WO2025198586A1 - Protective and comfortable cut resistant lining and glove - Google Patents

Abstract

The present invention provides a two-layer cut resistant hand covering (40), such as a glove or mitten comprising: an outer layer (42); and an inner layer (44), configured for providing cut resistance and comfort against the hand of a wearer, the inner layer (44) comprising a knitted fabric made from a yarn (20) comprising a steel central core (24, 48) and a plurality of staple fibers (22, 46) spun around said central core (24, 48), said inner layer (44) then knitted in a 16 gauge knitting machine.

Description

PROTECTIVE AND COMFORTABLE CUT RESISTANT LINING AND GLOVE

TECHNICAL FIELD

[0001] The current invention relates to protective gloves and more particularly, to materials and methods suitable for manufacturing cut resistant linings of protective gloves and the glove created from such linings. The gloves created from the yarn and fabric in accordance with the invention are especially useful in work environments that require skills with high manual dexterity and improve the efficiency of such work while maintaining a sufficient amount of cut resistance.

BACKGROUND INFORMATION

[0002] Most gloves are designed to protect the wearer from some sort of hazard be it from abrasion, vibration, sharp objects, or to combat environmental conditions. Cycling gloves pad the cyclist's hands to reduce road shock, ski gloves repel moisture and provide important insulation, leather work gloves add grip and protect the hands from minor scrapes and abrasion. Chain mail gloves and the like protect the wearer from sharp objects and cuts from knives.

[0003] The human hands are a person' s primary tactile interface with the world and possess incredible amounts of dexterity that allow for the fine motor skills. Normal everyday tasks require fine motor control from the hands. Writing with a pencil, putting keys in a lock, typing on a computer, cooking and using utensils are mundane examples of tasks requiring hand dexterity. Many job-related tasks require similar amounts of "every day" dexterity. Moreover, special tasks such as operating certain machines and using tools may require excellent dexterity to perform the task optimally. When gloves are required, the fine motor movements become more difficult. Gloves take away the natural dexterity and make jobs harder to perform. However, in certain situations and workplace environments they provide needed protection and may be required as part of worksite safety .

[0004] Cut protection gloves may be required in certain hazardous work conditions. Gloves are often required in jobs and work spaces that have a prevalence for accidents to the hand. Meat cutters, factory workers, and many other jobs require gloves since accidents, in addition to the personal harm, have a cost to industry in the form of lost wages, insurance and medical bills, and decreased productivity. A glove that protects the wearer from cuts while also providing dexterity to perform normal and specialty tasks is beneficial and preferred.

[0005] The construction of a typical cut-lining includes the use of materials that will stop the penetration of sharp objects such as knives, and, as is the case of many manufacturing jobs, the sharp edges and points of materials that the user might be subject to while carrying out their manufacturing duties. For instance, handling glass, sheet metal and the like are examples of such manuf cturing duties.

[0006] A cut-lining is created by knitting or weaving yarns with cut protection built into the yarn. The cut protection of the yarn is provided by constructing the core of the yarn with a filament fiber made from metal, glass (fiberglass) , or aramid fibers that have a high resistance to cutting. These cut-proof yarns are then knitted or woven into a fabric. During the knitting or weaving process, the core of the yarns (filament fiber) can be broken, producing a sharp point of metal or glass. Breakage of the metal or glass core can also occur during normal wear and tear when the product is in use.

[0007] There are multiple methods of manufacturing a glove. The circular knit "sock" construction uses a specialized knit machine to create the desired form. A circular knit machine is dedicated to the manufacturing of tubular forms such as socks, gloves, t-shirts, and other tube structures. The specialized machinery can be automated and produce items efficiently but requires considerable investment. Moreover, the final item tends to be more uniform as it is knitted from one or two yarns. [0008] Various methods of creating a yarn with a cutresistant core is known in the art. For example, US patent 4, 384, 449 discloses a yarn with a core of flexible wire alongside a strand of aramid fiber with the core wrapped in aramid fibers by wrapping the fibers in a spiraling pattern around the core fibers. US Patent 5,248, 548 discloses the use of a multi-strand metal core wire with one or more non-metallic yarns and fibers wrapped around the metal core wires in a spiral formation. US Patent 5, 644, 907 uses a yarn with a core of at least two strands and a covering having at least one strand typically made from a polyolefin or nylon material. When two or more fiber strands are used, they are wrapped around the core in opposite directions. Patent US 7, 762, 053 discloses a composite yarn with a metal core and covering layer that is formed by wrapping one covering fiber around the core. The core has an attending yarn that is wrapped around the metal wire. A cutresistant glove is then formed from the yarn. During glove construction the yarn is combined with a plating fiber that adds to comfort. The glove shape is formed via circular knit technigues to form a glove with a single layer of a multi-fiber yarn .

