CA2236414A1 - Waterproof, breathable articles of apparel - Google Patents
Waterproof, breathable articles of apparel Download PDFInfo
- Publication number
- CA2236414A1 CA2236414A1 CA002236414A CA2236414A CA2236414A1 CA 2236414 A1 CA2236414 A1 CA 2236414A1 CA 002236414 A CA002236414 A CA 002236414A CA 2236414 A CA2236414 A CA 2236414A CA 2236414 A1 CA2236414 A1 CA 2236414A1
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- CA
- Canada
- Prior art keywords
- bladder
- hand
- continuous
- generally
- waterproof
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41B—SHIRTS; UNDERWEAR; BABY LINEN; HANDKERCHIEFS
- A41B11/00—Hosiery; Panti-hose
- A41B11/005—Hosiery made essentially of a multi-ply construction
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D19/00—Gloves
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D19/00—Gloves
- A41D19/0006—Gloves made of several layers of material
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D19/00—Gloves
- A41D19/001—Linings
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D19/00—Gloves
- A41D19/0055—Plastic or rubber gloves
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D27/00—Details of garments or of their making
- A41D27/28—Means for ventilation
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
- A41D31/10—Impermeable to liquids, e.g. waterproof; Liquid-repellent
- A41D31/102—Waterproof and breathable
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
- A41D31/18—Elastic
- A41D31/185—Elastic using layered materials
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D2300/00—Details of garments
- A41D2300/50—Seams
- A41D2300/52—Seams made by welding or gluing
Abstract
An article of clothing and the method of making the same which will allow water vapor due to perspiration to transpire through the article but will prevent liquid water from external sources from reaching the wearer's extremity. One form of the article of the invention comprises a sock which is of a three-ply construction with the inside (20) and outside (22) plies being knit and the intermediate ply (12) being made from a stretch and return polyurethane film. Another form of the mandrel comprises a glove which is of a similar three-ply construction.
Description
CA 02236414 1998-0~-01 Method of Making Waterproof, Breathable Articles of Apparel BACKGROUND OF T~ lNVENTION
s 1. Field of the Invention The present invention relates generally to articles ot apparel. More particularly, the invention concerns articles of apparel used to cover the wearer s extremities such as an im-proved, waterproof sock that will permit pe,~i,ation to transpire th;ough the sock. but will keep 10 water from external sources away from the wearer's foot 2. Description of the Prior Art Various attempts have been made in the past to produce hreathable. waterproof articles of apparel such as gloves and socks that will keep the wearer's hands and feet drv and at the 15 same time permit p~ uildtion to Lldll~ilC through the article Materials which will accomplish this desired function have been known for sometime. For example. U S. Patent No. 3.953,566 discloses a method of making an expanded polytetrafluoroethylene (PTFE) that possesses the ~.u~. Lies of being both breathable and waterproof. An improvement of this material is described in U.S. Patent No. 4.194,041. While both of these materials have been used in the 20 construction of footwear, they exhibit the drawback that thev have limited stretchability, thereby making them less than ideally suited for construction of footwear such as socks. In addition.
such footwear typically has sewn seems and tapes which make it bulky and uncomfortable.
In an apparent attempt to overcome the problems dicc--ccec~ in the prece~iing paragraph, a multi-component sock type article was suggested. This article. which is described in U.S.
Patent No. 4.819.447 issued to Pacanowsky, et al.. comprises a waterproof. nonelastic~
non-stretch sole component. a non-stretch calf component and a vamp component ~tt~'h-~-l to the sole and calf components.
As will be better appreciated from the discussion which follows. the footwear article of the present invention provides. for the first time, footwear such as socks construction which 30 exhibit the comfort and stretchability of a traditional type of sport sock and at the same time are both breathable and completely w~L~ of.
CA 02236414 1998-0~-01 SUMMARY OF THE rNVENTION
It is an object of the present invention to provide comfortable articles of apparel and the method of making the same which will allow water vapor due to perspiration to transpire 5 through the article but will prevent water from external sources from reaching the wearer's extremities.
A particular object of the invention is to provide a footwear article of the aforementioned character which fits well, is pliant and is durable in use.
Arlother object of the invention is to provide an article such as a glove or sock in which 10 water vapor from perspiration can be tr~n~mit~ from inside to outside so that the natural evaporative cooling effect can be achieved.
Another object of the invention is to provide a method of making articles of the character described in the preceding paragraphs which is simple and straight forward. does not require the use of complicated equipment such as sewing and seaming equipment and can be performed by 15 unskilled workmen with a minimllm of training.
A particular object of the invention is to provide a sock as described in the precerling paragraphs which is of simple construction and is easy to m~nllf~cture.
In its preferred form, the footwear article of the invention comprises a sock which is of three-ply construction with the inside and outside plies being knit and the intermediate ply being 20 made from an elastomeric polyurethane film. The three-plies are uniquely bonded together using a pliant. waterproof adhesive.
BRIEF DESCRIPIION OF THE DRAWINGS
Figure 1 is a side-elevational view illustrating the method of making the footwear article of the invention and showing the components of the article in position over a foot-shaped planar mandrel.
Figure 2 is an enlarged cross-sectional view taken along lines 2-2 of Figure 1.
Figure 3 is a side-elevational view of one form of the footwear article of the invention.
Figure 4 is an enlarged cross-sectional view taken along lines 4-4 of Figure 3.
Figure 5 is a top plan view illustrating the method of making a glove article of the invention and showing the components of the article in position over a hand-shaped planar CA 022364l4 l998-0~-Ol mandrel.
Figure 6 is a enlarged, cross-sectional view taken along lines 6-6 of Figure 5.
Figure 7 is an enlarged cross-sectional view taken along lines 7-7 of Figure 5.
S DETAILE:D DESCRIPIION O~ THE INVENTION
In the description which follows:
The term "breathable" means the ability of an article to transport interior moisture vapor to the exte~nal envirorlment.
As used herein, the term "waterproof" means the ability of an article to subst~nti~lly prevent liquid water from external sources from reaching the interior of the article.
Similarly, the term "fabric" as used herein means a material made by weaving, knitting, or felting. fibers.
The term "sock" as used herein means a short, close-fitting covering for the foot and lower leg constructed from any suitable material such as natural and synthetic fibers.
Referring to the drawings, Figures 3 and 4 show one form of the clothing article of the present invention. The article here comprises a sock construction including a thin, pliant bladder 12 constructed from a waterproof, breathable material, such as polyurethane sheet. Bladder 12 includes a foot portion 14 having an outer surface 16 and an inner surface 18. Bladder 12 has the unique capability of generally conforming to the contours of the human foot so that it can be comfortably worn inside a boot or shoe.
Bonded to the inner surface 18 of the bladder is a light-weight covering member such as a fabric inner sock 20 of standard constructiOn which is preferably made from knitted natural or synthetic fibers.
The article of the invention shown in Figure 3 also includes an outer sock 22 which is bonded to the outer surface of bladder 12. Outer sock 22 can also be constructed from filament or spun yarns. The outer sock can also be constructed from natural fibers: such as wool fibers, or from a variety of synthetic fibers such as polyester nylon and combinations thereof.
