阅读说明：本技术 用于织物的分层涂层 (Layered coating for fabrics ) 是由 叶天士 陈晓威 张靖 于 2020-04-24 设计创作，主要内容包括：本申请涉及用于织物的分层涂层。提供了涂层织物及其制造方法。经涂覆织物包括底涂层。所述底涂层限定光滑涂层以阻止液体渗透到所述织物。经涂覆织物还包括沉积在底涂层的至少一部分上的中间泡沫涂层。所述中间泡沫涂层限定中间层泡沫密度并被配置成至少吸收一部分液体。经涂覆织物还包括沉积在中间泡沫涂层的至少一部分上的外泡沫涂层。所述外泡沫层限定外层泡沫密度并被配置成具有孔以允许液体渗透到所述中间泡沫层。中间层泡沫密度小于外层泡沫密度。还提供了相应的制造方法。(The present application relates to layered coatings for fabrics. Coated fabrics and methods of making the same are provided. The coated fabric includes a base coat. The base coat defines a lubricious coating to resist liquid penetration into the fabric. The coated fabric further includes an intermediate foam coating deposited over at least a portion of the base coating. The intermediate foam coating defines an intermediate foam density and is configured to absorb at least a portion of the liquid. The coated fabric further includes an outer foam coating deposited on at least a portion of the intermediate foam coating. The outer foam layer defines an outer foam density and is configured with pores to allow liquid to penetrate to the intermediate foam layer. The middle layer foam density is less than the outer layer foam density. A corresponding method of manufacture is also provided.)

1. A coated fabric, comprising:

a base coat defining a lubricious coating to resist liquid penetration into the fabric;

an intermediate foam coating deposited on at least a portion of the base coating, the intermediate foam layer defining an intermediate foam density and configured to absorb at least a portion of the liquid; and

an outer foam coating deposited on at least a portion of the intermediate foam coating, the outer foam layer defining an outer foam density and the outer foam layer being configured to have pores to allow liquid to penetrate to the intermediate foam layer such that the outer foam layer increases the abrasion resistance of the coated fabric;

wherein the middle layer foam density is less than the outer layer foam density.

2. The coated fabric of claim 1, wherein the middle layer foam density is 0.25 kg/L-0.60 kg/L.

3. The coated fabric of claim 1, wherein the middle layer foam density is 0.45 kg/L-0.60 kg/L.

4. The coated fabric of claim 1, wherein the outer layer foam density is 0.70 kg/L-0.9 kg/L.

5. The coated fabric of claim 1, wherein at least one of the base coat, the intermediate foam coating, or the outer foam coating comprises a nitrile rubber compound.

6. The coated fabric of claim 5, wherein the nitrile rubber compound of the at least one of the base coat, the middle foam coat, or the outer foam coat comprises 45% nitrile latex.

7. The coated fabric of claim 1, wherein the coated fabric is used to form a glove.

8. The coated fabric of claim 7, wherein the base coat, the middle foam coating, and the outer foam coating are each applied to at least the palm area of the glove.

9. The coated fabric of claim 7, wherein the glove is one of a mechanical glove or a chemical glove.

10. The coated fabric of claim 1, wherein the base coat further comprises a nylon backing.

11. A method of making a coated fabric, the method comprising:

applying a base coat composition, said base coat defining a lubricious coating to resist liquid penetration into said fabric;

applying an intermediate foam coating composition over at least a portion of the base coat, the intermediate foam layer defining an intermediate foam density and configured to absorb at least a portion of the liquid; and

applying an outer foam coating composition over at least a portion of the intermediate foam coating, the outer foam layer defining an outer foam density and the outer foam layer being configured with apertures to allow liquid to penetrate to the intermediate foam layer such that the outer foam layer increases the grip and abrasion resistance of the coated fabric;

wherein the middle layer foam density is less than the outer layer foam density.

12. The method of claim 11, further comprising applying a first coagulant to the fabric prior to the step of applying the base coat.

13. The method of claim 12, further comprising applying the first coagulant to the fabric prior to the step of applying the intermediate foam coating.

14. The method of claim 13, further comprising applying a second coagulant to the fabric prior to the step of applying the outer foam coating.

15. The method of claim 14, further comprising applying a third coagulant to the fabric prior to the step of applying the outer foam coating.

16. The method of claim 11, further comprising heating the coated fabric on a hand mold prior to the step of applying the base coat.

