the user 300 and covering the mouth of the user, and as a headband around the forehead of the user 300. In one or more such embodiments, the at least one elastic band 328 can be used to hold the gaiter 320 at the desired position. Notwithstanding, in one or more other embodiments, an entire length of the gaiter 320 may be made from an elastic fabric such that an elastic band 328 is not needed. Further, other types of face coverings, including other gaiter constructions may utilize the fabric 322 and are considered to be included within the scope of the present disclosure.

[0043] Besides those garments depicted, the fabric 102, 202, 322 can be used to make other garments, such as a balaclava, a t-shirt, a helmet liner, or a cooling towel, amongst other possibilities.

[0044] As will be described more fully below, the fabric for the PPE, such as the fabric 102, 202, 322 of the glove 100, sleeve 200, or gaiter 320, is prepared from at least a first yarn. In one or more embodiments, the first yarn is configured to cool the wearer such as by providing improved heat transfer away from the user and/or by providing improved one-way moisture transport, breathability, and/or moisture wicking. In one or more embodiments, the fabric 102, 202, 322 is formed form a combination of yarns, in particular at least the first yarn and a second yarn in which the second yarn is configured to provide cut protection in addition to the cooling function of the first yarn. Notwithstanding, the fabric 102, 202, 322 may provide other functions, such as UV protection, anti-microbial odor resistance, and/or moisture-wicking, amongst other possibilities. In one or more embodiments, the fabric is a single jersey fabric, but other knitted, woven, or nonwoven fabrics may also be used. In one or more embodiments, the fabric is plated, having a first color on a surface facing the wearer and a second color on a surface facing away from the wearer.

[0045] In the fabric, the first yarn comprises a filament yarn. FIG. 5 depicts an example of such a filament yarn 400. As can be seen, in one or more embodiments, the filament yarn 400 may include a core filament 402 surrounded by a sheath 404 of outer filaments 406. However, in one or more other embodiments, the filament yarn may just include all filaments 406 of a single type. In one or more embodiments, the core filament 402 may be spun with the outer filaments 406 during a yarn production process, or in one or more other embodiments, the core filament 402 may be added to the outer filaments 406 as two separate yarns at a knitting machine.

[0046] In one or more embodiments, where included, the core filament 402 is an elastic material that maintains the stretchability of the fabric of the PPE. In one or more embodiments, the core filament 402 comprises elastane. In one or more embodiments, the core filament 402 comprises a linear mass density in a range of 10 denier to 60 denier, in particular in a range of 20 denier to 40 denier, and most particularly about 20 denier.

[0047] In one or more embodiments, the sheath 404 of outer filaments 406 is configured to wick away moisture and heat from the wearer. In one or more embodiments, the individual outer filaments 406 of the sheath 404 comprise a linear mass density in a range of 1 denier to 3 denier, in particular about 2 denier. In one or more embodiments, the filaments 406 of the sheath 404 together comprise a linear mass density in a range of 50 denier to 150 denier, in particular 90 denier to 110 denier, and most particularly about 105 denier. In one or more embodiments, the sheath 404 of the filament yarn 400 comprises from 35 to 105, in particular about 50, outer filaments 406.

[0048] In one or more embodiments, the outer filaments 406 of the sheath 404 are comprised of a polymer, in particular a polymer that has low water absorption (e.g., as measured by moisture regain). In one or more embodiments, the outer filaments 406 of the sheath 404 comprise a moisture regain of 5 w/w % or less, in particular 1 w/w % or less. Moisture regain of a filament refers to the amount of moisture that the filament is able to reabsorb after the filament has been dried, and moisture regain is expressed as a ratio of the water in a filament to the filament's dry weight. In one or more embodiments, the outer filaments are comprised of polyester, polyamide, or a blend of polyester and polyamide. In one or more preferred embodiments, the filaments are comprised of polyamide, in particular polyamide 6 or polyamide 6,6.

[0049] In one or more embodiments, the first yarn 400 comprises a powder configured to enhance the thermal effusivity of the first yarn 400 (as measured according to ASTM Test Method D7984-16). In one or more embodiments, the powder is dusted or coated onto the yarn 400, embedded in the yarn 400, or otherwise attached to the yarn 400. In one or more embodiments, the powder is pyroxene mineral, such as jadeite. Advantageously, in one or more embodiments, the powder is selected to have a high internal thermal conductance, which can be used to conduct heat away from a wearer's body.

[0050] In one or more embodiments, the first yarn 400 comprises a powder or coating (alternatively or in addition to the powder configured to enhance the thermal effusivity) to provide enhanced antimicrobial properties, amongst other functional enhancements.