Inner and outer socks 20 and 22 are preferably bonded to bladder 12 by means of a waterproof. heat activated adhesive. A water-borne urethane heat activated, two stage fluid adhesive sold by Stahl U.S.A. of Peabody, M~ss~rhll~etts, under the designation UE-41742 has proved satisfactory for this purpose. Other adhesives can, of course, also be used, including CA 02236414 1998-o~-ol Wo 97/16082 PCT/usg6/173sl breathable adhesives. In any event, the adhesive should be selected and applied in a manner that the breathability of the footwear is not destroyed or subst~nti~lly reduced.
For certain applications the footwear article of the invention can be constructed by bonding to the bladder only a single inner or outer sock. This two, rather than three-ply 5 construction, can be used in a number of applications in which the three or more ply constructions are too bulky or too expensive.
Considering now the method of the invention, the first step involved in the construction of the waterproof breathable bladder. In one form of the method of the invention this is accomplished 'oy overlaying two thin sheets of thermo plastic material of a character that will 10 prevent penetration of liquid water while at the same time permitting free passage of moisture vapor such as perspiration. This material can be a polyurethane sometimes described as thermoplastic urethane. A suitable material of this type is sold by Fabrite T ~min~ring Corp. of Woodridge~ New Jersey. Other suitable materials include elastomers made from polyesters, polyamides. cellulose derivatives, polyacrylic acid and its holologs, natural or synthetic rubber 15 with hydrophilic impurities, copolyo~zlmi~les, polyureas, polyelectrolytes, polyphosphates, polyvinylamide. polyvimacohol, polyether. and copolymers thereof, polythioether,polythioether-polyether. copolyepichlorohydrin-ether, polysulphosphates. copolyester-ether and derivatives or mixtures thereof.
The next step in the method of one form of the invention is to define on the sheets of 20 material a line circumscribing the boundary of the bladder. This done. the sheets of material are heated along the boundary line to a temperature sufficient to sealably bond the sheets together along the boundary line.
The heating-fusion step can be accomplished in several ways well known to those skilled in the art. including using a heated wire or die having the shape of the bladder-boundary.
25 Heating can also be accomplished through the use of well-known radio frequency and ultrasonic welding techniques.
One technique which has proven to be satisfactory in making the footwear of the invention. involves the use of a heated platen press embodying a die having the shape of the outer boundary of the bladders. The die is electrically heated to about 500 degrees Fahrenheit.
30 One of the cooperating platens of the platen press is m~im~in~ at room temperature and. is lined with a flexible fabric such as felt. The two sheets of the bladder material, such as polyurethane film. are placed between two sheets of polytetrafluoroethylene coated fiber glass CA 02236414 1998-0~-01 sheets which act as separator material and also allow the heat from the die to penetrate to the film. A~ uL~liate heating of the dies causes the sheets of bladder material to be effectively welded, or sealably joined together along the boundary line to make the sock-shaped bladder.
After the welding process, the excess material outside the bladder boundary is m~nll~lly stripped 5 away and the bladder is removed from the platen press.
As illustrated in Figures 1 and 2 of the drawings, the next step in the process of the invention is to place the first covering member~ or inner sock 20 over a generally foot-shaped, approximately 1/8th inch thick, generally planar mandrel 27. Sock 20, which has inner and outer surfaces 20a and 20b is placed over the mandr~l so that inner surface 20a tnereof is disposed in engagement with the faces 27a of mandrel 27. As previously discussed. sock 20 can be constructed from a variety of materials. However. a socl; w hich is made by Wigwam Mills, Inc. of Sheboygan. Wisconsin special knit pattern of its ~,tandard BK-1188 has proven satisfactory. An alternate inner sock~ also made by Wigwam. is intended to imparl cold weather comfort to the waterproof footwear article of the present invention depending on the climate 15 encountered. For cold weather comfort, the inner sock can be made lltili7ing THERMAXR made by E. I. duPont de Nemours and Co. of Wilmington, Delaware. For warm weather comfort the inner sock can be made utili~ing COOLMAXR made by duPont. The yarn used in this alternative sock~ is a high bulk insulative blend comprising acrylic~ wool and nylon fibers.
After sock 20 has been placed over mandrel 27 and smoothed out so that its inner surface 20 is in close engagement with the faces of the mandrel 27. a light coating 30 of the Stahl UE-41742 adhesive is applied to the exposed surface of sock O. The adhesive can be applied to sock 20 by spraying~ rolling, painting or in any other customary way.
After the adhesive applied to sock 20 has dried, bladder 12 is carefully placed over the assemblage of sock 20 and mandrel 27 and is smoothed so that the inner surface of the bladder 25 is in close engagement with the adhesive coated sock 20.
Either before or after emplacement of the bladder over the mandrel. second covering member or sock 22 is emplaced over another mandrel 27 and appropriately smoothed out. The exposed or second surface of sock 22 is then coated with a layer 32 of the Stahl UE-41742 adhesive and the adhesive is allowed to dry. The second sock is then removed from the 30 mandrel, turned inside out and placed over bladder 12 which is mounted on the first mandrel 27 over first sock 20. With this arrangement, the adhesive coated second side of sock 22 is in engagement with the exposed surface of bladder 12.
CA 02236414 1998-o~-ol Wo 97/16082 PCT/US96/17391 It is to be noted that the proper application of the adhesive to the inner and outer socks is critical to the success of the m~n-lf~ lring process, since, when completed. the sock must be both breathable and waterproof and it must with.ct~n-l laundering and physical abuse while being worn.
SThe Stahl adhesive is a two-stage adhesive. It is applied in a water solution and then dried. After the adhesive has been applied and dried, it can be safely handled. stored, and manipulated. It is activated by applying heat and ~l~s~ e, and when elevated to about 300 degrees F it becomes permanently set and chemical cross linking occurs.
The adhesive can also be applied to the bladder rnaterial. When this approach is10followed. the adhesive can be applied by spraying, brushing, rolling or any other suitable means.
A particular method which has proven satisfactory involves the use of an adhesive consisting of a mixture of 100 parts of SolucotoR 1024-5C material and 6.5 parts of Spenbond~ 651. SolucotoR
is sold by Soluo Chemical Co., Inc. of West Warwick, Rhode Island and SpenbondR is sold by Reichold Chemicals. Inc. of Pensacola, Florida. When this adhesive is used. it is applied to the 15bladder of a dot matrix by spraying the adhesive through a perforated mylar film mask to form a multiplicity of dots of adhesive on the bladder surfaces.
When the adhesive is applied to the bladder. the adhesive is first applied to the outer surface of the bladder in the manner described to form a coated bladder. Next, the outer sock is placed over the bladder to form a subassembly. The subassembly is then turned inside out 20to expose the non-coated side of the bladder. A thin coat of adhesive is then applied to this sur-face. preferably in a dot matrix. and the inside sock. which has been turned inside out, is placed over the subassembly to forrn a precursor article.
It is to be understood that various adhesives, including waterproof breathable adhesives can be applied to the bladder in a number of ways well known to those skilled in the art.
25However. as previously mentioned, the adhesive should not detrimentally effect the free breathability of the finichPcl article.
