Layered coating for fabrics

Abstract

This application relates to layered coatings for fabrics. Coated fabrics and methods of making the same are provided. A coated fabric includes a base coating. The base coating defines a smooth coating to resist liquid penetration to the fabric. The coated fabric also includes an intermediate foam coating deposited on at least a portion of the base coating. The intermediate foam coating defines an intermediate layer foam density and is configured to at least absorb a portion of the liquid. The coated fabric also includes an outer foam coating deposited on at least a portion of the intermediate foam coating. The outer foam layer defines an outer layer foam density and is configured to have pores to allow liquid penetration to the intermediate foam layer. The intermediate layer foam density is less than the outer layer foam density. Corresponding methods of making are also provided.

Description

TECHNICAL FIELD

[0001] Exemplary embodiments of the present application relate generally to high performance coating materials, and more particularly to coated fabrics. BACKGROUND

[0002] Applicants have discovered a number of deficiencies and problems associated with conventional gloves as they are insufficient to provide both adequate grip and abrasion resistance in wet or oily environments. Through efforts, creativity, and innovation, many of these discovered problems have been addressed by developing solutions included in embodiments of the present disclosure, many examples of which are described in detail herein. SUMMARY

[0003] Exemplary embodiments of the present disclosure relate to a three-layer coated fabric and related manufacturing method. In one exemplary embodiment, a coated fabric is provided. The coated fabric includes a base coating layer. The base coating layer defines a smooth coating to resist liquid penetration to the fabric. The coated fabric also includes an intermediate foam coating deposited on at least a portion of the base coating layer. The intermediate foam layer defines an intermediate layer foam density and the intermediate foam layer is configured to absorb at least a portion of a liquid. The coated fabric further includes an outer foam coating deposited on at least a portion of the intermediate foam coating. The outer foam layer defines an outer layer foam density and the outer foam layer is configured to be porous to allow liquid penetration to the intermediate foam layer such that the outer foam layer increases abrasion resistance of the coated fabric. The intermediate layer foam density is less than the outer layer foam density.

[0004] In some embodiments, the intermediate layer foam density is 0.25 kg / L to 0.60 kg / L. In some embodiments, the intermediate layer foam density is 0.45 kg / L to 0.60 kg / L. In some embodiments, the outer layer foam density is 0.70 kg / L to 0.9 kg / L. In some embodiments, at least one of the base coating layer, the intermediate foam coating, or the outer foam coating comprises a nitrile compound. In some embodiments, the nitrile compound of the at least one of the base coating layer, the intermediate foam coating, or the outer foam coating comprises 45% of a nitrile latex. In some embodiments, the coated fabric is used to form a glove. In some embodiments, the base coating layer, the intermediate foam coating, and the outer foam coating are each applied to at least a palm region of a glove. In some embodiments, the glove is one of a mechanical glove or a chemical glove. In some embodiments, the base coating layer further includes a nylon liner.

[0005] In another example embodiment, a method of manufacturing a coated fabric is provided. The method includes applying a primer coating composition. The primer coating defines a smooth coating to resist liquid penetration into the fabric. The method also includes applying an intermediate foam coating composition over at least a portion of the primer coating. The intermediate foam layer defines an intermediate layer foam density and the intermediate foam layer is configured to absorb at least a portion of the liquid. The method further includes applying an outer foam coating composition over at least a portion of the intermediate foam coating. The outer foam layer defines an outer layer foam density and the outer foam layer is configured to be porous to allow liquid penetration into the intermediate foam layer such that the outer foam layer increases the grip ability and abrasion resistance of the coated fabric. The intermediate layer foam density is less than the outer layer foam density.

[0006] In some embodiments, the method further includes applying a first coagulant to the fabric prior to the step of applying the primer coating. In some embodiments, the method further includes applying the first coagulant to the fabric prior to the step of applying the intermediate foam coating. In some embodiments, the method further includes applying a second coagulant to the fabric prior to the step of applying the outer foam coating. In some embodiments, the method further includes applying a third coagulant to the fabric prior to the step of applying the outer foam coating. In some embodiments, the method further includes heating the coated fabric on a hand model prior to the step of applying the primer coating. In some embodiments, the method further includes heating the coated fabric after the step of applying the outer foam coating. In such embodiments, at least one of the primer coating, the intermediate foam coating, or the outer foam coating is vulcanized in response to the heat. In some embodiments, applying the outer foam coating further includes washing off uncoagulated coating on the surface of the fabric after applying the outer foam coating. In some embodiments, the first coagulant is a calcium nitrate compound, the second coagulant is an acetic acid compound, and the third coagulant is a calcium nitrate compound. In some embodiments, the coated fabric is a glove.

