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.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a protective glove having a knitted palm covering and a related method of manufacture.

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.

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.

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.

Accordingly, there remains room for improvement in the field of protective gloves.

SUMMARY OF THE INVENTION

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

FIG. 1 is a top view of a dorsal side of a glove including a palm covering according to a current embodiment;

FIG. 2 is a bottom view of a palm side of the glove of FIG. 1;

FIG. 3 is a side view of a medial side of the glove of FIG. 1;

FIG. 4 is side view of a lateral side of the glove of FIG. 1; and

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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® 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.

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° C.-250° 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/cm³-1.60 g/cm³, further optionally 0.90 g/cm³-1.2 g/cm³ at 20° 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° 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° C., further optionally less than 325° C., yet further optionally less than 310° C., even further optionally less than 280° C. Suitable polyamides can be optionally ULTRAMID® A3X2G5 Uncolored Polyamide commercially available from BASF of Florham Park, N.J., further optionally Emarex™ 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.

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.

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.

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.

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.

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.

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®. 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.

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.

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.

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).

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.

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.