The precursor assembly comprising the bonded together first adhesive coated sock 20, the bladder 12 and the second adhesive coated sock 22 is then heated and compressed in the direction of the arrows 34 in Figure 2 to form the finished article. This step is accomplished 30by placing the mandrel. upon which the precursor assembly is mounted, between two platens which can be controllably heated and urged together. More particularly, the platens are preferably electrically heated to a temperature of between about 280 and 310 degrees ~ahrenheit CA 02236414 1998-0~-01 and are controllably moved into pressural engagement with the precursor assembly by any type of hydraulically ~cnl~te~ s~u~e imparting assembly of a character well known to those skilled in the art. During this temperature-pressure step the polymer of the adhesive is cross linked making a permanent, waterproof bond of inner sock 20 to outside of the bladder and the outer sock 22 to the other side of the bladder. The minimllm temperature required to activate the Stahl adhesive is about 280 degrees F That temperature must be exceeded with the corresponding ap~lo~iate dwell time to cross link the adhesive polymer. Other adhesives may, of course, require that a different pressure temperature regime be followed.
The precursor assembly is then r~moved fro~n the press and allowed to cool thoroughly prior to doffing the completed waterproof footwear article from the mandrel.
When removed from the mandrel, the footwear article is generally planar in shape.
However~ upon inserting the foot into the open cuff of the article~ the foot eng~ging portion of the sock will neatly and smoothly conform to the shape of the wearer's foot.
It is to be understood that the method of the invention can be used to produce various articles of clothing such as socks and gloves. Such articles can be made in various sizes and design configurations to fit a wide variety of users.
Referring next to Figures 5 through 7 of the drawings, an alternate t'orm of the clothing article of the present invention is there illustrated. The article here comprises a glove con-struction including a thin, pliant bladder 42 constructed from a waterproofi breathable material, such as polyurethane sheet. Bladder 42 includes a hand portion 44 having an outer surface 46 and an inner surface 48 (Figure 6). Bladder 42iS of similar construction to previouslv described sock bladder 1'~ but in this case has the unique capability of generally conforming to the contours of the human hand so that it can be comfortably worn in the same manner as conventional dress or work gloves.
Bonded to the inner surface 48 of the bladder is a lightweight, generally hand-shaped covering member such as a fabric inner layer 50 of standard construction which is preferably made from knitted natural or synthetic fibers such as nylon and various types of polyesters. The glove article of the invention shown in Figures 5, 6, and 7 also include a hand-shaped outer layer 52 constructed of similar materials, which is bonded to the outer surface of the bladder.
The choice of materials for constructing inner and outer layers 50 and 52 is quite important to the character of the final assembly. For example, elasticity is very important for the reason that the fabric layers must be stretched over the assembly forms Therefore, the nature of the CA 02236414 1998-0~-01 stitches in a knit fabric must be such that the fabric will stretch as the yarns adjust one against the other.
To impart the stretch quality desired to make a glove conform to a variety of differing peoples' hand, both a stretch and return characteristic in the fiber layers is also desirable. For 5 this reason, fabrics which incorporate an elastic fiber such as fiber produced by duPont and sold under the name and style "LYCRA" have proven desirable particularly for use in construction of the outer layer 52. For certain end product applications, fabric layers embodying LYCRA
brand fibers are suitable for use in constructing both the inner and outer fabric layers 50 and 52.
I~nitting of the fabric layers 50 and 52 can be accomplished in ~arious ways. For 10 example. the knitting can be accomplished on a flat bed knitting m~chin~ of a character well known to those skilled in the art. The product of these machines is a glove which is se~
and will conform to the hand easily because it has great stretch and resiliency. However, in the method of this latest form of the invention wherein the bladder is fitted over the inner knit component~ which is, in turn, fitted over the mandrel, followed by the emplacement of the outer 15 knit component of the bladder tends to flimini~h the stretch and return capability of the kn~tted fabric layers. Accordingly, the addition of elastic fibers such as LYCRA brand fibers, to the knitting yards, is particularly desirable when the fabric gloves are constructed using flat-bed knitting machines.
Another method of fabrication of the fabric glove components for use in the method of 20 the invention can be accomplished using the so-called "cut & sew" method. In this technique, the fabric is first woven or knit as a flat sheet or roll of material. The sheet is then cut into pieces in an a~plopliate shape to be sewn together to forrn a glove. Using this method, an extensive array of fibers can be used. As before, the stretch and return characteristics of the fabric can be enh~nre-l by incorporating the duPont LYCRA brand fibers in the knittin~ or 25 weaving process.
Hand and glove shaped inner and outer layers 50 and 52 are preferably bonded to bladder 42 by means of a waterproof. heat activated adhesive "A". As before~ a water-borne urethane heat activated, two-stage fluid adhesive sold by Stahl U.S.A. of Peabody, ~ a~hll~etr.~ under the designation of UE~1742 has proved satisfactory for this purpose. Other adhesives can, of 30 course. also be used, including breathable adhesives. In any event, the adhesive should be selected and applied in a manner that the breathability of the article is no~ destroyed or sub-stantially reci~lced CA 0 2 2 3 6 4 1 4 1 9 9 8 - o ~ - o l wo 97/16082 PCT/Usg6/173sl For certain applications, the glove or handwear article of the invention can be constructed by bonding to the bladder only a single inner or outer fabric, glove shaped member. This two rather than three-ply construction, can be used in a number of applications in which the three or more ply constructions are too bulky or too expensive.
Considering now the method of this latest form of the invention, the first step involved in the construction of the waterproof breathable glove is accomplished by overlaying two thin sheets of thermo plastic material of a character that will prevent penetration of liquid water while at the same time permitting free passage of moisture vapor such as perspiration. This material can be a polyurethane som~im~c described as thermoE~lastic urethane. A suitable material of this type is sold by Fabrite T ~min~ting Corp. of Woodridge. New Jersey. Other suitable mate-rials include elastomers made from polyesters, polyamides~ cellulose derivatives, polyacrylic acid and its holologs, natural or synthetic rubber with hydrophilic impurities. copolyo7~mi~1f s, polyureas, polyelectrolytes. polyphosphates, polyvinylamide~ polyvinlacohok polyether, and copolymers thereof~ polythioether, polythioether-polyether~ copolyepichlorohydrin-ether, poly-sulphosphates, copolyester-ether and derivatives or mixtures thereof.
The next step in the method of this latest form of the invention is to define on the sheets of material a line circumscribing the boundary of the bladder. This done, the sheets of material are heated along the boundary line to a temperature sufficient to sealably bond the sheets together along the boundary line.
As in the earlier described method of the invention~ the heating-fusion step can be accomplished in several ways well known to those skilled in the art. including using a heated wire or die having the shape of the bladder-boundary. Heating can also be accomplished through the use of well-known radio frequency and ultrasonic welding techniques.The technique that has proven most s~ti~f~tory for making the glove article of the invention, involves the use of a heated platen press similar to that previously described herein which embodies a die having the shape of the outer boundary of the generally hand shaped bladder. The die is electrically heated to about 500 degrees Fahrenheit. As before~ one of the cooperating platens of the platen press is m~int~in.--l at room temperature and, is lined with a ilexible fabric such as felt. The two sheets of the bladder material, such as polyul~tllal.e film, are placed between two sheets of polytetrafluoroethylene coated fiber glass sheets which act as separator material and also allow the heat from the die to penetrate to the film. Ayyloyliat~
heating of the dies causes the sheets of bladder material to be effectively welded, or sealably CA 02236414 1998-0~-01 WO 97/16082 PCT/US96/1739]
joined together along the boundary line to make the generally hand-shaped bladder. After the welding process, the excess material outside the bladder boundary is m:~n~lly stripped away and the bladder is removed from the platen press.