[0007] The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of the application. Thus, it will be appreciated that the above described embodiments are merely examples and should not be construed as limiting the scope or spirit of the application in any way. It will be appreciated that the scope of the application encompasses many potential embodiments, some of which will be further described hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0008] Having generally described certain exemplary embodiments of the present disclosure, reference will now be made to the drawings. Components shown in the drawings can or can not be present in certain embodiments described herein. Some embodiments can include fewer (or more) components than those shown in the drawings.

[0009] Figure 1A and 1B shows a three-layer coated fabric of the present disclosure implemented in an exemplary coated glove;

[0010] Figure 2 is a cross-sectional view of a three-layer coated fabric according to one exemplary embodiment of the present disclosure;

[0011] Figure 3A is a micro cross-sectional view of a three-layer coated fabric according to one exemplary embodiment of the present disclosure;

[0012] Figure 3B is a micro view of an intermediate foam coating according to one exemplary embodiment of the present disclosure;

[0013] Figure 3C is a micro view of an outer foam coating according to one exemplary embodiment of the present disclosure; and

[0014] Figure 4 is a flow chart of a method of manufacturing a three-layer coated fabric according to one exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0015] SUMMARY

[0016] The present invention(s) will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. As used herein, the terms "front," "rear," "top," "bottom," and the like, as provided in the examples below, are used for descriptive purposes only and are not intended to be limiting. Moreover, the terms "substantially" and "about" are used herein to represent the inherent

[0017] The term "comprising" means including, but not limited to, and should be interpreted in the manner it is typically used in the patent context that a complete listing of elements recited are included but not limited to additional unrecited elements. The phrases "in one embodiment," "according to one embodiment," and the like, generally mean that the particular feature, structure, or characteristic following the phrase can be included in at least one embodiment of the present application, and can be included in more than one embodiment of the present application (importantly, such phrases are not necessarily referring to the same embodiment). If the specification is described as "exemplary" or "example," it should be understood that such terminology is used to illustrate examples of the present application and is not intended to limit the scope of the application.

[0018] Grip performance is one of the key features of a useful working glove. In environments with severe exposure to liquids, such as water or oil, conventional gloves can not be able to keep the user's hands dry, which affects the grip ability of the glove. Additionally, conventional gloves with desirable grip properties lack the required abrasion resistance. Accordingly, various embodiments of the present disclosure enable, in some instances, an abrasion resistant fabric that maintains high grip performance by using an intermediate foam coating to absorb liquids, while an outer foam coating provides abrasion resistance in some instances. Various embodiments herein discuss use with respect to gloves, but the coating methods and coated fabrics of the example embodiments can be used in various applications.

[0019] As discussed herein, example embodiments can be described with reference to coating methods that enable, in some instances, optimized grip and abrasion resistance when applied to gloves (e.g., mechanical or chemical gloves) or other wearable items such as other personal protective equipment (e.g., helmets and / or protective footwear). In this regard, fabrics, composites, or other structures described herein as coated fabrics can refer to a tri-coating structure in some instances. For the sake of clarity in description, example embodiments of the present application described herein refer to "three layers" with respect to the number of coatings (e.g., a base coating, an intermediate foam coating, and an outer foam layer), and can not include additional non-coatings such as glove liners. Alternative layers to the "three layers" or additional layers beyond the "three layers" can be used in some embodiments, while fewer layers than the "three layers" can be used in other embodiments.