[0009] Generally, circular knit gloves require all functional components to be included in the yarn. The yarn is then knitted into the desired shape of a glove. Cut and sew gloves on the other hand can be constructed from multiple layers with each layer serving a different purpose. For instance, a glove can be constructed with a leather outer layer and a textile inner layer that provides comfort and moisture management.

[0010] A common construction of "cut and sew" cut-resistant glove includes constructing 3 layers: the outer layer of the glove; the cut-lining; and a comfort lining. The outer/exterior layer functions as an interface to the world and provides features such as grip, protection from the elements (waterproof) , shock absorption, and desired aesthetics. The cutlining layer provides protection from sharp objects, while the comfort lining is adjacent the user' s skin and provides general comfort and adds a layer between the hand and the cut-lining.

[0011] In the above example, the comfort lining serves two purposes. The comfort lining provides primary comfort, for example, next-to-skin feel, warmth, and moisture management. It also serves to protect the wearer' s skin from shards of metal and glass that can protrude from the cut-lining layer. This is due to the methods and elements often used to construct the cutlining .

[0012] Cut and sewn glove production has advantages over circular knit construction. Firstly, the machines necessary to create the cut protection are simple, widely available, and inexpensive. Typically, a factory needs a die cutter and sewing machines as the primary tools. Secondly, the construction and necessary features can be distributed among multiple layers of materials. Leather can be used on the outer layer, cut protection fabrics for the middle layer, and soft lining materials for the inner layer. Therefore, each individual layer does not need to contain all of the features, easing the requirements on the yarn components and adding flexibility to the construction methods and design. A disadvantage of the cut and sew construction is that additional layers add bulk to the glove and reduce much need dexterity.

[0013] A glove that can be constructed using readily available and inexpensive machinery, which provides necessary cut protection, but still provides good dexterity would be an advantage for many jobs in the workplace. The above-mentioned construction would be especially useful in jobs where comfortable gloves persuade the wearer to keep the gloves on and use them throughout their work day. One can imagine that someone handling extremely dangerous materials or performing dangerous work will not need to be persuaded to wear gloves and therefore, will continue to wear them regardless of their comfort level.

[0014] For instance, the handling of extremely hot materials, manufacturing glass, or using hazardous tools such as chainsaws come to mind as such jobs. Other jobs that are less dangerous might entice the user to remove the glove only to find their bare hand in danger when least expected. Moreover, there are jobs that require occasional protection as well as clerical or office work where finger and hand dexterity are needed. Gloves suited for these jobs should allow the user to perform all of their duties without removing the gloves.

[0015] Jobs that fit the above description might be first responders such as DEA agents, police, National Guard, and TSA agents. Many of these positions require computer and other clerical work. However, their jobs also require hand protection from sharp objects like needles, knives, and the like.

[0016] Accordingly, what is needed is a cut resistance glove and method for making same that provides a knitted fabric made from a yarn that provides the required cut resistance with comfort features that allow for comfort against the skin and a protective glove made from the cut resistant and comfort fabric. Such a method and use of yarns creates a glove with fewer layers than traditional cut-resistant gloves by incorporating a comfort layer into the primary cut lining. The protective layer and comfort layer are included in the same yarn and knitted into a single fabric to provide protection and comfort. The reduced layers add comfort and dexterity to the glove to enhance comfort and work efficiency. SUMMARY OF THE INVENTION

[0017] The present invention features a glove with a comfort and cut resistant liner (commonly referred to as a "cut lining") that are one and the same material. Combining both functions into a single material or layer reduces overall glove thickness, lowers cost and manuf cturing complexity, reduces weight, and adds comfort and dexterity. Importantly, this invention addresses gloves made with "cut and sew" construction rather than gloves made with a circular knit construction as is common for sock production and other components as well as certain glove styles.

[0018] This invention addresses and utilizes the cut and sew method of glove production. This method uses multiple manuf cturing techniques to produce a glove and thus, can produce a product made with heterogeneous materials. The method requires the factory to cut pattern pieces from flat materials and fashion a glove by stitching pieces together. To those familiar with the manufacturing methods, it is understood that complex composites can be manufactured including material layers made from different materials and multiple layers stitched together to form a multi-layered glove or a patchwork glove where a single layer is made from multiple materials.

[0019] A glove that can be made with readily available resources, at the correct price, that enables the wearer to use the glove throughout their workday is reguired. Traditional cut and sew gloves with cut protection tend to be bulky with low dexterity. A method of constructing a glove with cut protection and good dexterity is a benefit to first responders and other jobs .

[0020] While the three layers of a typical "cut and sew" glove do a good job of protecting the hands from sharp objects, the additional layer of material produces a less than ideal product. The additional layer adds manufacturing complexity and additional cost and manufacturing time. Moreover, the final product has added layers and bulk that reduce dexterity, affecting fine motor skills.

[0021] A cut and sew style protective glove that protects as needed but uses fewer layers to achieve the protection would be advant geous. A preferred embodiment of such a glove with good cut protection and good dexterity is discussed below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein: [0023] Figure 1 shows a yarn with a metal core filament fiber wrap in nominal thickness staple fibers; [0024] Figure 2 shows a novel yarn with a metal core filament fiber wrap in high loft staple fibers;

[0025] Figure 3 shows a cross section of a cut protection glove with the standard 3 layers of material;

[0026] Figure 4 shows a cross section of a preferred embodiment with 2 layers of material;

[0027] Figure 5 shows a magnified view of a standard knit prior art construction;

[0028] Figure 6 shows a magnified view of a preferred knit construction with high-loft yarn and low knit bend angle according to the invention;

[0029] Figure 7 shows the construction of a "cut and sew" glove with the preferred cut and comfort lining with cut protection in the palm; and

[0030] Figure 8 shows the construction of a "cut and sew" glove with the preferred cut and comfort ling with cut protection in the full hand of the glove.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] To create a 2-layer cut protection glove as disclosed by the present invention as opposed to a 3-layer glove, it is necessary to include multiple features into a single layer. In this preferred embodiment, the cut protection layer also serves as the comfort (next to skin) layer by incorporating a lofted yarn and knitting the yarn with enhanced tension and spacing. [0032] Figure 1 shows a cross-section of a standard, Prior Art protective yarn 10 with a metal core monofilament fiber 14. The metal fiber monofilament core 14 is surrounded with staple fibers 12 made from a polyethylene or other suitable fiber. Those skilled in the art will be aware of many fibers that can be used for surrounding the metal core including many different polymers such as nylon, polyester, and polyaramids, to name a few. The gauge and loft of this yarn is such that when knitted into a fabric the tight turns of the knitting can break the metal core filament and the filament can poke through the staple fibers that are wrapping the filament, causing discomfort to the wearer of the cut protection gloves.

[0033] Referring to Figure 5, a magnified section of fabric 50 that is knitted with a standard gauge and interlock knitting pattern is shown, where an interlock knitting process is used to produce a knitted fabric 50, one can see that the standard gauge of the yarn requires steep bending angles 52 to fill the fabric. This steep bending angle 52 of the yarn 54 may result in breakage of the yarn's metal core (not shown) .

[0034] Figure 2 shows a cross-section of a preferred yarn 20 for inclusion in the single layer comfort and cut protection fabric for gloves. This preferred yarn has a core monofilament 24 made from stainless steel. The core monofilament 24 provides good cut protection via the stainless steel and can achieve a cut protection rating of A5 when used in a cut and sew glove. [0035] Staple fibers 22, made from polyethylene or another suitable polymer, create the outer layer of the yarn 20. Ideally, the staple fibers 22 are made from an HPPE polymer. Other polymers may be used and one skilled in the art can specify different polymer types. For instance, aramids are suitable as well as polypropylene or nylon fibers. Staple fibers 22 are spun onto the metal core fiber 24 in such a way that they create a lofted layer that is larger (thicker) than a traditional spun yarn. The higher loft and additional staple fibers create a yarn 20 that provides good protection and comfort in the event that the stainless-steel core is broken during manuf cturing or use.

[0036] Ideally, the core filament 24 has a dimension of 0.05 mm. The staple fibers 22 have nominal length of 38-58 mm and are entangled via spinning as is well known in the art. The spinning transforms the smooth fiber into a bulky yarn with added loft. The staple fiber is then spun into a yarn with a dimension of 40s x 2 representing two ply' s of yarn wrapped around the core filament 24. The stainless-steel core 24 and staple fiber layer 22 form a yarn that is then knitted in a 16 gauge machine. This gauge is lower than nominal knits used in cut protection gloves producing more loft, fill, and with larger radius turns in the knit. The above construction of the preferred yarn 20 makes it ideally suited for use in a cut protection fabric that provides protection up to an A5 level, with staple fibers that provide loft for protection against broken metal core filament and with comfort against the skin. The yarn is knitted into a fabric providing good cut protection as well as a comfortable feel against the skin. One skilled in the art will also appreciate that the lower gauge of 16 for this preferred yarn 20 provides ample fill for the fabric and allows the interlock knitting to use lower bending angles (see figure 6, item 62) . This advantageous low bending angle reduces the likelihood of breakage of the metal core fiber 24.

[0037] Once the yarn 20 with a core of stainless-steel 24 and a staple fiber shell 22 has been created, the yarn is knitted into a fabric for use in a glove. The characteristics of the yarn in combination with a knitting machine that has the properties and the ability to knit a 16 gauge yarn creates a material with properties ideally suited for cut protection and comfort against the skin.

[0038] Figure 6 shows a magnified section of a knitted fabric created with the preferred yarn with a gauge of 16. One can appreciate that the bending angle 62 of the of the preferred yarn 64 and knitting density of the preferred embodiment produces a fabric with similar fill and coverage for a given surface area, but with lower bending angles of the yarn 64. [0039] Nominal knitting density is 40-60 knits per inch for most fabrics. However, when a yarn is knitted at the above density, the angle of bending of the yarn can be severe and induce breaking of the metal core 14 due to the steep angle 52. A more ideal knitting density of 20-25 pics per inch enables the yarn to bend at a more forgiving angle. However, in order to knit a fabric that is sufficiently filled in, a thicker gauge of yarn is required. Previous versions of cut protection material have been knitted with gauges of 24-60 which place undue strain on the yarn with the high bending angle of the yarn. The 40 x 2S high lofted yarn 20 of the present invention is ideally suited for knitting at a lower knitting density and still providing full coverage and good strength to the final fabric. This ideal fabric is achieved with the combination of the high lofted yarn and a knitting density of 20-25 knits per inch. This combination of a 40s x 2 staple fiber yarn with metal filament core and knitted on a 16 gauge knitting machine produces a material with optimized features. It produces a fabric with cut protection that can achieve an A5 cut level for excellent cut protection, a good "skin feel", and resistance to metal fragments protruding through the dense staple fiber layer. [0040] Figure 3 shows a cross section 30 of fabric and materials used in a typical prior art cut protection glove. The layers of outer material 32 cut protection 34 and comfort lining 36 will produce a glove that is thicker than the preferred embodiment disclosed in this application. Each layer serves a single purpose but the combination of the layers produces a less than desirable outcome with respect to the manual dexterity that this glove will allow. The outer layer 32 can be made from a number of materials suitable for a glove including leather, synthetic, and numerous fabrics that those trained in the art are familiar with. The cut protection layer 34 can be made from various materials in the art including core fibers made from aramids or steel wrapped with various materials including aramids, high density polymers and the like. A limitation with current cut protection linings 34 made with metal core fibers is that the metal wire 38 can break and cause discomfort to the hand thus requiring the comfort liner 36 to shield the hand from sharp points in the broken metal or glass fiber. The comfort liner 36 can be made from numerous materials including cotton, synthetic polymers, and the like that are readily available in the art .

[0041] Figure 4 is a cross section of a preferred embodiment for a glove with cut protection. The outer layer 42 of the glove is the interface to external objects. One skilled in the art of glove making will appreciate that the outer layer 42 can be made from a number of suitable materials. Example materials include leather, synthetic leather, polyester, nylon, cotton and many others. The choice of materials is based on the gloves intended use and desired aesthetics. The lining 44 of this glove includes both comfort and cut protection features and, combined with the outer layer 42, is thinner than traditional cut protection gloves. The cut lining 44 and outer layer 42 can be combined by standard cut and sew methods that include die cutting each layer and stitching the layers together at the perimeter. These methods are familiar to one with expertise in the art. As discussed above, the high-loft staple fibers 22, combined with the unique knitting pattern 60 (Fig. 6) and yarn gauge reduce the breaking of the core stainless steel fiber 48 and allow the cut lining 44 to provide both cut protection and comfort against the skin.

[0042] Figure 7 shows the high-loft cut lining 74 stitched into the interior of the glove of a preferred embodiment for a glove with cut protection. One skilled in the art can appreciate the various shapes, dimensions, and techniques for including the high-loft cut lining 74 into a glove. For instance, the high- loft cut lining 74 can cover the entire interior surface of the glove for full protection against sharp objects (as shown in Fig. 8) or in strategic areas of the glove. This embodiment shows the cut and comfort lining 74 stitched into the palm of the glove 70. In this embodiment the lining is stitched to the perimeter of the exterior shell. One skilled in the art of glove making will appreciate that the comfort and cut lining 74 can be joined with the outer layer of the glove 72 using multiple techniques. For instance, the perimeter of the cut and comfort lining 74 can be stitched to the outer layer of the glove 72. Alternatively, the outer layer 72 and cut and comfort lining 74 may be joined using adhesives. The joining of the outer layer and cut and comfort ling is typically performed while the glove is inside-out. Once the two layers are fully joined, the glove is then turned so the cut lining 74 is on the inside of the glove .

[0043] Figure 8 shows a second embodiment where even greater protection is required. The outer layer 82 and cut and comfort lining 84 cover essentially the same surface area for the entirety of the glove. The two materials can be stitched at the periphery 86 via stitching techniques or joined together via adhesives. Similar to the above description the joining procedure is performed while the glove is inside out and then glove materials are turned right-side in so the outer layer faces the outside and the cut and comfort lining faces the skin. [0044] As will be readily appreciated, the above description for joining the outer layer and the cut and comfort lining does not limit the construction of a glove to the two examples. One skilled in the art could apply these techniques to many configurations with the cut and comfort lining covering a large or small surface area.

[0045] Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the allowed claims and their legal equivalents.

[0046] Figure Components:

[0047] 10 - regular loft yarn with cut protection

[0048] 12 - regular loft staple fibers

[0049] 14 - Stainless Steel cut protection filament wire

[0050] 20 - High loft yarn with cut protection

[0051] 24 - Stainless Steel cut protection filament wire

[0052] 30 - Three-layer material with cut protection

[0053] 32 - Outer layer

[0054] 34 - Cut Protection Layer

[0055] 36 - Comfort Layer

[0056] 38 - Stainless Steel cut protection filament wire

[0057] 39 - Polymer Wrap Fibers

[0058] 40 - Two-layer material with cut protection

[0059] 42 - Outer Layer

[0060] 44 - Cut protection Layer with high loft

[0061] 46 - High Loft Staple fibers [0062] 48 - Stainless Steel cut protection filament wire

[0063] 50 - Yarn with interlock stitch

[0064] 52 - Yarn with high bending angle

[0065] 54 - Yarn with standard loft

[0066] 60 - High loft yarn with shallow bend angle

[0067] 62 - Yarn with shallow bend angle

[0068] 64 - Yarn with high loft

[0069] 70 - Glove with Cut protection in the Palm

[0070] 72 - Outer glove layer with no cut protection

[0071] 74 - Cut Protection Liner

[0072] 76 - Attachment of Cut protection liner to outer glove layer

[0073] 80 - Glove with Full Hand Cut Protection

[0074] 82 - Outer glove layer with no cut protection

[0075] 84 - Cut Protection Liner

[0076] 86 - Attachment of Cut protection liner to outer glove layer

Claims

Claims What is claimed is:

1. A two-layer cut resistant hand covering, such as a glove or mitten comprising: an outer layer; and an inner layer, configured for providing cut resistance and comfort against the hand of a wearer, the inner layer comprising a knitted fabric made from a yarn comprising a steel central core and a plurality of staple fibers spun around said central steel core, said inner layer then knitted in a 16 gauge knitting machine.

2. The two-layer cut resistant hand covering according to claim

1, wherein said plurality of staple fibers are made from polyethylene or another suitable Polymer.

3. The two-layer cut resistant hand covering according to claim

2, wherein said other suitable Polymer includes an HPPE Polymer .

4. The two-layer cut resistant hand covering according to claim 1, wherein said staple fibers have a nominal length of 38mm to 58mm.

5. The two-layer cut resistant hand covering according to claim 4, wherein said yarn is a 40s x 2 staple fiber yarn with metal filament core.