As illustrated in Figures 5, 6 and 7 of the drawings, the next step in the process of the 5 invention is to place the first glove-like covering member, or inner layer 50 over a generally hand-shaped, approximately 1/8th inch thick, generally planar mandrel 57. Inner layer 50, which has inner and outer surfaces 50a and 50b is placed over the mandrel so that inner surface 50a is disposed in engagement with the faces 57a of mandrel 57. As previously ~ cllc~e~i~
member 20 can be constructed ~rom a variety cf natural and synthetic materials. For cold 10 weather comfort, the inner member can be made lltili7ing the previously identified THERMAXR
brand material made by E. I. duPont de Nemours and Co. of Wilmington~ Delaware. For warm weather comfort the inner member can be made ~ltili7ing COOLMAXR brand material made by duPont.
After inner layer 50 has been placed over mandrel 57 in the manner shown in Figure 5, a light coating A-l of the Stahl UE-41742 adhesive is applied to the exposed inner layer 50.
As before, adhesive can be applied to the inner layer 50 by spraying, rolling, painting or in any other customary way.
After the adhesive applied to inner layer 50 has dried, bladder 42 is carefully placed over the assemblage of inner layer 50 and mandrel 57 and is smoothed so that the inner surface of 20 the bladder is in close engagement with the adhesive coated glove-like member or liner 50.
Either before or after emplacement of the bladder over the mandrel. outer layer 52 is coated in the manner previously described with a layer of the Stahl UE-41742 adhesive and the adhesive is allowed to dry. Outer layer 52 is then turned inside out and placed over bladder 42 which is positioned on the mandrel 57 in an overlaying relationship with inner layer 50. With 25 this arrangement. the adhesive coated second side of outer layer 52 is in engagement with the exposed surface of bladder 42 in the manner shown in Figures 6 and 7.
As before the Stahl adhesive is activated by applying heat and pressure, and when elevated to about 300 degrees F it becomes permanently set and chemical cross linking occurs.
In the manner previously described in connection with the method of the invention for making 30 footwear. the adhesive can also be applied to the generally hand-shaped bladder material.
The precursor assembly comprising the bonded together inner layer 50, the bladder 42 and outer layer 52 is then heated and compressed in the direction of the arrows 64 in Figure 6 CA 02236414 1998-0~-01 to form the finished article. This step is accomplished by placing the mandrel. upon which the precursor assembly is mounted, beLweell two platens which can be controllable heated and urged together. Once again, the platens are preferably electrically heated to a temperature of between about 280 and 310 degrees Fahrenheit and are controllable moved into pressural engagement S with the precursor assembly by any type of hydraulically ~çtll~t~-~ pressure imparting assembly of a character well known to those skilled in the art- During this temperature-pressure step the polymer of the adhesive is cross linked making a permanent, waterproof bond of inner member 50 to outside of the bladder and the outer member 52 to the other side of the bladder. The minimllm temperature required to activate the Stahl adhesive is about 280 degrees F. ~at 10 temperature must be exceeded with the corresponding a~L~o~liate dwell time to cross link the adhesive polymer. Other adhesives may, of course, require that a different pressure temperature regime be followed.
The precursor assembly is then removed from the press and allowed to cool thoroughly prior to doffing the completed waterproof glove from the mandrel.
When removed from the mandrel, the glove is generally planar in shape. However, upon inserting the hand into the open cuff of the article, the glove body will neatly and smoothly conform to the shape of the wearer's hand.
While different mandrels can be used to produce right and left hand waLel~loof, breathable gloves. a single mandrel of the character shown in Figure 5 can be used to produce 20 a glove that is ambidextrous. That is, two identical gloves will make a pair either of which can be worn on either the right or left hand.
Having now described the invention in detail in accordance with the requirements of the patent statutes. those skilled in this art will have no difficulty in making changes and modifi-cations in the individual parts or their relative assembly in order to meet specific requirements 25 or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims.
s 1. Field of the Invention The present invention relates generally to articles ot apparel. More particularly, the invention concerns articles of apparel used to cover the wearer s extremities such as an im-proved, waterproof sock that will permit pe,~i,ation to transpire th;ough the sock. but will keep 10 water from external sources away from the wearer's foot 2. Description of the Prior Art Various attempts have been made in the past to produce hreathable. waterproof articles of apparel such as gloves and socks that will keep the wearer's hands and feet drv and at the 15 same time permit p~ uildtion to Lldll~ilC through the article Materials which will accomplish this desired function have been known for sometime. For example. U S. Patent No. 3.953,566 discloses a method of making an expanded polytetrafluoroethylene (PTFE) that possesses the ~.u~. Lies of being both breathable and waterproof. An improvement of this material is described in U.S. Patent No. 4.194,041. While both of these materials have been used in the 20 construction of footwear, they exhibit the drawback that thev have limited stretchability, thereby making them less than ideally suited for construction of footwear such as socks. In addition.
such footwear typically has sewn seems and tapes which make it bulky and uncomfortable.
In an apparent attempt to overcome the problems dicc--ccec~ in the prece~iing paragraph, a multi-component sock type article was suggested. This article. which is described in U.S.
Patent No. 4.819.447 issued to Pacanowsky, et al.. comprises a waterproof. nonelastic~
non-stretch sole component. a non-stretch calf component and a vamp component ~tt~'h-~-l to the sole and calf components.
As will be better appreciated from the discussion which follows. the footwear article of the present invention provides. for the first time, footwear such as socks construction which 30 exhibit the comfort and stretchability of a traditional type of sport sock and at the same time are both breathable and completely w~L~ of.
CA 02236414 1998-0~-01 SUMMARY OF THE rNVENTION
It is an object of the present invention to provide comfortable articles of apparel and the method of making the same which will allow water vapor due to perspiration to transpire 5 through the article but will prevent water from external sources from reaching the wearer's extremities.
A particular object of the invention is to provide a footwear article of the aforementioned character which fits well, is pliant and is durable in use.
Arlother object of the invention is to provide an article such as a glove or sock in which 10 water vapor from perspiration can be tr~n~mit~ from inside to outside so that the natural evaporative cooling effect can be achieved.
Another object of the invention is to provide a method of making articles of the character described in the preceding paragraphs which is simple and straight forward. does not require the use of complicated equipment such as sewing and seaming equipment and can be performed by 15 unskilled workmen with a minimllm of training.
A particular object of the invention is to provide a sock as described in the precerling paragraphs which is of simple construction and is easy to m~nllf~cture.
In its preferred form, the footwear article of the invention comprises a sock which is of three-ply construction with the inside and outside plies being knit and the intermediate ply being 20 made from an elastomeric polyurethane film. The three-plies are uniquely bonded together using a pliant. waterproof adhesive.
BRIEF DESCRIPIION OF THE DRAWINGS
Figure 1 is a side-elevational view illustrating the method of making the footwear article of the invention and showing the components of the article in position over a foot-shaped planar mandrel.
Figure 2 is an enlarged cross-sectional view taken along lines 2-2 of Figure 1.
Figure 3 is a side-elevational view of one form of the footwear article of the invention.
Figure 4 is an enlarged cross-sectional view taken along lines 4-4 of Figure 3.
Figure 5 is a top plan view illustrating the method of making a glove article of the invention and showing the components of the article in position over a hand-shaped planar CA 022364l4 l998-0~-Ol mandrel.
Figure 6 is a enlarged, cross-sectional view taken along lines 6-6 of Figure 5.
Figure 7 is an enlarged cross-sectional view taken along lines 7-7 of Figure 5.