[0020] With reference to FIG. 1, an example three-layer coated glove 100 is shown that implements and / or is comprised of an example three-layer coating. As shown, the glove 100 can be manufactured or formed with a three-layer coating manufactured according to the example embodiments discussed herein. For example, the glove 100 can have a fabric 105, a base coating 110, a middle foam coating 115, and an outer foam layer 120. As shown, the coatings 110, 115, 120 can be applied to at least a portion of the glove (e.g., all three coatings are applied to the palm where they can be most useful during operation). In a preferred embodiment, the base coating 110 can be defined at least in the palm region of the coated fabric and the inner side of each finger (e.g., in the case where the fabric is in the shape of a glove). For example, the base coating 110 can be coated around each finger at the proximal end portion of the finger and completely around the finger at the distal end of the finger. In various embodiments, the middle foam coating 115 can be deposited on at least a portion of the base coating 110 such that the middle foam coating 115 can be defined at least in the palm region of the coated fabric and the inner side of each finger (e.g., in the case where the fabric is in the shape of a glove). In various embodiments, the outer foam coating 120 can be deposited on at least a portion of the middle foam coating 115 such that the outer foam coating 120 can be defined at least in the palm region of the coated fabric and the inner side of each finger (e.g., in the case where the fabric is in the shape of a glove). In various embodiments, the three-layer coated fabric and method of manufacturing the same can be used for chemical gloves or mechanical gloves. In various embodiments, the material of the fabric 105 can depend on the type of glove. In various embodiments, the fabric 105 can be any material that can be coated with the base coating 110. For example, the fabric 105 can be a glove liner. In various embodiments, the fabric 105 can be a material used for mechanical or chemical gloves. In various embodiments, the fabric 105 can be a material such as nylon, polyester, cotton, high-performance polyethylene (HPPE), aramid, stainless steel, fiberglass, rayon, polypropylene (PP), basalt, spandex, and / or the like.

[0021] In various embodiments, the three-layer coated fabric and methods of making the same can also be used in various applications, not limited to gloves. In various embodiments, the three-layer coating discussed herein can be applied to other PPE. In one exemplary embodiment, the three-layer coating discussed herein can be applied to a helmet. For example, the base coating 110 can be applied to at least a portion of a helmet material, the middle foam coating 115 can be at least partially applied to the base coating 110, and the outer foam coating 120 can be at least partially applied to the middle foam coating 115. In one exemplary embodiment, the three-layer coating discussed herein can be applied to a protective shoe. For example, the base coating 110 can be applied to at least a portion of a protective shoe material, the middle foam coating 115 can be at least partially applied to the base coating 110, and the outer foam coating 120 can be at least partially applied to the middle foam coating 115. In various embodiments, the three-layer coating can be applied to various other applications with similar results to those discussed herein.

[0022] Figure 2 and 3A is a cross-sectional view of a three-layer coating according to one exemplary embodiment. Additionally, Figure 3B is a micro view of the middle foam coating 115 of one exemplary embodiment, and Figure 3C is a micro view of the outer foam coating 120 of one exemplary embodiment. In various embodiments, the base coating 110 can be a smooth nitrile coating. In various embodiments, the base coating 110 can include a composite of at least one of a nitrile latex (e.g., X 6617 and / or XVT-LA), a pH adjuster (e.g., KOH solution), a curing package (e.g., sulfur dispersion, ZDEC dispersion, and / or ZnO dispersion), a pigment / filler (e.g., Ti02and / or black pigment), and / or a thickener (e.g., CMC solution). In various embodiments, the base coating 110 can be about 40% to 60% nitrile latex. In various embodiments, the base coating 110 can be about 40% to 50% nitrile latex. For example, the base coating 110 can be about 45% nitrile latex. In various embodiments, the base coating 110 can be relatively thin (e.g., thinner than the middle foam coating 115). In one exemplary embodiment, the base coating 110 can be about 0.10 millimeters to 0.20 millimeters thick. In various embodiments, the base coating 110 can be thinner and / or thicker in various instances based on wear resistance and / or grip requirements of the coated fabric.