17. The method of claim 11, further comprising heating the coated fabric after the step of applying the outer foam coating, wherein at least one of the base coat, the intermediate foam coating, or the outer foam coating cures in response to heat.

18. The method of claim 11, wherein the applying the outer foam coating further comprises washing away unsolidified coating on a surface of the fabric after applying the outer foam coating.

19. The method of claim 15, wherein the first coagulating agent is a calcium nitrate compound, the second coagulating agent is an acetic acid compound, and the third coagulating agent is a calcium nitrate compound.

20. The method of claim 11, wherein the coated fabric is a glove.

Technical Field

Exemplary embodiments of the present application relate generally to high performance coating materials, and more particularly to coated fabrics.

Background

Applicants have discovered a number of drawbacks and problems associated with conventional gloves because they are insufficient to provide both adequate grip and abrasion resistance in wet or oily environments. Many of these discovered problems have been solved by the development of solutions included in embodiments of the present disclosure through efforts, creations and innovations, many examples of which are described in detail herein.

Disclosure of Invention

Exemplary embodiments of the present disclosure relate to a three-layer coated fabric and related methods of manufacture. In one exemplary embodiment, a coated fabric is provided. The coated fabric includes a base coating layer. The base coat defines a lubricious coating to resist liquid penetration into the fabric. The coated fabric further includes an intermediate foam coating deposited on at least a portion of the base coating. The intermediate foam layer defines an intermediate foam density and is configured to absorb at least a portion of the liquid. The coated fabric further includes an outer foam coating deposited on at least a portion of the intermediate foam coating. The outer foam layer defines an outer foam density and is configured with apertures to allow liquid to penetrate to the intermediate foam layer such that the outer foam layer increases the abrasion resistance of the coated fabric. The middle layer foam density is less than the outer layer foam density.

In some embodiments, the middle layer foam density is from 0.25 kg/L to 0.60 kg/L. In some embodiments, the middle layer foam density is from 0.45 kg/L to 0.60 kg/L. In some embodiments, the outer layer foam density is from 0.70 kg/L to 0.9 kg/L. In some embodiments, at least one of the primer coating, the intermediate foam coating, or the outer foam coating comprises a nitrile rubber compound (nitrile compound). In some embodiments, the nitrile rubber compound of the at least one of the base coat, the intermediate foam coat, or the outer foam coat comprises 45% nitrile latex. In some embodiments, the coated fabric is used to form a glove. In some embodiments, the base coat, the middle foam coating, and the outer foam coating are each applied to at least the palm area of the glove. In some embodiments, the glove is one of a mechanical glove or a chemical glove. In some embodiments, the primer layer further comprises a nylon lining.

In another exemplary embodiment, a method of making a coated fabric is provided. The method includes applying a basecoat composition. The base coat defines a lubricious coating to resist liquid penetration into the fabric. The method further includes applying an intermediate foam coating composition over at least a portion of the base coat. The intermediate foam layer defines an intermediate foam density and is configured to absorb at least a portion of the liquid. The method further includes applying an outer foam coating composition over at least a portion of the middle foam coating. The outer foam layer defines an outer foam density and is configured with apertures to allow liquid to penetrate to the intermediate foam layer such that the outer foam layer increases the gripping ability and abrasion resistance of the coated fabric. The middle layer foam density is less than the outer layer foam density.

In some embodiments, the method further comprises applying a first coagulant to the fabric prior to the step of applying the base coat. In some embodiments, the method further comprises applying the first coagulant to the fabric prior to the step of applying the intermediate foam coating. In some embodiments, the method further comprises applying a second coagulant to the fabric prior to the step of applying the outer foam coating. In some embodiments, the method further comprises applying a third coagulant to the fabric prior to the step of applying the outer foam coating. In some embodiments, the method further comprises heating the coated fabric on a hand mold (hand model) prior to the step of applying the base coat. In some embodiments, the method further comprises heating the coated fabric after the step of applying the outer foam coating. In such embodiments, at least one of the base coat, the intermediate foam coating, or the outer foam coating cures in response to heat. In some embodiments, applying the outer foam coating further comprises washing away the unset coating on the surface of the fabric after applying the outer foam coating. In some embodiments, the first coagulating agent is a calcium nitrate compound, the second coagulating agent is an acetic acid compound, and the third coagulating agent is a calcium nitrate compound. In some embodiments, the coated fabric is a glove.