S DETAILE:D DESCRIPIION O~ THE INVENTION
In the description which follows:
The term "breathable" means the ability of an article to transport interior moisture vapor to the exte~nal envirorlment.
As used herein, the term "waterproof" means the ability of an article to subst~nti~lly prevent liquid water from external sources from reaching the interior of the article.
Similarly, the term "fabric" as used herein means a material made by weaving, knitting, or felting. fibers.
The term "sock" as used herein means a short, close-fitting covering for the foot and lower leg constructed from any suitable material such as natural and synthetic fibers.
Referring to the drawings, Figures 3 and 4 show one form of the clothing article of the present invention. The article here comprises a sock construction including a thin, pliant bladder 12 constructed from a waterproof, breathable material, such as polyurethane sheet. Bladder 12 includes a foot portion 14 having an outer surface 16 and an inner surface 18. Bladder 12 has the unique capability of generally conforming to the contours of the human foot so that it can be comfortably worn inside a boot or shoe.
Bonded to the inner surface 18 of the bladder is a light-weight covering member such as a fabric inner sock 20 of standard constructiOn which is preferably made from knitted natural or synthetic fibers.
The article of the invention shown in Figure 3 also includes an outer sock 22 which is bonded to the outer surface of bladder 12. Outer sock 22 can also be constructed from filament or spun yarns. The outer sock can also be constructed from natural fibers: such as wool fibers, or from a variety of synthetic fibers such as polyester nylon and combinations thereof.
Inner and outer socks 20 and 22 are preferably bonded to bladder 12 by means of a waterproof. heat activated adhesive. A water-borne urethane heat activated, two stage fluid adhesive sold by Stahl U.S.A. of Peabody, M~ss~rhll~etts, under the designation UE-41742 has proved satisfactory for this purpose. Other adhesives can, of course, also be used, including CA 02236414 1998-o~-ol Wo 97/16082 PCT/usg6/173sl breathable adhesives. In any event, the adhesive should be selected and applied in a manner that the breathability of the footwear is not destroyed or subst~nti~lly reduced.
For certain applications the footwear article of the invention can be constructed by bonding to the bladder only a single inner or outer sock. This two, rather than three-ply 5 construction, can be used in a number of applications in which the three or more ply constructions are too bulky or too expensive.
Considering now the method of the invention, the first step involved in the construction of the waterproof breathable bladder. In one form of the method of the invention this is accomplished 'oy overlaying two thin sheets of thermo plastic material of a character that will 10 prevent penetration of liquid water while at the same time permitting free passage of moisture vapor such as perspiration. This material can be a polyurethane sometimes described as thermoplastic urethane. A suitable material of this type is sold by Fabrite T ~min~ring Corp. of Woodridge~ New Jersey. Other suitable materials include elastomers made from polyesters, polyamides. cellulose derivatives, polyacrylic acid and its holologs, natural or synthetic rubber 15 with hydrophilic impurities, copolyo~zlmi~les, polyureas, polyelectrolytes, polyphosphates, polyvinylamide. polyvimacohol, polyether. and copolymers thereof, polythioether,polythioether-polyether. copolyepichlorohydrin-ether, polysulphosphates. copolyester-ether and derivatives or mixtures thereof.
The next step in the method of one form of the invention is to define on the sheets of 20 material a line circumscribing the boundary of the bladder. This done. the sheets of material are heated along the boundary line to a temperature sufficient to sealably bond the sheets together along the boundary line.
The heating-fusion step can be accomplished in several ways well known to those skilled in the art. including using a heated wire or die having the shape of the bladder-boundary.
25 Heating can also be accomplished through the use of well-known radio frequency and ultrasonic welding techniques.
One technique which has proven to be satisfactory in making the footwear of the invention. involves the use of a heated platen press embodying a die having the shape of the outer boundary of the bladders. The die is electrically heated to about 500 degrees Fahrenheit.
30 One of the cooperating platens of the platen press is m~im~in~ at room temperature and. is lined with a flexible fabric such as felt. The two sheets of the bladder material, such as polyurethane film. are placed between two sheets of polytetrafluoroethylene coated fiber glass CA 02236414 1998-0~-01 sheets which act as separator material and also allow the heat from the die to penetrate to the film. A~ uL~liate heating of the dies causes the sheets of bladder material to be effectively welded, or sealably joined together along the boundary line to make the sock-shaped bladder.
After the welding process, the excess material outside the bladder boundary is m~nll~lly stripped 5 away and the bladder is removed from the platen press.
As illustrated in Figures 1 and 2 of the drawings, the next step in the process of the invention is to place the first covering member~ or inner sock 20 over a generally foot-shaped, approximately 1/8th inch thick, generally planar mandrel 27. Sock 20, which has inner and outer surfaces 20a and 20b is placed over the mandr~l so that inner surface 20a tnereof is disposed in engagement with the faces 27a of mandrel 27. As previously discussed. sock 20 can be constructed from a variety of materials. However. a socl; w hich is made by Wigwam Mills, Inc. of Sheboygan. Wisconsin special knit pattern of its ~,tandard BK-1188 has proven satisfactory. An alternate inner sock~ also made by Wigwam. is intended to imparl cold weather comfort to the waterproof footwear article of the present invention depending on the climate 15 encountered. For cold weather comfort, the inner sock can be made lltili7ing THERMAXR made by E. I. duPont de Nemours and Co. of Wilmington, Delaware. For warm weather comfort the inner sock can be made utili~ing COOLMAXR made by duPont. The yarn used in this alternative sock~ is a high bulk insulative blend comprising acrylic~ wool and nylon fibers.
After sock 20 has been placed over mandrel 27 and smoothed out so that its inner surface 20 is in close engagement with the faces of the mandrel 27. a light coating 30 of the Stahl UE-41742 adhesive is applied to the exposed surface of sock O. The adhesive can be applied to sock 20 by spraying~ rolling, painting or in any other customary way.
After the adhesive applied to sock 20 has dried, bladder 12 is carefully placed over the assemblage of sock 20 and mandrel 27 and is smoothed so that the inner surface of the bladder 25 is in close engagement with the adhesive coated sock 20.
Either before or after emplacement of the bladder over the mandrel. second covering member or sock 22 is emplaced over another mandrel 27 and appropriately smoothed out. The exposed or second surface of sock 22 is then coated with a layer 32 of the Stahl UE-41742 adhesive and the adhesive is allowed to dry. The second sock is then removed from the 30 mandrel, turned inside out and placed over bladder 12 which is mounted on the first mandrel 27 over first sock 20. With this arrangement, the adhesive coated second side of sock 22 is in engagement with the exposed surface of bladder 12.
CA 02236414 1998-o~-ol Wo 97/16082 PCT/US96/17391 It is to be noted that the proper application of the adhesive to the inner and outer socks is critical to the success of the m~n-lf~ lring process, since, when completed. the sock must be both breathable and waterproof and it must with.ct~n-l laundering and physical abuse while being worn.
SThe Stahl adhesive is a two-stage adhesive. It is applied in a water solution and then dried. After the adhesive has been applied and dried, it can be safely handled. stored, and manipulated. It is activated by applying heat and ~l~s~ e, and when elevated to about 300 degrees F it becomes permanently set and chemical cross linking occurs.
The adhesive can also be applied to the bladder rnaterial. When this approach is10followed. the adhesive can be applied by spraying, brushing, rolling or any other suitable means.