[0023] In various embodiments, the intermediate foam coating 115 can be a microfoam coating. In one exemplary embodiment, the intermediate layer foam density can be about 0.25 kilograms (kg) per liter (L) to about 0.60 kg / L. In some embodiments, the intermediate layer foam density can be about 0.45 kg / L to about 0.60 kg / L. For example, the intermediate layer foam density can be about 0.60 kg / L. In various embodiments, the intermediate foam coating 115 can have about 50 bubbles per square millimeter. In various embodiments, the lower the foam density, the higher the number of bubbles per square millimeter. In one exemplary embodiment, more bubbles in the coating can enable enhanced grip, but can also slightly decrease abrasion resistance. In various embodiments, the intermediate foam coating 115 can include a composite of at least one of a nitrile latex (e.g., Synthomer X 6617), a pH adjuster (e.g., KOH solution), a surfactant (e.g., SDBS and / or a foam stabilizer / BASF A-18), a curing package (e.g., a sulfur dispersion, a ZDEC dispersion, and / or a ZnO dispersion), a pigment / filler (e.g., Ti02and / or black pigment), and / or a thickener (e.g., a CMC solution). In various embodiments, the intermediate foam coating 115 can be about 40% to 60% nitrile latex. In various embodiments, the intermediate foam coating 115 can be about 40% to 50% nitrile latex. For example, the intermediate foam coating 115 can be about 45% nitrile latex. In various embodiments, the thickness of the intermediate foam coating 115 can affect the grip ability of the coated fabric (e.g., in some instances, a higher thickness of the intermediate foam coating 115 and / or other layers can result in better performance, but with decreased abrasion resistance). In one exemplary embodiment, the intermediate foam coating 115 can be about 0.50 millimeters to 0.60 millimeters. In various embodiments, the intermediate foam coating 115 can be thinner and / or thicker in various instances, based on the abrasion resistance and / or grip requirements of the coated fabric.

[0024] In various embodiments, the outer foam coating 120 can be a wash foam coating. In various embodiments, the outer layer foam density can be higher than the intermediate layer foam density. In one exemplary embodiment, the outer coating foam density can be about 0.80 kg / L. In various embodiments, the outer foam coating 120 can have fewer bubbles per square millimeter than the intermediate foam coating 115. For example, in instances where the outer layer foam density is about 0.80 kg / L, the outer foam coating 120 can have about 15 bubbles per square millimeter. As such, in some instances, the outer foam coating 120 can provide increased abrasion resistance to the coated fabric. In various embodiments, the outer layer foam density can be based on the desired abrasion resistance of the coated fabric. For example, in instances where the coated fabric is desired to provide good abrasion resistance for 8000 cycles (e.g., the coated fabric can be capable of performing 8000 cycles under the EN 388 standard), the outer layer foam density can be about 0.8 kg / L. In various embodiments, the coating can be adjusted to provide greater abrasion resistance (e.g., capable of performing 15000 cycles or more under the EN 388 standard). In various embodiments, the level of abrasion resistance can be based on the outer foam density (e.g., a lower foam density can be used for coated fabrics that require lower abrasion resistance). In various embodiments, the thickness of the outer foam coating 120 can affect the abrasion resistance of the coated fabric (e.g., in some instances, a higher thickness of the outer foam coating 120 can result in higher abrasion resistance and decreased hand (grip)). In one exemplary embodiment, the outer foam coating 120 can be about 0.10 millimeters to 0.20 millimeters. In various embodiments, the outer foam coating 120 can be thinner and / or thicker in various instances based on the abrasion resistance and / or grip requirements of the coated fabric.

[0025] In various embodiments, the outer foam coating 120 may comprise a composite material of at least one of nitrile rubber latex (e.g., X 6617 and / or XVT-LA), a pH adjuster (e.g., KOH solution), a surfactant (e.g., SDBS), a curing pack (e.g., sulfur dispersion, ZDEC dispersion, and / or ZnO dispersion), a pigment / filler (e.g., TiO2 and / or black pigment), and / or a thickener (e.g., CMC solution). In various embodiments, the outer foam coating 120 may be about 40% to 60% nitrile rubber latex. In various embodiments, the outer foam coating 120 may be about 40% to 50% nitrile rubber latex. For example, the outer foam coating 120 may be about 45% nitrile rubber latex. In some embodiments, the outer foam coating 120 may have one or more bubbles 200, allowing liquid to permeate the outer foam coating 120 and be absorbed by the intermediate foam coating 115. For example, a washfoam process may enable the formation of a foam coating with larger pore diameters (e.g., as shown in the image). Figure 2 The outer foam coating 120 is a thinner coating (as shown in bubble 200, compared to bubble 205). In this embodiment, the outer foam coating 120 can remain relatively dry during use (e.g., in cases where liquid is introduced into the glove when it is worn by the user).

[0026] Now for reference Figure 4 This document provides methods for manufacturing three-layer warp-coated fabrics according to various embodiments. Unless otherwise explicitly stated, various embodiments of the described methods may be performed in a different order than that described herein. Additional operations may also be performed during the method of manufacturing the three-layer warp-coated fabric, therefore the steps are not exhaustive. In various embodiments, the three-layer warp-coated fabric may be a glove. Temperatures mentioned in some steps discussed herein are merely exemplary and may not be prohibitive.