The above summary is provided merely to summarize some exemplary embodiments to provide a basic understanding of some aspects of the present invention. Therefore, it should be understood that the above-described embodiments are merely examples and should not be construed as limiting the scope or spirit of the present invention in any way. It will be appreciated that the scope of the invention encompasses many possible embodiments in addition to those outlined herein, some of which are described further below.

Drawings

Having thus described certain exemplary embodiments of the present disclosure in general terms, reference will now be made to the accompanying drawings. The components shown in the figures may or may not be present in certain embodiments described herein. Some embodiments may include fewer (or more) components than those shown in the figures.

FIGS. 1A and 1B illustrate a three-layer coated fabric of the present disclosure implemented in an exemplary coated glove;

FIG. 2 is a cross-sectional view of a three-layer coated fabric according to an exemplary embodiment of the present disclosure;

FIG. 3A is a microscopic cross-sectional view of a three-layer coated fabric according to an exemplary embodiment of the present disclosure;

FIG. 3B is a microscopic view of an intermediate foam coating according to an exemplary embodiment of the present disclosure;

fig. 3C is a microscopic view of an outer foam coating according to an exemplary embodiment of the present disclosure; and

fig. 4 is a flow chart of a method of making a three-layer coated fabric according to an exemplary embodiment of the present disclosure.

Detailed Description

SUMMARY

The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. As used herein, terms such as "front," "back," "top," and the like are used in the examples provided below for illustrative purposes to describe the relative position of certain components or portions of components. Furthermore, as will be apparent to one of ordinary skill in the art having had the benefit of the present disclosure, the terms "substantially" and "about" mean that the referenced elements or associated description are accurate within applicable engineering tolerances.

The term "comprising" means including but not limited to, and should be interpreted in the manner in which it is commonly used in the patent context. The phrases "in one embodiment," "according to one embodiment," and the like generally indicate that a particular feature, structure, or characteristic described after the phrase may be included in at least one embodiment of the invention, and may be included in more than one embodiment of the invention (importantly, the phrases do not necessarily refer to the same embodiment). If the specification states something as "exemplary" or "an example," it should be understood to mean a non-exclusive example.

Grip performance is one of the key features of a useful work glove. In environments of severe exposure to liquids (e.g., water or oil), conventional gloves may not be able to keep the user's hands dry, which affects the grip of the glove. In addition, conventional gloves having desirable gripping characteristics lack the desired abrasion resistance. Thus, various embodiments of the present disclosure enable, in some instances, abrasion resistant fabrics that maintain high grip performance by absorbing liquid using an intermediate foam coating, while an outer foam coating provides abrasion resistance in some instances. The various embodiments herein discuss uses with respect to gloves, but the coating methods and coated fabrics of the exemplary embodiments may be used in a variety of applications.

As discussed herein, exemplary embodiments may be described with reference to coating methods that, when applied to gloves (e.g., mechanical or chemical gloves) or other wearable items, such as other personal protective equipment (e.g., helmets and/or protective shoes), in some examples enable optimized grip and abrasion resistance. In this regard, the fabric, composite, or other structure described herein as a coated fabric may refer in some instances to a three-coat structure. For clarity of description, exemplary embodiments of the present application described herein with respect to "three layers" refer to the number of coatings (e.g., base coat, intermediate foam coating, and outer foam layer) and may not include additional non-coatings, such as glove liners. Alternative layers to the "three layers" or additional layers beyond the "three layers" may be used in some embodiments, while fewer layers than the "three layers" may be used in other embodiments.