A particular method which has proven satisfactory involves the use of an adhesive consisting of a mixture of 100 parts of SolucotoR 1024-5C material and 6.5 parts of Spenbond~ 651. SolucotoR
is sold by Soluo Chemical Co., Inc. of West Warwick, Rhode Island and SpenbondR is sold by Reichold Chemicals. Inc. of Pensacola, Florida. When this adhesive is used. it is applied to the 15bladder of a dot matrix by spraying the adhesive through a perforated mylar film mask to form a multiplicity of dots of adhesive on the bladder surfaces.
When the adhesive is applied to the bladder. the adhesive is first applied to the outer surface of the bladder in the manner described to form a coated bladder. Next, the outer sock is placed over the bladder to form a subassembly. The subassembly is then turned inside out 20to expose the non-coated side of the bladder. A thin coat of adhesive is then applied to this sur-face. preferably in a dot matrix. and the inside sock. which has been turned inside out, is placed over the subassembly to forrn a precursor article.
It is to be understood that various adhesives, including waterproof breathable adhesives can be applied to the bladder in a number of ways well known to those skilled in the art.
25However. as previously mentioned, the adhesive should not detrimentally effect the free breathability of the finichPcl article.
The precursor assembly comprising the bonded together first adhesive coated sock 20, the bladder 12 and the second adhesive coated sock 22 is then heated and compressed in the direction of the arrows 34 in Figure 2 to form the finished article. This step is accomplished 30by placing the mandrel. upon which the precursor assembly is mounted, between two platens which can be controllably heated and urged together. More particularly, the platens are preferably electrically heated to a temperature of between about 280 and 310 degrees ~ahrenheit CA 02236414 1998-0~-01 and are controllably moved into pressural engagement with the precursor assembly by any type of hydraulically ~cnl~te~ s~u~e imparting assembly of a character well known to those skilled in the art. During this temperature-pressure step the polymer of the adhesive is cross linked making a permanent, waterproof bond of inner sock 20 to outside of the bladder and the outer sock 22 to the other side of the bladder. The minimllm temperature required to activate the Stahl adhesive is about 280 degrees F That temperature must be exceeded with the corresponding ap~lo~iate dwell time to cross link the adhesive polymer. Other adhesives may, of course, require that a different pressure temperature regime be followed.
The precursor assembly is then r~moved fro~n the press and allowed to cool thoroughly prior to doffing the completed waterproof footwear article from the mandrel.
When removed from the mandrel, the footwear article is generally planar in shape.
However~ upon inserting the foot into the open cuff of the article~ the foot eng~ging portion of the sock will neatly and smoothly conform to the shape of the wearer's foot.
It is to be understood that the method of the invention can be used to produce various articles of clothing such as socks and gloves. Such articles can be made in various sizes and design configurations to fit a wide variety of users.
Referring next to Figures 5 through 7 of the drawings, an alternate t'orm of the clothing article of the present invention is there illustrated. The article here comprises a glove con-struction including a thin, pliant bladder 42 constructed from a waterproofi breathable material, such as polyurethane sheet. Bladder 42 includes a hand portion 44 having an outer surface 46 and an inner surface 48 (Figure 6). Bladder 42iS of similar construction to previouslv described sock bladder 1'~ but in this case has the unique capability of generally conforming to the contours of the human hand so that it can be comfortably worn in the same manner as conventional dress or work gloves.
Bonded to the inner surface 48 of the bladder is a lightweight, generally hand-shaped covering member such as a fabric inner layer 50 of standard construction which is preferably made from knitted natural or synthetic fibers such as nylon and various types of polyesters. The glove article of the invention shown in Figures 5, 6, and 7 also include a hand-shaped outer layer 52 constructed of similar materials, which is bonded to the outer surface of the bladder.
The choice of materials for constructing inner and outer layers 50 and 52 is quite important to the character of the final assembly. For example, elasticity is very important for the reason that the fabric layers must be stretched over the assembly forms Therefore, the nature of the CA 02236414 1998-0~-01 stitches in a knit fabric must be such that the fabric will stretch as the yarns adjust one against the other.
To impart the stretch quality desired to make a glove conform to a variety of differing peoples' hand, both a stretch and return characteristic in the fiber layers is also desirable. For 5 this reason, fabrics which incorporate an elastic fiber such as fiber produced by duPont and sold under the name and style "LYCRA" have proven desirable particularly for use in construction of the outer layer 52. For certain end product applications, fabric layers embodying LYCRA
brand fibers are suitable for use in constructing both the inner and outer fabric layers 50 and 52.
I~nitting of the fabric layers 50 and 52 can be accomplished in ~arious ways. For 10 example. the knitting can be accomplished on a flat bed knitting m~chin~ of a character well known to those skilled in the art. The product of these machines is a glove which is se~
and will conform to the hand easily because it has great stretch and resiliency. However, in the method of this latest form of the invention wherein the bladder is fitted over the inner knit component~ which is, in turn, fitted over the mandrel, followed by the emplacement of the outer 15 knit component of the bladder tends to flimini~h the stretch and return capability of the kn~tted fabric layers. Accordingly, the addition of elastic fibers such as LYCRA brand fibers, to the knitting yards, is particularly desirable when the fabric gloves are constructed using flat-bed knitting machines.
Another method of fabrication of the fabric glove components for use in the method of 20 the invention can be accomplished using the so-called "cut & sew" method. In this technique, the fabric is first woven or knit as a flat sheet or roll of material. The sheet is then cut into pieces in an a~plopliate shape to be sewn together to forrn a glove. Using this method, an extensive array of fibers can be used. As before, the stretch and return characteristics of the fabric can be enh~nre-l by incorporating the duPont LYCRA brand fibers in the knittin~ or 25 weaving process.
Hand and glove shaped inner and outer layers 50 and 52 are preferably bonded to bladder 42 by means of a waterproof. heat activated adhesive "A". As before~ a water-borne urethane heat activated, two-stage fluid adhesive sold by Stahl U.S.A. of Peabody, ~ a~hll~etr.~ under the designation of UE~1742 has proved satisfactory for this purpose. Other adhesives can, of 30 course. also be used, including breathable adhesives. In any event, the adhesive should be selected and applied in a manner that the breathability of the article is no~ destroyed or sub-stantially reci~lced CA 0 2 2 3 6 4 1 4 1 9 9 8 - o ~ - o l wo 97/16082 PCT/Usg6/173sl For certain applications, the glove or handwear article of the invention can be constructed by bonding to the bladder only a single inner or outer fabric, glove shaped member. This two rather than three-ply construction, can be used in a number of applications in which the three or more ply constructions are too bulky or too expensive.
Considering now the method of this latest form of the invention, the first step involved in the construction of the waterproof breathable glove is accomplished by overlaying two thin sheets of thermo plastic material of a character that will prevent penetration of liquid water while at the same time permitting free passage of moisture vapor such as perspiration. This material can be a polyurethane som~im~c described as thermoE~lastic urethane. A suitable material of this type is sold by Fabrite T ~min~ting Corp. of Woodridge. New Jersey. Other suitable mate-rials include elastomers made from polyesters, polyamides~ cellulose derivatives, polyacrylic acid and its holologs, natural or synthetic rubber with hydrophilic impurities. copolyo7~mi~1f s, polyureas, polyelectrolytes. polyphosphates, polyvinylamide~ polyvinlacohok polyether, and copolymers thereof~ polythioether, polythioether-polyether~ copolyepichlorohydrin-ether, poly-sulphosphates, copolyester-ether and derivatives or mixtures thereof.