[0027] Now for reference Figure 4 Box 400, the manufacturing method may include heating a fabric. In some embodiments, the fabric may be heated on a mold. For example, in the case where the fabric is a glove, the glove may be heated on a hand mold. In various embodiments, the fabric may be heated to about 50 degrees Celsius. In various embodiments, different temperatures may be used where the pulse time is adjusted (e.g., lower temperatures may require longer pulse times). For example, in some embodiments, the fabric may be heated to about 30 to 70 degrees Celsius. Now refer to Figure 4At block 410, the method of manufacture can include applying a first coagulant to the fabric. In various embodiments, the first coagulant can be a compound of a cation (e.g., calcium nitrate) and a solvent (e.g., methanol). In one exemplary embodiment, the first coagulant can be about 1% to about 10% calcium nitrate. In some embodiments, the first coagulant can be about 1% to about 5% calcium nitrate. For example, the first coagulant can be about 2% calcium nitrate. In such embodiments, the first coagulant can be about 98% methanol.

[0028] In one exemplary embodiment, the first coagulant can be applied to the fabric by immersing the fabric in the first coagulant. In one exemplary embodiment, the first coagulant can be applied to the fabric for about 60 seconds to 120 seconds. In one exemplary embodiment, the fabric can be immersed in the first coagulant for about 80 seconds. For example, the fabric can be immersed in the first coagulant at a speed of about 3.7 centimeters per second (cm / s) for a dwell time of 2 seconds, a leaching time of 5 seconds, and an evening time of 75 seconds (e.g., two immersion cycles can be used to even the first coagulant). In some embodiments, the first coagulant can be applied to only a portion of the fabric (e.g., only the portion of the fabric where the primer is to be applied). For example, in cases where the fabric is a glove, only the palm of the glove can be immersed in the first coagulant.

[0029] Reference is now made to Figure 4At block 420 of FIG. 4, the manufacturing method can include applying a primer composition to the fabric. As discussed above, the primer composition can be a smooth nitrile (e.g., a butadiene nitrile latex compound). In various embodiments, the primer composition can be applied by immersing the fabric into the primer composition. In various embodiments, the application of the primer composition can take about 3 to about 5 minutes. For example, the fabric can be immersed into the primer composition at a speed of about 3.7 centimeters per second (cm / s), a dwell time of about 2 seconds, and a homogenization time of about 75 seconds (e.g., two immersion cycles can be used to homogenize the primer). In some embodiments, the fabric can be shaken in the primer composition to remove excess butadiene nitrile (e.g., to reduce coating thickness). For example, the fabric can be shaken about 20 times to remove excess butadiene nitrile. In various embodiments, less shaking or no shaking can occur in cases where there is no thickness limitation. In various embodiments, the fabric can be rotated during the immersion process to obtain a uniform coating level. In some embodiments, the primer can be pre-cured after the application of the primer composition is complete. For example, the fabric can be heated at about 70 degrees Celsius for about 15 to 20 minutes prior to the steps of block 430. In one preferred embodiment, the primer 110 can be defined at least on the palm region of the coated fabric and the inner side of each finger (e.g., in cases where the fabric is in the shape of a glove). In some embodiments, the primer can be coated around each finger on the proximal portion of the finger and completely around the finger on the distal portion of the finger.

[0030] Referring now to Figure 4 At block 430 of FIG. 4, the manufacturing method can include applying a first coagulant to the fabric. In various embodiments, the first coagulant can be the same or similar to the coagulant discussed with respect to block 410. In one exemplary embodiment, the first coagulant can be applied to the fabric by immersing the fabric into the first coagulant. In one exemplary embodiment, the first coagulant can be applied to the fabric for about 60 to 120 seconds. In one exemplary embodiment, the fabric can be immersed into the first coagulant for about 70 seconds. For example, the fabric can be immersed into the first coagulant at a speed of about 3.7 centimeters per second (cm / s), a dwell time of 1 second, a drain time of 10 seconds, and a homogenization time of 60 seconds (e.g., two immersion cycles can be used to homogenize the first coagulant). In some embodiments, the first coagulant can be applied only to a portion of the fabric (e.g., only the portion of the fabric where the intermediate foam coating is to be applied). For example, in cases where the fabric is a glove, only the palm of the glove can be immersed into the first coagulant.