[0051] Further, in one or more embodiments, the cross-sectional shape of the outer filaments 406 is designed to enhance the moisture wicking and thermal conductance. For example, in the embodiment shown in FIG. 5, the outer filaments 406 are each shaped like a star. The star shape increases inter-fabric capillaries, which improves moisture wicking ability.

[0052] Notwithstanding, the outer filaments 406 can be any of a variety of other shapes as shown in FIG. 6. In particular, FIG. 6 includes a table 500 showing 30 different fiber extrusion shapes for the filaments 406. As shown in FIG. 6, the shape of the filaments 404 can be, for example, a variety of polygonal, curved, lobed, and segmented shapes. In the table 500, one or more embodiments of the shapes are rectangular shapes or are created by the intersection of rectangular shapes, including flat bar (500-1), I-shaped (500-2), T-shaped (500-5), cross (500-6), and thin cross (500-7). In one or more embodiments, the cross-sectional shapes comprise a plurality of lobes, such as three lobes (500-3), rounded lobes (500-4), two lobes (500-8), five lobes (500-9), six lobes (500-10), or eight lobes (500-11). In one or more embodiments, the cross-sectional shapes comprise segments of a circle, such as one segment (500-23), two segments (500-24), three segments (500-25), or four segments (500-26). In one or more embodiments, the cross-sectional shape defines a hollow interior, such as segmented triangles (500-15, 500-16, 500-24, 500-25, 500-26). In one or more embodiments, the cross-sectional shape is comprised of multiple intersecting T-shapes, such as three intersecting T-shapes (500-27), four rounded intersecting T-shapes (500-28), and four straight intersecting T-shapes (500-30). Other potential shapes include W-shaped (500-12), three-arm spiral (500-13), connected beads (500-14), chevron shaped (500-17), and segmented three-arm spiral (500-29). The cross-sections are merely exemplary, and the outer filaments 406 can have other cross-sectional shapes in one or more other embodiments.

[0053] As shown in FIG. 7, the outer filaments 406 can be produced in the desired cross-sectional shape by extruding the outer filaments 406. In one or more embodiments, a spinneret 600 receives a spinning solution 602, and the spinning solution 602 is forced through a plurality of holes 604 defining the desired cross-sectional shape to produce the outer filaments 406. The filaments 406 may be cooled, e.g., in air or in a water bath 606 and then taken up on a reel 608 from which the filaments 406 can be stranded around the core filament 402. In one or more embodiments, the molten polymer is air cooled while stretching the filaments 406 (in a process known as drawing) which allows the filaments 406 to be formed at the desired size while increasing the crystallinity of the polymer structure while aligning the polymer crystals along the length of the filaments 406.

[0054] In one or more embodiments in which the fabric comprises at least two yarns, the second yarn include a cut-resistant yarn in addition to the first yarn. In one or more embodiments, the fabric comprises from 10% to 90%, by weight, of the first yarn and from 10% to 90%, by weight, of the second yarn. In one or more embodiments, the fabric further comprises a third yarn, in particular an elastic yarn, in an amount in a range of 1% to 50%, by weight.

[0055] In one or more embodiments, the cut-resistant yarn comprises fibers or filaments of high density polyethylene (HDPE), ultrahigh molecular weight polyethylene (UHMWPE), polyamide, basalt, glass, tungsten, carbon, and steel (e.g., stainless steel). In one or more embodiments, the cut-resistant yarn comprises a core or is coreless. For example, the cut-resistant yarn having a core may comprise a polymer coating (e.g., HDPE or UHMWPE) around a core of at least one of basalt, glass, steel, tungsten, or carbon fibers, or a coreless cut-resistant yarn may comprise filaments of HPPE, UHMWPE, or polyamide, optionally comprising crystalline particles to enhance strength. Such cut resistant yarns are known in the art and are available from a variety of commercial sources.

[0056] In one or more embodiments, the incorporation of the cut-resistant yarn into the fabric 102, 202, 322 allows the PPE including the fabric 102, 202, 322 to achieve a cut rating of at least 1, in particular at least 2, most particularly at least 3, according to ANSI/ISEA 105-2016. In one or more embodiments, the incorporation of the cut-resistant yarn into the fabric 102, 202, 322 allows the PPE including the fabric 102, 202, 322 to achieve a cutting rating of at least level A, in particular at least level B, according to EN 388:2016.

[0057] It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for description purposes only and should not be regarded as limiting.

[0058] Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, use of certain materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.

[0059] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article a is intended to include one or more component or element, and is not intended to be construed as meaning only one.

[0060] Various embodiments of the disclosure relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements or components of any of the other embodiments discussed above.

[0061] While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

[0062] In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.