Referring to FIG. 1, a coated glove 100 embodying and/or consisting of an exemplary three-layer coating is shown. As shown, glove 100 may be manufactured or formed with a three-layer coating manufactured according to the exemplary embodiments discussed herein. For example, glove 100 may have a fabric 105, a base coat 110, an intermediate foam coat 115, and an outer foam layer 120. As shown, the coatings 110, 115, 120 may be applied to at least a portion of the glove (e.g., all three coatings applied to the palm where they may be most useful during operation). In a preferred embodiment, the base coat 110 may be defined at least in the palm area of the coated fabric and on the inside of each finger (e.g., in the case where the fabric is in the shape of a glove). For example, the base coating 110 may be coated around each finger at the proximal portion of the finger and completely around the finger at the distal portion of the finger. In various embodiments, the intermediate foam coating 115 can be deposited on at least a portion of the base coating 110 such that the intermediate foam coating 115 can define at least the palm area and the inner side of each finger of the coated fabric (e.g., in the case where the fabric is in the shape of a glove). In various embodiments, the outer foam coating 120 can be deposited on at least a portion of the intermediate foam coating 115 such that the outer foam coating 120 can be defined at least in the palm area and inside of each finger of the coated fabric (e.g., in the case where the fabric is in the shape of a glove). In various embodiments, the three-layer coated fabric and methods of making the same may be used in chemical or mechanical gloves. In various embodiments, the material of the fabric 105 may depend on the type of glove. In various embodiments, the fabric 105 may be any material that is capable of being coated with the primer layer 110. For example, fabric 105 may be a glove liner. In various embodiments, fabric 105 may be a material used for mechanical or chemical gloves. In various embodiments, the fabric 105 may be a material, such as nylon, polyester, cotton, High Performance Polyethylene (HPPE), aramid, stainless steel, fiberglass, rayon (rayon), polypropylene (PP), basalt (basalt), spandex (spandex), and/or the like.

In various embodiments, the three-layer coated fabric and method of making the same may also be used in various applications, not limited to gloves. In various embodiments, the three-layer coating discussed herein may be applied to other PPEs. In one exemplary embodiment, the three-layer coating discussed herein can be applied to a helmet. For example, the base coat 110 can be applied to at least a portion of the helmet material, the middle foam coat 115 can be at least partially applied to the base coat 110, and the outer foam coat 120 can be at least partially applied to the middle foam coat 115. In one exemplary embodiment, the three-layer coating discussed herein may be applied to protective footwear. For example, a base coat 110 may be applied to at least a portion of the protective shoe material, a middle foam coat 115 may be at least partially applied to the base coat 110, and an outer foam coat 120 may be at least partially applied to the middle foam coat 115. In various embodiments, the three-layer coating may be applied to various other applications with similar results to those discussed herein.

FIGS. 2 and 3A are rootsA cross-sectional view of a three-layer coating according to an exemplary embodiment. Additionally, fig. 3B is a microscopic view of an exemplary embodiment of the intermediate foam coating 115, and fig. 3C is a microscopic view of an exemplary embodiment of the outer foam coating 120. In various embodiments, the base coat 110 may be a smooth nitrile rubber coating (nitrile coating). In various embodiments, the primer layer 110 may include a nitrile latex (e.g., X6617 and/or XVT-LA), a pH adjuster (e.g., KOH solution), a curing package (e.g., sulfur dispersion, ZDEC dispersion, and/or ZnO dispersion), a pigment/filler (e.g., TiO dispersion, ZDEC dispersion, and/or ZnO dispersion), a pigment/filler (e.g., a pigment/filler, a binder, and/or a binder₂And/or black pigment) and/or a thickener (e.g., a CMC solution). In various embodiments, the primer layer 110 may be about 40% to 60% nitrile latex. In various embodiments, the primer layer 110 may be about 40% to 50% nitrile latex. For example, the primer layer 110 may be about 45% nitrile latex. In various embodiments, the primer layer 110 may be relatively thin (e.g., thinner than the intermediate foam layer 115). In an exemplary embodiment, the primer layer 110 may be about 0.10 mm to 0.20 mm thick. In various embodiments, the base coat 110 may be thinner and/or thicker in various examples based on the abrasion resistance and/or gripping requirements of the coated fabric.

In various embodiments, the intermediate foam coating 115 may be a microfoam coating (microfoam coating). In an exemplary embodiment, the middle layer foam density may be about 0.25 kilograms (kg) per liter (L) to about 0.60 kg/L. In some embodiments, the middle layer foam density may be from about 0.45 kg/L to about 0.60 kg/L. For example, the middle layer foam density may be about 0.60 kg/L. In various embodiments, the intermediate foam coating 115 may have about 50 bubbles per square millimeter. In various embodiments, the lower the foam density, the higher the number of bubbles per square millimeter. In an exemplary embodiment, more bubbles in the coating may enable enhanced grip, but may also slightly reduce abrasion resistance. In various embodiments, the intermediate foam coating 115 may include a nitrile latex (e.g., Synthomer X6617), a pH adjuster (e.g., KOH solution), a surfactant (e.g., SDBS and/or foam stabilizer/BA)SF A-18), curing packages (e.g. sulfur dispersions, ZDEC dispersions and/or ZnO dispersions), pigments/fillers (e.g. TiO₂And/or black pigment) and/or a thickener (e.g., a CMC solution). In various embodiments, the intermediate foam coating 115 may be about 40% to 60% nitrile latex. In various embodiments, the intermediate foam coating 115 may be about 40% to 50% nitrile latex. For example, the intermediate foam coating 115 may be about 45% nitrile latex. In various embodiments, the thickness of the intermediate foam coating 115 can affect the gripping ability of the coated fabric (e.g., in some instances, a higher thickness of the intermediate foam coating 115 and/or other layers can result in better performance, but with reduced abrasion resistance). In an exemplary embodiment, the intermediate foam coating 115 may be about 0.50 millimeters to 0.60 millimeters. In various embodiments, the intermediate foam coating 115 may be thinner and/or thicker in various examples based on the abrasion resistance and/or gripping requirements of the coated fabric.

In various embodiments, the outer foam coating 120 may be a wash foam coating. In various embodiments, the outer layer foam density may be higher than the middle layer foam density. In one exemplary embodiment, the outer coating foam density may be about 0.80 kg/L. In various embodiments, the outer foam coating 120 may have fewer bubbles per square millimeter than the middle foam coating 115. For example, in the case where the outer foam density is about 0.80 kg/L, the outer foam coating 120 may have about 15 bubbles per square millimeter. As such, in some examples, the outer foam coating 120 may provide increased abrasion resistance to the coated fabric. In various embodiments, the outer layer foam density may be based on the desired abrasion resistance of the coated fabric. For example, where it is desired that the coated fabric provide good abrasion resistance for 8000 cycles (e.g., the coated fabric may be able to pass the EN 388 standard for 8000 cycles), the outer layer foam density may be about 0.8 kg/L. In various embodiments, the coating may be adjusted to provide greater wear resistance (e.g., capable of 15000 cycles or more under EN 388 standard). In various embodiments, the level of abrasion resistance can be based on the outer foam density (e.g., a lower foam density can be used for coated fabrics requiring lower abrasion resistance). In various embodiments, the thickness of the outer foam coating 120 can affect the abrasion resistance of the coated fabric (e.g., in some instances, a higher thickness of the outer foam coating 120 can result in higher abrasion resistance and reduced hand (grip)). In an exemplary embodiment, the outer foam coating 120 may be about 0.10 millimeters to 0.20 millimeters. In various embodiments, the outer foam coating 120 may be thinner and/or thicker in various examples based on the abrasion resistance and/or gripping requirements of the coated fabric.

In various embodiments, the outer foam coating 120 can include a nitrile latex (e.g., X6617 and/or XVT-LA), a pH adjuster (e.g., KOH solution), a surfactant (e.g., SDBS), a cure package (e.g., sulfur dispersion, ZDEC dispersion, and/or ZnO dispersion), a pigment/filler (e.g., TiO dispersion, ZDEC dispersion, and/or ZnO dispersion), a pigment/filler (e.g., a pigment/filler, a binder, and/or a binder₂And/or black pigment) and/or a thickener (e.g., a CMC solution). In various embodiments, the outer foam coating 120 may be about 40% to 60% nitrile latex. In various embodiments, the outer foam coating 120 may be about 40% to 50% nitrile latex. For example, the outer foam coating 120 may be about 45% nitrile latex. In some embodiments, the outer foam coating 120 may have one or more gas bubbles 200 such that liquid may penetrate the outer foam coating 120 and be absorbed by the intermediate foam coating 115. For example, a wash foam process may enable a thinned coating in which the pores have a larger diameter (e.g., as shown by bubble 200 in fig. 2, as compared to bubble 205). In such embodiments, the outer foam coating 120 can remain relatively dry during use (e.g., in cases where liquid is introduced to the glove while being worn by the user).

Referring now to fig. 4, a method of making a three-layer coated fabric according to various embodiments is provided. Unless explicitly stated otherwise, various embodiments of the described methods may be performed in a different order than described herein. Additional operations may also be performed during the process of making a three-layer coated fabric, and thus the following steps are not exhaustive. In various embodiments, the three-layer coated fabric may be a glove. In some steps discussed herein, the temperatures mentioned may be merely exemplary and may not be prohibitive.

Referring now to block 400 of fig. 4, a method of manufacturing may include heating a fabric. In some embodiments, the fabric may be heated on the former. For example, where the fabric is a glove, the glove may be heated on a hand mold. In various embodiments, the fabric may be heated to about 50 degrees celsius. In various embodiments, different temperatures may be used in cases where the pulse time is adjusted (e.g., lower temperatures may require longer pulse times). For example, in some embodiments, the fabric may be heated to about 30 to 70 degrees celsius. Referring now to block 410 of fig. 4, a method of manufacturing may include applying a first coagulant to a fabric. In various embodiments, the first coagulant may be a compound of a cation (e.g., calcium nitrate) and a solvent (e.g., methanol). In an exemplary embodiment, the first coagulant may be about 1% to about 10% calcium nitrate. In some embodiments, the first coagulant may be about 1% to about 5% calcium nitrate. For example, the first coagulant may be about 2% calcium nitrate. In such an embodiment, the first coagulant may be about 98% methanol.

In one exemplary embodiment, the first coagulant may be applied to the fabric by dipping the fabric into the first coagulant. In an exemplary embodiment, the first coagulant may be applied to the fabric for about 60 seconds to 120 seconds. In one exemplary embodiment, the fabric may be immersed in the first coagulant for about 80 seconds. For example, the fabric may be immersed into the first coagulant at a speed of about 3.7 centimeters per second (cm/s), a residence time of 2 seconds, a leaching time (leaching time) of 5 seconds, and an homogenization time (evening time) of 75 seconds (e.g., two immersion cycles may be used to homogenize the first coagulant). In some embodiments, the first coagulant may be applied to only a portion of the fabric (e.g., only the portion of the fabric in which the base coat is to be applied). For example, in the case where the fabric is a glove, only the palm of the glove may be dipped into the first coagulant.

Referring now to block 420 of fig. 4, the method of manufacture may include applying a primer coating composition to the fabric. As discussed above, the basecoat composition may be a smooth nitrile rubber (nitrile) (e.g., a nitrile latex compound). In various embodiments, the basecoat composition may be applied by dipping the fabric into the basecoat composition. In various embodiments, application of the basecoat composition may take from about 3 to about 5 minutes. For example, the fabric may be dipped into the primer composition at a speed of about 3.7 centimeters per second (cm/s), a residence time of about 2 seconds, and a homogenization time of about 75 seconds (e.g., two dipping cycles may be used to homogenize the primer). In some embodiments, the fabric can be shaken in the underlying coating composition to remove excess nitrile rubber (e.g., to reduce the coating thickness). For example, the fabric may be shaken about 20 times to remove excess nitrile rubber. In various embodiments, in cases where there is no thickness limitation, little or no shaking may occur. In various embodiments, the fabric may be rotated during the immersion process to achieve a uniform coating level. In some embodiments, the primer layer may be presulfided after application of the primer layer composition is complete. For example, the fabric may be heated at about 70 degrees celsius for about 15 to 20 minutes prior to the step of block 430. In a preferred embodiment, the base coat 110 may be defined at least in the palm area of the coated fabric and on the inside of each finger (e.g., in the case where the fabric is in the shape of a glove). In some embodiments, the primer coating may be coated around each finger at the proximal portion of the finger and completely around the finger at the distal portion of the finger.

Referring now to block 430 of fig. 4, the method of manufacturing may include reapplying the first coagulant to the fabric. In various embodiments, the first coagulant may be the same or similar coagulant as discussed with respect to block 410. In an exemplary embodiment, the first coagulant may be applied to the fabric by dipping the fabric into the first coagulant. In an exemplary embodiment, the first coagulant may be applied to the fabric for about 60 seconds to 120 seconds. In one exemplary embodiment, the fabric may be immersed in the first coagulant for about 70 seconds. For example, the fabric may be dipped into the first coagulant at a speed of about 3.7 centimeters per second (cm/s), a residence time of 1 second, a leaching time of 10 seconds, and a homogenization time of 60 seconds (e.g., two dipping cycles may be used to homogenize the first coagulant). In some embodiments, the first coagulant may be applied to only a portion of the fabric (e.g., only the portion of the fabric where the intermediate foam coating is to be applied). For example, in the case where the fabric is a glove, only the palm of the glove may be dipped into the first coagulant.

Referring now to block 440 of fig. 4, the method of manufacturing may include applying an intermediate foam coating composition over at least a portion of the intermediate foam coating. As discussed above, the intermediate foam coating composition may be a microfoam nitrile rubber (e.g., a nitrile latex compound). In various embodiments, the intermediate foam coating composition may be applied by dipping the fabric into the intermediate foam coating composition. In various embodiments, application of the intermediate foam coating composition may take about 45 to 90 seconds (e.g., 60 seconds). For example, the fabric may be dipped into the intermediate foam coating composition at a speed of about 3.7 centimeters per second (cm/s), a residence time of about 10 seconds, a shaking time of about 15 seconds, and a homogenization time of about 60 seconds (e.g., two dipping cycles may be used to homogenize the intermediate foam coating). In some embodiments, the fabric may be shaken in the intermediate foam coating composition to remove excess nitrile rubber (e.g., to reduce the thickness of the coating). In various embodiments, the shaking of the fabric can make the intermediate foam coating thinner and softer (spongy) than it would be if the fabric was not shaken during application. In various embodiments, the fabric may be rotated during the immersion process to achieve a uniform coating level. In various embodiments, the resulting intermediate foam coating may have an intermediate layer foam density of about 0.25 kilograms (kg) per liter (L) to about 0.60 kg/L. In some embodiments, the middle layer foam density may be from about 0.45 kg/L to about 0.60 kg/L. For example, the middle layer foam density may be about 0.60 kg/L. In a preferred embodiment, the intermediate foam coating 115 can be deposited on at least a portion of the base coating. For example, the intermediate foam coating 115 may be defined at least in the palm area of the coated fabric and the inside of each finger (e.g., in the case where the fabric is in the shape of a glove). In some embodiments, the intermediate foam coating may be coated around each finger at the proximal portion of the finger and completely around the finger at the distal portion of the finger.

Referring now to block 450 of fig. 4, the method of manufacturing may include applying a second coagulant to the fabric. In various embodiments, the second coagulant may be a compound of a cation (e.g., acetic acid) and a solvent (e.g., methanol). In an exemplary embodiment, the second coagulant may be about 1% to about 10% acetic acid. In some embodiments, the second coagulant may be about 1% to about 5% acetic acid. For example, the second coagulant may be about 4% acetic acid. In such embodiments, the second coagulant may be about 96% methanol.

In an exemplary embodiment, the second coagulant may be applied to the fabric by dipping the fabric into the second coagulant. In an exemplary embodiment, the second coagulant may be applied to the fabric for about 60 seconds to 120 seconds. In one exemplary embodiment, the fabric may be immersed in the second coagulant for about 80 seconds. For example, the fabric may be dipped into the second coagulant at a rate of about 3.7 centimeters per second (cm/s) for a residence time of about 1 second until the intermediate foam coating 115 may be approximately fully coagulated. In some embodiments, the second coagulant may be applied to only a portion of the fabric (e.g., only the portion of the fabric where the outer foam coating 120 is to be applied). For example, in the case where the coated fabric is a glove, only the palm of the glove may be dipped into the second coagulant. In some embodiments, the fabric may be rotated while being immersed in the second coagulant. In various embodiments herein, other application methods (e.g., spraying) besides immersion may be used for one or more applications of the coating compositions and/or coagulants discussed herein.

Referring now to block 460 of fig. 4, the method of manufacturing may include applying a third coagulant to the fabric. In various embodiments, the third coagulant may be a compound of a cation (e.g., calcium nitrate) and a solvent (e.g., methanol). In an exemplary embodiment, the third coagulant may be about 30% to about 50% calcium nitrate. In some embodiments, the third coagulant may be about 40% to about 50% calcium nitrate. For example, the third coagulant may be about 50% calcium nitrate. In such embodiments, the third coagulant may be about 50% methanol.

In an exemplary embodiment, the third coagulant may be applied to the fabric by dipping the fabric into the third coagulant. In an exemplary embodiment, the third coagulant may be applied to the fabric for about 90 seconds to 150 seconds. In an exemplary embodiment, the fabric may be immersed in the third coagulant for about 120 seconds. For example, the fabric may be dipped into the third coagulant at a speed of about 3.7 centimeters per second (cm/s), a residence time of about 5 seconds, a leaching time of about 5 seconds, and a homogenization time of about 110 seconds. In some embodiments, the third coagulant may be applied to only a portion of the fabric (e.g., only the portion of the fabric where the outer foam coating 120 is to be applied). For example, in the case where the fabric is a glove, only the palm of the glove may be dipped into the third coagulant. In various embodiments, the fabric may be rotated while being immersed in the third coagulant.

Referring now to block 470 of fig. 4, the method of manufacture may include applying an outer foam coating composition over at least a portion of the intermediate foam coating. As discussed above, the outer foam coating composition may be a wash foam nitrile rubber (e.g., a nitrile latex compound). In various embodiments, the outer foam coating composition may be applied by dipping the fabric into the outer foam coating composition. In some embodiments, the outer foam coating composition may be applied to the fabric by using a dive tapping process. In various embodiments, the fabric can be dipped into the outer foam coating composition for several seconds (e.g., about 2 seconds) until the outer foam coating 120 is partially set and then removed. For example, the fabric may be dipped into the outer foam coating composition for two seconds, shaken twice, and then removed. As such, in some instances, the method may take significantly less time than the application of the primer or intermediate foam coating. In various embodiments, the resulting outer foam coating 120 can have an outer foam density of about 0.7 kg/L to about 0.9 kg/L. In various embodiments, the resulting outer foam coating 120 can have an outer foam density that is higher than the middle layer foam density (e.g., the outer foam density can be about 0.80 kg/L). In some embodiments, the outer foam coating composition may be applied to only a portion of the fabric. For example, in the case where the fabric is a glove, only the palm of the glove may be dipped into the outer foam coating composition. In various embodiments, the fabric may be rotated while immersed in the outer foam coating composition.

In some embodiments, the fabric may be rinsed (e.g., to remove the unset coating from the surface of the fabric) after the fabric has been dipped into the outer foam coating composition. For example, the fabric (e.g., glove) can be rinsed using a soft wash (e.g., low pressure and low flow) using a square elevation wash for about 60 seconds or more. In a preferred embodiment, the outer foam coating 120 can be deposited on at least a portion of the intermediate foam coating. For example, the outer foam coating 120 may be defined at least in the palm area of the coated fabric and the inside of each finger (e.g., in the case where the fabric is in the shape of a glove). In some embodiments, the outer foam coating may be coating wrapped around each finger at a proximal portion of the finger and completely around the finger at a distal portion of the finger.

Referring now to block 480 of fig. 4, the manufacturing method may include heating the fabric in an oven. In various embodiments, one or more of the coatings may be cured during heating. For example, a fabric (e.g., a glove) can be placed in an oven at a set temperature for a set amount of time to cure the coating. The temperature of the oven and the amount of time in the oven can be based on the coating composition. For example, the coated fabric may be placed in an oven at 100 degrees celsius for 60 minutes. In one exemplary embodiment, the curing process may use multiple ovens at different temperatures to cure the coating. For example, the coated fabric may be placed in an oven for 20 minutes each as follows: a first oven at about room temperature, a second oven at about 70 degrees celsius, a third oven at about 90 degrees celsius, and a fourth oven at about 110 degrees celsius. Various embodiments may use different numbers of ovens (e.g., one oven) to cure the coating. In some embodiments, there may also be a pre-cure prior to heating in the oven (e.g., the coated fabric may be heated at 70 degrees celsius). Additionally, the coated fabric may be subjected to one or more washes prior to vulcanization (e.g., an online wash may be performed at about 50 degrees for about 10 minutes prior to vulcanization). In various embodiments, vulcanization may cause a chemical reaction in one or more layers of the coated fabric (e.g., a chemical reaction may occur in one or more coating layers in which sulfur and/or zinc oxide in one or more coating layers may crosslink with one or more latex materials in the coating layer).

Referring now to block 490 of fig. 4, the method of manufacturing may include drying the fabric. In various embodiments, the fabric may be removed from the mold after the coating has been cured (e.g., the glove may be removed from the hand mold). In some embodiments, an additional off-line wash may be performed to remove any excess nitrile rubber. In some embodiments, the drying of the fabric may be performed in an oven (e.g., the same or different oven used to cure the fabric). In various embodiments, drying of the fabric (e.g., glove) aids in the formation of open-cell foam on the coating.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.