[0031] Referring now to Figure 4At block 440 of FIG. 4, the method of manufacture can include applying an intermediate foam coating composition on at least a portion of the intermediate foam coating. As discussed above, the intermediate foam coating composition can be a microfoam nitrile (e.g., a nitrile latex compound). In various embodiments, the intermediate foam coating composition can be applied by immersing the fabric into the intermediate foam coating composition. In various embodiments, the application of the intermediate foam coating composition can take about 45 to 90 seconds (e.g., 60 seconds). For example, the fabric can be immersed into the intermediate foam coating composition at a speed of about 3.7 centimeters per second (cm / s), a dwell time of about 10 seconds, a shake time of about 15 seconds, and a leveling time of about 60 seconds (e.g., two immersion cycles can be used to level the intermediate foam coating). In some embodiments, the fabric can be shaken in the intermediate foam coating composition to remove excess nitrile rubber (e.g., to reduce the thickness of the coating). In various embodiments, the shaking of the fabric can result in an intermediate foam coating that is thinner and more spongy than if the fabric were not shaken during application. In various embodiments, the fabric can be rotated during the immersion process to achieve an even coating level. In various embodiments, the resulting intermediate foam coating can have an intermediate layer foam density of about 0.25 kilograms (kg) per liter (L) to about 0.60 kg / L. In some embodiments, the intermediate layer foam density can be about 0.45 kg / L to about 0.60 kg / L. For example, the intermediate layer foam density can be about 0.60 kg / L. In a preferred embodiment, the intermediate foam coating 115 can be deposited on at least a portion of the base coating. For example, the intermediate foam coating 115 can be defined at least in the palm region and the inner side of each finger of the coated fabric (e.g., in the case where the fabric is in the shape of a glove). In some embodiments, the intermediate foam coating can be coated around each finger at the proximal portion of the finger and completely around the finger at the distal portion of the finger.

[0032] Referring now to FIG. 4, Figure 4 At block 450 of FIG. 4, the method of manufacture can include applying a second coagulant to the fabric. In various embodiments, the second coagulant can be a compound of a cation (e.g., acetic acid) and a solvent (e.g., methanol). In one exemplary embodiment, the second coagulant can be about 1% to about 10% acetic acid. In some embodiments, the second coagulant can be about 1% to about 5% acetic acid. For example, the second coagulant can be about 4% acetic acid. In such embodiments, the second coagulant can be about 96% methanol.

[0033] In an example embodiment, the second coagulant can be applied to the fabric by immersing the fabric in the second coagulant. In an example embodiment, the second coagulant can be applied to the fabric for about 60 seconds to 120 seconds. In an example embodiment, the fabric can be immersed in the second coagulant for about 80 seconds. For example, the fabric can be immersed in the second coagulant at a speed of about 3.7 centimeters per second (cm / s) for a dwell time of about 1 second until the intermediate foam coating 115 can be approximately fully coagulated. In some embodiments, the second coagulant can be applied to only a portion of the fabric (e.g., only the portion of the fabric where the outer foam coating 120 is to be applied). For example, in cases where the coated fabric is a glove, only the palm of the glove can be immersed in the second coagulant. In some embodiments, the fabric can be rotated while being immersed in the second coagulant. In various embodiments herein, other application methods (e.g., spraying) can be used for one or more applications of the coating compositions and / or coagulants discussed herein in addition to immersion.

[0034] Referring now to Figure 4 At block 460 of FIG. 4, the method of manufacturing can include applying a third coagulant to the fabric. In various embodiments, the third coagulant can be a compound of a cation (e.g., calcium nitrate) and a solvent (e.g., methanol). In an example embodiment, the third coagulant can be about 30% to about 50% calcium nitrate. In some embodiments, the third coagulant can be about 40% to about 50% calcium nitrate. For example, the third coagulant can be about 50% calcium nitrate. In such embodiments, the third coagulant can be about 50% methanol.

[0035] In an example embodiment, the third coagulant can be applied to the fabric by immersing the fabric in the third coagulant. In an example embodiment, the third coagulant can be applied to the fabric for about 90 seconds to 150 seconds. In an example embodiment, the fabric can be immersed in the third coagulant for about 120 seconds. For example, the fabric can be immersed in the third coagulant at a speed of about 3.7 centimeters per second (cm / s) for a dwell time of about 5 seconds, a drain time of about 5 seconds, and a leveling time of about 110 seconds. In some embodiments, the third coagulant can be applied to only a portion of the fabric (e.g., only the portion of the fabric where the outer foam coating 120 is to be applied). For example, in cases where the fabric is a glove, only the palm of the glove can be immersed in the third coagulant. In various embodiments, the fabric can be rotated while being immersed in the third coagulant.

[0036] Referring now to Figure 4At block 470, the method can include applying an outer foam coating composition on at least a portion of the intermediate foam coating. As discussed above, the outer foam coating composition can be a wash foam nitrile (e.g., a butadiene nitrile latex compound). In various embodiments, the outer foam coating composition can be applied by dipping the fabric into the outer foam coating composition. In some embodiments, the outer foam coating composition can be applied to the fabric using a dive dipping process. In various embodiments, the fabric can be dipped into the outer foam coating composition for several seconds (e.g., about 2 seconds) until the outer foam coating 120 partially sets, and then removed. For example, the fabric can be dipped into the outer foam coating composition for two seconds, shaken twice, and then removed. As such, in some instances, the method can take significantly less time than the application of the base coating or the intermediate foam coating. In various embodiments, the resulting outer foam coating 120 can have an outer layer foam density of about 0.7 kg / L to about 0.9 kg / L. In various embodiments, the resulting outer foam coating 120 can have an outer layer foam density that is higher than the intermediate layer foam density (e.g., the outer layer foam density can be about 0.80 kg / L). In some embodiments, the outer foam coating composition can be applied only to a portion of the fabric. For example, in instances where the fabric is a glove, only the palm of the glove can be dipped into the outer foam coating composition. In various embodiments, the fabric can be rotated while being dipped into the outer foam coating composition.

[0037] In some embodiments, after the fabric has been dipped into the outer foam coating composition, the fabric can be rinsed (e.g., to remove un-set coating from the surface of the fabric). For example, the fabric (e.g., glove) can be rinsed for about 60 seconds or more using a soft wash (e.g., low pressure and low flow) using a quadrant elevation wash. In a preferred embodiment, the outer foam coating 120 can be deposited on at least a portion of the intermediate foam coating. For example, the outer foam coating 120 can be defined at least in the palm region of the coated fabric and the inner side of each finger (e.g., in instances where the fabric is in the shape of a glove). In some embodiments, the outer foam coating can be coated around each finger at the proximal end portion of the finger and completely around the finger at the distal end of the finger.

[0038] Reference is now made to Figure 4At block 480, the manufacturing method can include heating the fabric in an oven. In various embodiments, one or more of the coatings can be vulcanized during the heating process. For example, the fabric (e.g., glove) can be placed in an oven at a set temperature for a set amount of time to vulcanize the coating. The temperature of the oven and the amount of time in the oven can be based on the coating composition. For example, the coated fabric can be placed in an oven at 100 degrees Celsius for 60 minutes. In one exemplary embodiment, the vulcanization process can use multiple ovens at different temperatures to vulcanize the coating. For example, the coated fabric can be placed in each of the following ovens for 20 minutes: a first oven at about room temperature, a second oven at about 70 degrees Celsius, a third oven at about 90 degrees Celsius, and a fourth oven at about 110 degrees Celsius. Various embodiments can use a different number of ovens (e.g., one oven) to vulcanize the coating. In some embodiments, there can also be a pre-vulcanization before heating in the oven (e.g., the coated fabric can be heated at 70 degrees Celsius). Additionally, the coated fabric can be washed one or more times before vulcanization (e.g., an online wash can be performed at about 50 degrees for about 10 minutes before vulcanization). In various embodiments, the vulcanization can cause a chemical reaction in one or more layers of the coated fabric (e.g., a chemical reaction can occur in one or more of the coatings in which sulfur and / or zinc oxide in one or more of the coatings can crosslink with one or more of the latex materials in the coating).

[0039] Referring now to Figure 4 At block 490, the manufacturing method can include drying the fabric. In various embodiments, after the coating has been vulcanized, the fabric can be removed from the former (e.g., the glove can be removed from the hand former). In some embodiments, an additional offline wash can be performed to remove any excess nitrile rubber. In some embodiments, the drying of the fabric can be performed in an oven (e.g., the same oven used to vulcanize the fabric or a different oven). In various embodiments, the drying of the fabric (e.g., glove) facilitates the formation of the open cell foam on the coating.