The next step in the method of this latest form of the invention is to define on the sheets of material a line circumscribing the boundary of the bladder. This done, the sheets of material are heated along the boundary line to a temperature sufficient to sealably bond the sheets together along the boundary line.
As in the earlier described method of the invention~ the heating-fusion step can be accomplished in several ways well known to those skilled in the art. including using a heated wire or die having the shape of the bladder-boundary. Heating can also be accomplished through the use of well-known radio frequency and ultrasonic welding techniques.The technique that has proven most s~ti~f~tory for making the glove article of the invention, involves the use of a heated platen press similar to that previously described herein which embodies a die having the shape of the outer boundary of the generally hand shaped bladder. The die is electrically heated to about 500 degrees Fahrenheit. As before~ one of the cooperating platens of the platen press is m~int~in.--l at room temperature and, is lined with a ilexible fabric such as felt. The two sheets of the bladder material, such as polyul~tllal.e film, are placed between two sheets of polytetrafluoroethylene coated fiber glass sheets which act as separator material and also allow the heat from the die to penetrate to the film. Ayyloyliat~
heating of the dies causes the sheets of bladder material to be effectively welded, or sealably CA 02236414 1998-0~-01 WO 97/16082 PCT/US96/1739]
joined together along the boundary line to make the generally hand-shaped bladder. After the welding process, the excess material outside the bladder boundary is m:~n~lly stripped away and the bladder is removed from the platen press.
As illustrated in Figures 5, 6 and 7 of the drawings, the next step in the process of the 5 invention is to place the first glove-like covering member, or inner layer 50 over a generally hand-shaped, approximately 1/8th inch thick, generally planar mandrel 57. Inner layer 50, which has inner and outer surfaces 50a and 50b is placed over the mandrel so that inner surface 50a is disposed in engagement with the faces 57a of mandrel 57. As previously ~ cllc~e~i~
member 20 can be constructed ~rom a variety cf natural and synthetic materials. For cold 10 weather comfort, the inner member can be made lltili7ing the previously identified THERMAXR
brand material made by E. I. duPont de Nemours and Co. of Wilmington~ Delaware. For warm weather comfort the inner member can be made ~ltili7ing COOLMAXR brand material made by duPont.
After inner layer 50 has been placed over mandrel 57 in the manner shown in Figure 5, a light coating A-l of the Stahl UE-41742 adhesive is applied to the exposed inner layer 50.
As before, adhesive can be applied to the inner layer 50 by spraying, rolling, painting or in any other customary way.
After the adhesive applied to inner layer 50 has dried, bladder 42 is carefully placed over the assemblage of inner layer 50 and mandrel 57 and is smoothed so that the inner surface of 20 the bladder is in close engagement with the adhesive coated glove-like member or liner 50.
Either before or after emplacement of the bladder over the mandrel. outer layer 52 is coated in the manner previously described with a layer of the Stahl UE-41742 adhesive and the adhesive is allowed to dry. Outer layer 52 is then turned inside out and placed over bladder 42 which is positioned on the mandrel 57 in an overlaying relationship with inner layer 50. With 25 this arrangement. the adhesive coated second side of outer layer 52 is in engagement with the exposed surface of bladder 42 in the manner shown in Figures 6 and 7.
As before the Stahl adhesive is activated by applying heat and pressure, and when elevated to about 300 degrees F it becomes permanently set and chemical cross linking occurs.
In the manner previously described in connection with the method of the invention for making 30 footwear. the adhesive can also be applied to the generally hand-shaped bladder material.
The precursor assembly comprising the bonded together inner layer 50, the bladder 42 and outer layer 52 is then heated and compressed in the direction of the arrows 64 in Figure 6 CA 02236414 1998-0~-01 to form the finished article. This step is accomplished by placing the mandrel. upon which the precursor assembly is mounted, beLweell two platens which can be controllable heated and urged together. Once again, the platens are preferably electrically heated to a temperature of between about 280 and 310 degrees Fahrenheit and are controllable moved into pressural engagement S with the precursor assembly by any type of hydraulically ~çtll~t~-~ pressure imparting assembly of a character well known to those skilled in the art- During this temperature-pressure step the polymer of the adhesive is cross linked making a permanent, waterproof bond of inner member 50 to outside of the bladder and the outer member 52 to the other side of the bladder. The minimllm temperature required to activate the Stahl adhesive is about 280 degrees F. ~at 10 temperature must be exceeded with the corresponding a~L~o~liate dwell time to cross link the adhesive polymer. Other adhesives may, of course, require that a different pressure temperature regime be followed.
The precursor assembly is then removed from the press and allowed to cool thoroughly prior to doffing the completed waterproof glove from the mandrel.
When removed from the mandrel, the glove is generally planar in shape. However, upon inserting the hand into the open cuff of the article, the glove body will neatly and smoothly conform to the shape of the wearer's hand.
While different mandrels can be used to produce right and left hand waLel~loof, breathable gloves. a single mandrel of the character shown in Figure 5 can be used to produce 20 a glove that is ambidextrous. That is, two identical gloves will make a pair either of which can be worn on either the right or left hand.
Having now described the invention in detail in accordance with the requirements of the patent statutes. those skilled in this art will have no difficulty in making changes and modifi-cations in the individual parts or their relative assembly in order to meet specific requirements 25 or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims.
Claims (10)
1. A method of making a waterproof glove comprising the steps of:
(a) forming a waterproof, breathable material into a stretchable bladder having an open cuff portion and a continuous hand receiving portion having the general shape of the wearer's hand including a continuous outer surface and a continuous inner surface generally conformable to the contours of the wearer's hand: and (b) bonding a first generally hand-shaped covering member to said inner surface of said hand receiving portion of said bladder to form a subassembly portion of said article, said first generally hand-shaped covering member being made from a yarn comprising elastic fibers.
(a) forming a waterproof, breathable material into a stretchable bladder having an open cuff portion and a continuous hand receiving portion having the general shape of the wearer's hand including a continuous outer surface and a continuous inner surface generally conformable to the contours of the wearer's hand: and (b) bonding a first generally hand-shaped covering member to said inner surface of said hand receiving portion of said bladder to form a subassembly portion of said article, said first generally hand-shaped covering member being made from a yarn comprising elastic fibers.
2. A method as defined in Claim 1 including the further step of bonding a second generally hand-shaped covering member to said outer surface of said hand receiving portion of said bladder to form a precursor article.
3. A method as defined in Claim 2 in which said first generally hand-shaped covering member is bonded to said inner surface of said hand receiving portion of said bladder by applying a multiplicity of particles of waterproof adhesives to said waterproof, breathable material in a dot matrix form.
4. A method as defined in Claim 3 including the further steps of heating and compressing said precursor article.
5. A method of making a waterproof glove constructed of an inner fabric member, an outer fabric member and an intermediate pliant, waterproof breathable bladder having a continuous hand-receiving portion in the general shape of the wearer's hand and having a continuous inner and outer surface, said method comprising the steps of:
(a) applying a multiplicity of heat activated adhesive particles to said bladder to form a coated bladder;
(b) placing said coated bladder over said inner fabric member to form a subassembly;
(c) placing said coated outer fabric member over said subassembly to form a precursor article; and (d) heating said precursor article to a temperature sufficient to activate said particles of heat activated adhesive, whereby said inner and outer members will be adhesively bonded to the continuous inner and outer surfaces of the bladder.