[0040] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A coated fabric comprising: a base coat layer, the base coat layer defining a smooth coating to resist liquid penetration into the fabric; an intermediate foam coat layer deposited on at least a portion of the base coat layer, the intermediate foam layer defining an intermediate layer foam density and the intermediate foam layer configured to absorb at least a portion of a liquid; and an outer foam coat layer deposited on at least a portion of the intermediate foam coat layer, the outer foam layer defining an outer layer foam density and the outer foam layer configured to be porous to allow liquid penetration into the intermediate foam layer such that the outer foam layer increases the abrasion resistance of the coated fabric; wherein the intermediate layer foam density is 0.25 kg / L - 0.60 kg / L, and wherein the intermediate layer foam density is less than the outer layer foam density.

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

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

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

5. The coated fabric of claim 4, wherein the nitrile rubber compound of the at least one of the base coat layer, the intermediate foam coat layer, or the outer foam coat layer comprises 45% of a nitrile latex.

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

7. The coated fabric of claim 6, wherein the base coat layer, the intermediate foam coat layer, and the outer foam coat layer are each applied to at least a palm region of the glove.

8. The coated fabric of claim 6, wherein the glove is one of a mechanical glove or a chemical glove.

9. The coated fabric of claim 1, wherein the base coat layer further comprises a nylon liner.

10. A method of manufacturing a coated fabric, the method comprising: applying a base coat layer composition, the base coat layer defining a smooth coating to resist liquid penetration into the fabric; applying an intermediate foam coat layer composition on at least a portion of the base coat layer, the intermediate foam layer defining an intermediate layer foam density and the intermediate foam layer configured to absorb at least a portion of a liquid; and applying an outer foam coat layer composition on at least a portion of the intermediate foam coat layer, the outer foam layer defining an outer layer foam density and the outer foam layer configured to be porous to allow liquid penetration into the intermediate foam layer such that the outer foam layer increases the grip ability and abrasion resistance of the coated fabric; wherein the intermediate layer foam density is 0.25 kg / L - 0.60 kg / L, and wherein the intermediate layer foam density is less than the outer layer foam density.

11. The method of claim 10, further comprising applying a first coagulant to the fabric prior to the step of applying the base coat layer.

12. The method of claim 11, further comprising applying the first coagulant to the fabric prior to the step of applying the intermediate foam coating.

13. The method of claim 12, further comprising applying a second coagulant to the fabric prior to the step of applying the outer foam coating.

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

15. The method of claim 10, further comprising heating the coated fabric on a hand former prior to the step of applying the base coating.

16. The method of claim 10, further comprising heating the coated fabric after the step of applying the outer foam coating, wherein at least one of the base coating, the intermediate foam coating, or the outer foam coating vulcanizes in response to heat.

17. The method of claim 10, wherein the applying the outer foam coating further comprises washing off uncoagulated coating on the surface of the fabric after applying the outer foam coating.

18. The method of claim 14, wherein the first coagulant is a calcium nitrate compound, the second coagulant is an acetic acid compound, and the third coagulant is a calcium nitrate compound.

19. The method of claim 10, wherein the coated fabric is a glove.

20. The coated fabric of claim 1, wherein the coated fabric is used to form a helmet.

21. The coated fabric of claim 1, wherein the coated fabric is used to form a protective shoe.

22. The coated fabric of claim 1, wherein at least one of the base coating, the intermediate foam coating, and the outer foam coating comprises a composite of at least one of a nitrile latex, a pH adjuster, a cure package, a pigment, a filler, a surfactant, and a thickener.

23. The coated fabric of claim 4, wherein the nitrile rubber compound of the at least one of the base coating, the intermediate foam coating, and the outer foam coating comprises 40% to 60% of a nitrile latex.

24. The coated fabric of claim 1, wherein the base coating comprises a smooth nitrile rubber coating.

25. The coated fabric of claim 1, wherein the intermediate foam coating comprises a microfoam coating.

26. The coated fabric of claim 1, wherein the outer foam coating comprises a wash foam coating.

27. The method of claim 10, wherein the coated fabric is used to form a helmet.

28. The method of claim 10, wherein the coated fabric is used to form a protective shoe.

29. The method of claim 10, wherein at least one of the base coating, the intermediate foam coating, and the outer foam coating comprises a composite of at least one of a nitrile latex, a pH adjuster, a cure package, a pigment, a filler, a surfactant, and a thickener.

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