(a) applying a multiplicity of heat activated adhesive particles to said bladder to form a coated bladder;
(b) placing said coated bladder over said inner fabric member to form a subassembly;
(c) placing said coated outer fabric member over said subassembly to form a precursor article; and (d) heating said precursor article to a temperature sufficient to activate said particles of heat activated adhesive, whereby said inner and outer members will be adhesively bonded to the continuous inner and outer surfaces of the bladder.
6. A method as defined in Claim 5 in which said precursor article is compressed during said heating step in a manner to urge said inner and outer members into close proximity with said bladder.
7. A method as defined in Claim 5 in which said adhesive particles comprise urethane polymer and in which said assembly is heated to a temperature sufficient to cross link said urethane polymer.
8. A method as defined in Claim 5 in which at least one of said first and second fabric members comprises yarns made of synthetic fibers and elastic fibers.
9. An article of apparel used to cover a wearer's hand comprising:
(a) a pliant, generally extremity-shaped hollow bladder constructed from a waterproof. breathable material, said bladder including as a part thereof, a continuous hand covering portion for substantially enclosing therewithin the user's hand including a continuous outer surface and a continuous inner surface generally conforming to the user's hand;
and (b) a generally hand-shaped covering member having a continuous surface attached directly to one of said continuous inner and outer surfaces of said bladder along a substantial portion thereof by means of a multiplicity of particles of adhesive provided on said bladder.
(a) a pliant, generally extremity-shaped hollow bladder constructed from a waterproof. breathable material, said bladder including as a part thereof, a continuous hand covering portion for substantially enclosing therewithin the user's hand including a continuous outer surface and a continuous inner surface generally conforming to the user's hand;
and (b) a generally hand-shaped covering member having a continuous surface attached directly to one of said continuous inner and outer surfaces of said bladder along a substantial portion thereof by means of a multiplicity of particles of adhesive provided on said bladder.
10. An article of apparel used to cover a wearer's hand comprising:
(a) a pliant generally extremity-shaped hollow bladder constructed from a waterproof, breathable material, said bladder including as a part thereof, a continuous hand covering portion for substantially enclosing therewithin the user' s hand including a continuous outer surface and a continuous inner surface generally to the user's hand;
(b) a first generally hand-shaped covering member constructed from a yarn comprising elastic fibers and having a continuous surface attached directly to said continuous inner surface of said bladder along a substantial portion thereof: and (c) a second generally hand-shaped covering member constructed from a yarn comprising elastic fibers and having a continuous surface attached directly to said continuous outer surface of said bladder along a substantial portion thereof.
(a) a pliant generally extremity-shaped hollow bladder constructed from a waterproof, breathable material, said bladder including as a part thereof, a continuous hand covering portion for substantially enclosing therewithin the user' s hand including a continuous outer surface and a continuous inner surface generally to the user's hand;
(b) a first generally hand-shaped covering member constructed from a yarn comprising elastic fibers and having a continuous surface attached directly to said continuous inner surface of said bladder along a substantial portion thereof: and (c) a second generally hand-shaped covering member constructed from a yarn comprising elastic fibers and having a continuous surface attached directly to said continuous outer surface of said bladder along a substantial portion thereof.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/553,040 | 1995-11-03 | ||
| US08/553,040 US5732413A (en) | 1992-10-09 | 1995-11-03 | Waterproof glove and method of making same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2236414A1 true CA2236414A1 (en) | 1997-05-09 |
Family
ID=24207866
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002236414A Abandoned CA2236414A1 (en) | 1995-11-03 | 1996-11-01 | Waterproof, breathable articles of apparel |
Country Status (9)
| Country | Link |
|---|---|
| US (1) | US5732413A (en) |
| EP (1) | EP0914047B1 (en) |
| JP (1) | JPH11514707A (en) |
| AT (1) | ATE213595T1 (en) |
| AU (1) | AU7483296A (en) |
| CA (1) | CA2236414A1 (en) |
| DE (1) | DE69619563T2 (en) |
| NZ (1) | NZ321487A (en) |
| WO (1) | WO1997016082A1 (en) |
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| US6139929A (en) * | 1997-03-07 | 2000-10-31 | Porvair Plc | Socks |
| US6009557A (en) * | 1998-03-04 | 2000-01-04 | Witta; Jay D. | Video game control glove |
| US6348679B1 (en) | 1998-03-17 | 2002-02-19 | Ameritherm, Inc. | RF active compositions for use in adhesion, bonding and coating |
| US20020170653A1 (en) * | 1999-08-27 | 2002-11-21 | Williams Cole | Waterproof, breathable articles of apparel |
| US6649888B2 (en) | 1999-09-23 | 2003-11-18 | Codaco, Inc. | Radio frequency (RF) heating system |
| US6415447B1 (en) | 1999-11-24 | 2002-07-09 | The Burton Corporation | Leakproof and breathable hand covering and method of making the same |
| US7162748B2 (en) * | 2000-02-02 | 2007-01-16 | Martin Hottner | Handcovering |
| DE10004355A1 (en) * | 2000-02-02 | 2001-08-23 | Gore W L & Ass Gmbh | Glove |
| IT1318737B1 (en) * | 2000-08-07 | 2003-09-10 | Nextec Srl | PROCEDURE FOR WATERPROOFING SEMI-FINISHED FOOTWEAR, GARMENTS AND CLOTHING ACCESSORIES, AS WELL AS SEMI-FINISHED PRODUCTS OBTAINED WITH SUCH |
| US7162746B2 (en) * | 2001-12-12 | 2007-01-16 | Reynolds Eric M | Body form-fitting rainwear |
| US7930767B2 (en) * | 2001-12-12 | 2011-04-26 | Reynolds Eric M | Body form-fitting rainwear |
| US6665883B2 (en) * | 2002-01-17 | 2003-12-23 | Dale A. Sloan | Oversock |
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-
1995
- 1995-11-03 US US08/553,040 patent/US5732413A/en not_active Expired - Lifetime
-
1996
- 1996-11-01 WO PCT/US1996/017391 patent/WO1997016082A1/en active IP Right Grant
- 1996-11-01 NZ NZ321487A patent/NZ321487A/en not_active IP Right Cessation
- 1996-11-01 DE DE69619563T patent/DE69619563T2/en not_active Expired - Lifetime
- 1996-11-01 CA CA002236414A patent/CA2236414A1/en not_active Abandoned
- 1996-11-01 AU AU74832/96A patent/AU7483296A/en not_active Abandoned
- 1996-11-01 JP JP9517507A patent/JPH11514707A/en not_active Ceased
- 1996-11-01 AT AT96937079T patent/ATE213595T1/en not_active IP Right Cessation
- 1996-11-01 EP EP96937079A patent/EP0914047B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| DE69619563D1 (en) | 2002-04-04 |
| NZ321487A (en) | 1998-12-23 |
| JPH11514707A (en) | 1999-12-14 |
| EP0914047A4 (en) | 1999-05-12 |
| US5732413A (en) | 1998-03-31 |
| AU7483296A (en) | 1997-05-22 |
| WO1997016082A1 (en) | 1997-05-09 |
| EP0914047B1 (en) | 2002-02-27 |
| DE69619563T2 (en) | 2004-04-15 |
| ATE213595T1 (en) | 2002-03-15 |
| EP0914047A1 (en) | 1999-05-12 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |