Method for manufacturing upcycled coated gloves using waste fibers, and upcycled coated gloves manufactured thereby

Abstract

The present invention relates to a method for manufacturing upcycled coated gloves using waste fibers and upcycled coated gloves manufactured thereby. The method for manufacturing upcycled coated gloves according to one embodiment comprises: a step for cutting and dismantling fabric waste to manufacture waste staple fibers; a mixing and blowing step for mixing raw materials including the waste staple fibers and reinforcement staple fibers and removing foreign substances; a carding step for manufacturing slivers using the raw materials that have undergone the blowing step; a drawing step for manufacturing a single sliver by combining and stretching the plurality of slivers; a spinning step for manufacturing yarn using the drawn sliver; a step for knitting the yarn to manufacture a glove-shaped knit; and a step for applying a coating solution to at least a portion of the knit and curing same, wherein the coating solution includes one or more of latex, polyurethane, polyvinyl chloride, natural rubber, or synthetic rubber.

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing upcycled coated gloves using waste fibers and upcycled coated gloves manufactured by the method.[Background Art]

[0002] Environmental pollution due to waste generation has become a serious global problem, and recycling is being implemented in many areas. The amount of textile waste, such as discarded clothing from daily life and fabric scraps generated during garment manufacturing processes, is increasing every year, making it urgent to establish measures to deal with this.

[0003] In particular, in large-scale clothing and footwear production sites, the amount of fabric scraps and other textile waste disposed of annually is enormous. Most of the waste is currently incinerated or landfilled. If these materials could be recycled to produce coated work gloves, it could contribute to both reducing waste and decreasing the use of petrochemical-based products used in conventional gloves.

[0004] However, there are still many limitations in recycling fabric scraps and other textile waste, and new technologies to address these challenges are urgently needed. Specifically, waste fiber is an item that must be recycled, but due to the lack of suitable processing methods, most of it is incinerated, landfilled, or disposed of at sea. Incineration of waste fiber is costly and increases greenhouse gas emissions, while landfill and ocean dumping can cause environmental harm due to the generation of leachate containing hazardous substances.

[0005] Therefore, research is underway to develop methods for manufacturing gloves with excellent mechanical properties by recycling discarded clothing and fiber scraps, thereby minimizing the costs associated with waste clothing disposal and preventing environmental pollution.

[0006] The background technology related to the present invention is disclosed in Korean Unexamined Patent Publication No. 2019-0089728 (published on July 31, 2019, title of the invention: System and Method for Recycling Fiber from Waste Fiber).[Disclosure][Technical Problem]

[0007] One object of the present invention is to provide a method for manufacturing upcycled coated gloves that have excellent economic efficiency by using waste fibers and excellent eco-friendliness by preventing environmental pollution.

[0008] Another object of the present invention is to provide a method for manufacturing upcycled coated gloves that exhibit excellent yarn strength and uniformity, while preventing the occurrence of pilling.

[0009] Still another object of the present invention is to provide a method for manufacturing upcycled coated gloves that exhibit excellent conductivity, thereby allowing touchscreen devices to be operated while wearing the gloves, and prevent static electricity, thereby allowing oil and gas to be safely handled.

[0010] Yet another object of the present invention is to provide upcycled coated gloves manufactured by the method for manufacturing upcycled coated gloves described above.[Technical Solution]

[0011] One aspect of the present invention relates to a method for manufacturing upcycled coated gloves using waste fibers. In one embodiment, the method for manufacturing upcycled coated gloves, includes a step of cutting and disintegrating fabric waste to manufacture waste staple fibers; a blowing step of mixing a raw material including the waste staple fibers and reinforcing staple fibers, and removing impurities; a carding step of manufacturing a sliver using the raw material that has undergone the blowing step; a drawing step of combining and stretching a plurality of slivers to manufacture a single sliver; a spinning step of manufacturing yarn using the drawn sliver; a knitting step of knitting the yarn to manufacture a glove-shaped knitted fabric; and a step of applying a coating solution onto at least a part of the knitted fabric, followed by curing, wherein the coating solution includes at least one of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber.

[0012] In one embodiment, the raw material may further include low-melting-point polyester staple fibers, wherein the low-melting-point polyester staple fiber may include a core comprising a polyester fiber having a melting point of 250 °C or higher and a sheath formed on an outer surface of the core and comprising low-melting-point polyester having a melting point of 110 to 200 °C.

[0013] In one embodiment, the yarn may have a fineness of Ne10 / 1 to Ne40 / 1 and a twist count of 300 to 1000 twists per meter (TPM). When the yarn is a two-ply yarn, a fineness may be Ne20 / 2 to Ne40 / 2 and a twist count may be 300 to 800 TPM. The yarn may have a tensile strength of 200 to 1,100 gf, an elongation of 6 to 13%, and a tenacity of 18 to 35 g / tex.

[0014] In one embodiment, the reinforcing staple fiber may include at least one of polyester fibers, cotton fibers, viscose rayon fibers, wool fibers, and acrylic fibers.

[0015] In one embodiment, between the drawing step and the spinning step, the method may further include a roving step of stretching and twisting the sliver.

[0016] In one embodiment, the step of manufacturing the glove-shaped knitted fabric may include knitting the yarn together with a conductive yarn to form a conductive part in at least a portion of the knitted fabric.

[0017] In one embodiment, the coating solution may further include a conductive material.

[0018] Another aspect of the present invention relates to upcycled coated gloves manufactured by the above-described method for manufacturing upcycled coated gloves using waste fibers. In one embodiment, the upcycled coated glove includes a glove part including a knitted fabric; and a coated part formed on at least a portion of the surface of the glove part, wherein the coated part includes at least one of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber, and the knitted fabric is manufactured by knitting yarn including waste staple fibers and reinforcing staple fibers.

[0019] In one embodiment, the yarn may further include low-melting-point polyester staple fibers.

[0020] In one embodiment, the glove part may further include a conductive part formed by knitting the yarn together with a conductive yarn in at least a portion of the glove part.

[0021] In one embodiment, the coated part may further include a conductive material.

[0022] In one embodiment, the yarn may have a fineness of Ne10 / 1 to Ne40 / 1 and a twist count of 300 to 1000 twists per meter (TPM). When the yarn is a two-ply yarn, a fineness may be Ne20 / 2 to Ne40 / 2 and a twist count may be 300 to 800 TPM. The yarn may have a tensile strength of 200 to 1,100 gf, an elongation of 6 to 13%, and a tenacity of 18 to 35 g / tex.[Advantageous Effects]

[0023] The upcycled coated glove according to the present invention is manufactured using discarded waste fibers, thereby minimizing waste clothing disposal costs and offering excellent economic efficiency and eco-friendliness by preventing environmental pollution. In addition, the glove exhibits superior conductivity, thereby allowing touchscreen devices to be operated while wearing it, prevents static electricity, thereby allowing oil and gas to be safely handled, and provides outstanding strength and uniformity, minimized pilling, ease of knitting or weaving, and excellent sensory properties such as a soft touch.[Description of Drawings]

[0024] FIG. 1 illustrates a method for manufacturing upcycled coated gloves using waste fibers according to one embodiment of the present invention. FIG. 2 shows one side of an upcycled coated glove using waste fibers according to one embodiment of the present invention. FIG. 3 shows the other side of an upcycled coated glove using waste fibers according to one embodiment of the present invention. [Best Mode]

[0025] In describing the present invention, detailed descriptions of related known technologies or configurations may be omitted if it is determined that such descriptions would unnecessarily obscure the gist of the present invention.

[0026] Furthermore, the terms described below are defined in consideration of the functions of the present invention, and these definitions may vary depending on the intentions or practices of users or operators. Therefore, the definitions should be interpreted based on the overall content of this specification describing the present invention.

[0027] The present invention has been developed in response to the above-described needs, and aims to provide a method for manufacturing coated gloves using recycled yarn (or spun yarn), which is manufactured by processing waste fabrics including discarded clothing through processes, such as cutting, shredding, and disintegrating to manufacture fiber for spinning, followed by processes such as blending, carding, drawing (sliver production), roving, and spinning (yarn production).Method for manufacturing upcycled coated gloves using waste fibers

[0028] One aspect of the present invention relates to a method for manufacturing upcycled coated gloves using waste fibers. FIG. 1 illustrates a method for manufacturing upcycled coated gloves using waste fibers according to one embodiment of the present invention. Referring to FIG. 1, the method for manufacturing upcycled coated gloves using waste fibers includes (S10) a step of manufacturing waste staple fibers; (S20) a blowing step; (S30) a carding step; (S40) a drawing step; (S50) a spinning step; (S60) a knitting step; and (S70) a step of manufacturing a coated glove.

[0029] More specifically, the method for manufacturing upcycled coated gloves using waste fibers, includes: (S10) a step of cutting and disintegrating fabric waste to manufacture waste staple fibers; (S20) a blowing step of mixing a raw material including the waste staple fibers and reinforcing staple fibers, and removing impurities; (S30) a carding step of manufacturing a sliver using the raw material that has undergone the blowing step; (S40) a drawing step of combining and stretching a plurality of slivers to manufacture a single sliver; (S50) a spinning step of manufacturing yarn using the drawn sliver; (S60) a knitting step of knitting the yarn to manufacture a glove-shaped knitted fabric; and (S70) a step of applying a coating solution onto at least a part of the knitted fabric, followed by curing, wherein the coating solution includes at least one of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber.

[0030] Hereinafter, the method for manufacturing upcycled coated gloves according to the present invention will be described in detail step by step.(S10) Manufacturing step for waste staple fibers

[0031] This step is for cutting and disintegrating fabric waste to manufacture waste staple fibers.

[0032] The fabric waste may be of any conventional type. For example, the fabric waste may include one or more types of post-industrial recycled (PIR) materials, such as waste scraps generated during garment and footwear manufacturing processes such as sewing, and post-consumer recycled (PCR) materials, such as discarded clothing after consumer use, but is not limited thereto.

[0033] For example, the fabric waste may include one or more of cotton fibers, thermoplastic elastomer fibers, thermoplastic polyurethane fibers, polyester fibers, nylon fibers, and viscose rayon fibers. When such types of fabric waste are included, it is possible to easily manufacture recycled yarn.

[0034] The fabric waste may be introduced into a cutting machine and cut to a predetermined size. For example, depending on the material, structure, and processing state of the fabric waste, it may be cut one or more times. For example, the fabric waste may be cut to a size of 7 cm or less in both width and length. This length may represent the maximum length of the fabric waste.

[0035] The cut fabric waste may be shredded and loosened using a tearing (opening) machine. This tearing process facilitates the subsequent disintegrating process, making it easier to manufacture waste staple fibers.

[0036] The torn fabric waste is then passed through a disintegrating machine equipped with 2 to 8 drums densely mounted with multiple needles, where it is disintegrated (disintegrating process) to achieve an optimal fiber length and condition, thereby manufacturing waste staple fibers.

[0037] In one embodiment, the waste staple fibers may have a length of 10 to 70 mm. Under these length conditions, the yarn of the present invention may be easily manufactured. For example, the fiber length may be 15 to 50 mm.(S20) Blowing step

[0038] This step is for mixing a raw material including the waste staple fibers and reinforcing staple fibers, and removing impurities. The blowing step may include blending, in which the raw materials are mixed in bulk, opening, in which the mixed fiber bundles are unraveled and evenly mixed, and cleaning, in which impurities present in the fibers are primarily removed.

[0039] For example, the raw material may include 10 to 40 wt% of waste staple fibers and 60 to 90 wt% of reinforcing staple fibers.

[0040] In one embodiment, the reinforcing staple fibers may have a length of 10 to 70 mm. Under these length conditions, the yarn may be easily manufactured. For example, the length may be 15 to 50 mm.

[0041] The reinforcing staple fibers may be included to ensure desirable physical properties and sensory properties, such as texture, in the yarn. In one embodiment, the reinforcing staple fiber may include at least one of polyester fibers, cotton fibers, viscose rayon fibers, wool fibers, and acrylic fibers.

[0042] In one embodiment, the polyester fibers may include at least one of recycled polyester fibers and virgin polyester fibers.

[0043] When the reinforcing staple fibers are included, the mechanical properties or sensory properties such as texture of the yarn may not be reduced, while providing excellent cost reduction effects through yarn recycling.

[0044] The recycled polyester fiber may be of any conventional type. For example, the recycled polyester fiber may be manufactured by melting waste polyester materials such as polyester fibers, polyester films, and bottles to obtain a molten substance; filtering out other inorganic substances, impurities, and degraded components to obtain a filtrate; extruding the filtrate to produce recycled polyester pellets; melting and kneading a mixture including the recycled polyester pellets and virgin polyester pellets to prepare a kneaded material; and spinning the kneaded material to manufacture fibers, which are then converted into staple fibers.

[0045] In one embodiment, the waste staple fibers may be included in an amount of 10 to 40 wt% based on the total weight of the raw material. When the waste staple fibers are included within this range, the reduction in manufacturing costs and economic efficiency may be excellent, glove fabric manufacturing is facilitated, and the mechanical properties of the coated glove may be superior. For example, the content may be 15 to 30 wt%. For example, the waste staple fibers may be included in an amount of 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 wt%, based on the total weight of the raw material.

[0046] In one embodiment, the reinforcing staple fibers may be included in an amount of 60 to 90 wt% based on the total weight of the raw material. When the reinforcing staple fibers are included within this range, glove fabric manufacturing is facilitated, and the mechanical properties of the coated glove may be superior. For example, the content may be 65 to 80 wt%. In another example, the content may be 70 to 85 wt%. For example, the reinforcing staple fibers may be included in an amount of 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, or 90 wt%, based on the total weight of the raw material.

[0047] In one embodiment, the raw material may further include low-melting-point polyester staple fibers. When the low-melting-point polyester staple fibers are included, pilling may be prevented and the mechanical properties of the coated glove may be improved.

[0048] In one embodiment, the low-melting-point polyester staple fiber may have a length of 10 to 70 mm. Under these length conditions, the yarn may be easily manufactured. For example, the length may be 15 to 50 mm.

[0049] The low-melting-point polyester staple fiber may be included for the purpose of being fused with the waste staple fibers and reinforcing staple fibers, thereby improving the mechanical properties and uniformity of the yarn and preventing the occurrence of pilling.

[0050] The low-melting-point polyester staple fiber may be manufactured by conjugate spinning of conventional polyester and modified low-melting-point polyester. The low-melting-point polyester staple fiber may be fused with the waste staple fibers and reinforcing staple fibers to form yarn using the low-melting polyester component's thermal bonding properties.

[0051] In particular, since the low-melting-point polyester staple fiber may be melted and bonded at relatively low temperatures, it is environmentally friendly due to reduced energy consumption and carbon dioxide emissions, and it may have excellent form stability after combining with other raw material components. For example, at a certain temperature, the sheath (outer layer) melts and has adhesiveness (while maintaining its shape), and after bonding with other raw material components and forming yarn, both the core and sheath may retain their respective shapes.

[0052] In one embodiment, the low-melting-point polyester staple fiber may include a core including a polyester fiber having a melting point of 250 °C or higher, and a sheath formed on the outer surface of the core and including a low-melting-point polyester having a melting point of 110 to 200 °C. For example, the core may include polyester fiber having a melting point of 250 to 320 °C or 250 to 270 °C.

[0053] When a sheath including low-melting-point polyester with a melting point of 110 to 200 °C is included, the raw material exhibits excellent adhesiveness, thereby facilitating yarn production, improving yarn uniformity, and preventing the occurrence of pilling.

[0054] In one embodiment, the low-melting-point polyester staple fiber may be manufactured using a composition including at least one of terephthalic acid, isophthalic acid, and adipic acid, as well as diol compounds. The diol compounds may include at least one of ethylene glycol and 1,4-butanediol.

[0055] For example, the composition may be spun using a spinneret, the spun composition may be cooled to produce a cooled material, and the cooled material may be drawn and heat-treated to manufacture the fiber.

[0056] In one embodiment, the low-melting-point polyester staple fiber may be included in an amount of 5 to 15 wt% based on the total weight of the raw material. When the low-melting-point polyester staple fiber is included within this range, the raw material may exhibit excellent adhesiveness, which facilitates yarn production, prevents an excessive increase in yarn hardness, improves the ease of knitting or weaving, and provides a superior texture. In addition, it may enhance yarn uniformity, prevent the occurrence of pilling, and ensure excellent stiffness and durability of the yarn. For example, the content may be 5 to 10 wt%. For example, the low-melting-point polyester staple fiber may be included in an amount of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 wt%, based on the total weight of the raw material.

[0057] In one embodiment, the raw material (or yarn) may include 10 to 35 wt% of waste staple fibers, 60 to 85 wt% of reinforcing staple fibers, and 5 to 15 wt% of low-melting-point polyester staple fibers.(S30) Carding step

[0058] This step is for manufacturing a sliver using the raw material that has undergone the blowing step. In the carding step, a sliver may be manufactured after the raw material from the blowing step is combed, aligned, and subjected to secondary impurity removal.

[0059] For example, the raw material may be introduced into a carding machine to remove residual fiber naps and other impurities from the waste staple fibers, comb and align the fibers in a parallel direction, and then manufacture a sliver using the material.

[0060] In one embodiment, a combing step may be further performed after the carding step. The combing step may involve combing the fibers with a finer comb that used in the carding step.(S40) Drawing step

[0061] This step is for combining and stretching a plurality of slivers to manufacture a single sliver.

[0062] In one embodiment, the manufactured sliver, typically five to eight strands, may be combined and stretched through a drawing process to form a single drawn sliver. For example, the drawing process may be performed one or more times so that the thin and thick portions of each sliver offset each other, thereby equalizing the overall thickness and adjusting the uniformity to manufacture a drawn sliver.

[0063] In one embodiment, after the drawing step (S40) and before the spinning step, a roving step may be further included, in which the sliver is stretched and given a twist. The roving step involves stretching and twisting the sliver to manufacture a roving, which is an intermediate state between a sliver and yarn.(S50) Spinning step

[0064] This step is for manufacturing yarn using the drawn sliver (or roving). For example, in this step, yarn may be manufactured from the drawn sliver (or roving) using spinning equipment.

[0065] In one embodiment, the yarn manufactured by the spinning equipment may further undergo a winding process in which it is wound into a cheese-shaped package.

[0066] In one embodiment, the yarn may be manufactured by one or more of the following methods: ring spinning, air jet spinning (or MVS spinning), and open-end spinning (OE).

[0067] In the ring spinning process, for example, yarn may be manufactured from a raw material including waste staple fibers by sequentially undergoing the blowing and mixing, carding, combing, drawing, roving, spinning, and winding steps.

[0068] In another specific example, in the MVS spinning or OE spinning process, yarn may be manufactured from a raw material including waste staple fibers by sequentially undergoing the blowing and mixing, carding, combing, drawing, and spinning steps. In the MVS spinning or OE spinning process, the yarn may be wound directly into a cheese-shaped package as it is manufactured from the sliver.

[0069] When the yarn is dyed first (pre-dyeing), thermal bonding may occur during the dyeing process, but for environmental considerations, the coated glove of the present invention may be manufactured without dyeing.

[0070] The low-melting-point polyester staple fibers undergo thermal bonding with other raw materials during the glove coating process described below, which may suppress pilling that may occur during glove use, thereby extending the service life of the glove and contributing to the reduction of secondary waste.

[0071] The yarn may have a fineness (count) of Ne10 / 1 to Ne40 / 1. Under this fineness condition, the yarn may have excellent durability, outstanding texture, and versatility for manufacturing various types of glove fabrics.

[0072] In one embodiment, the yarn may have a twist count of 300 to 1000 twists per meter (TPM). Under this twist count condition, the coated glove may have a soft touch and exhibit excellent strength and mechanical properties.

[0073] In another specific example, when the yarn is a two-ply yarn, it may have a fineness of Ne20 / 2 to Ne40 / 2 and a twist count of 300 to 800 TPM. Under these fineness and twist count conditions, the coated glove may have a soft touch and exhibit excellent strength and mechanical properties.

[0074] In one embodiment, the yarn may have a tensile strength of 200 to 1,100 gf, an elongation of 6 to 13%, and a tenacity of 18 to 35 g / tex. Under these conditions, the coated glove may have a soft touch and exhibit excellent strength and mechanical properties.

[0075] In one embodiment, the tensile strength, elongation, and tenacity of the yarn may be measured using a testing instrument. For example, these properties may be measured using a tester manufactured by USTER.(S60) Knitting step

[0076] This step is for knitting the yarn to manufacture a glove-shaped knitted fabric. The glove-shaped knitted fabric may be manufactured by knitting the yarn using a conventional glove knitting machine. For example, the glove knitting machine may manufacture knitted fabrics under gauge 7, 10, 13, 15, or 18 conditions. The gauge refers to the number of knitting needles per inch.

[0077] In the knitting step (S60), a covering yarn may additionally be included when manufacturing the glove-shaped knitted fabric. For example, the yarn and the covering yarn may be knitted together to manufacture a double-layered glove fabric.

[0078] The stretchability of the glove may be further enhanced by including the covering yarn. In one embodiment, the covering yarn may include at least one of spandex yarn, polyester yarn, and nylon yarn. When the covering yarn is included, the glove may exhibit excellent stretchability and mechanical properties. For example, the nylon yarn may include nylon draw textured yarn (DTY).

[0079] The covering yarn may have a fineness of 40 to 200 denier. For example, the covering yarn may use spandex / nylon draw textured yarn under conditions such as 20d / 40d, 30d / 40d, 40d / 40d, or 40d / 70d (denier).

[0080] In another specific example, the glove fabric may be manufactured as a single layer by directly covering the upcycled yarn with spandex. The spandex may have a fineness of 40 to 140 denier.

[0081] In one embodiment, the step of manufacturing the glove-shaped knitted fabric may include knitting the yarn together with a conductive yarn to form a conductive part in at least a portion of the knitted fabric. When the conductive part is formed in this manner, it is possible to operate touchscreen devices while wearing the coated glove and an anti-static effect is provided, so that safe handling of oil and gas is possible.

[0082] In one embodiment, the conductive yarn may include at least one of a copper-covered yarn and a carbon-based yarn. For example, the copper-covered yarn may be a nylon-based yarn whose surface is coated with copper (Cu).(S70) Step of manufacturing coated gloves

[0083] This step is for applying a coating solution onto at least a portion of the knitted fabric, followed by curing to manufacture coated gloves. For example, the coated glove may be manufactured by either applying the coating solution to at least a portion of the knitted fabric or immersing the knitted fabric in the coating solution, followed by curing to form a coated part.

[0084] In one embodiment, the coating solution includes at least one of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber. In one embodiment, the synthetic rubber may include at least one of acrylonitrile-butadiene rubber (ABR), nitrile-butadiene rubber (NBR), Buna-N rubber, and chloroprene. When the coating solution is included, the coated part may be easily formed, and the coated part may exhibit excellent slip resistance and mechanical properties.

[0085] In one embodiment, the coating component may be included in an amount of 5 to 60 wt% based on the total weight of the coating solution. Within this range, miscibility and dispersibility may be excellent, and the coated glove may have excellent slip resistance and mechanical properties. For example, the content may be 5 to 50 wt%, 5 to 40 wt%, 5 to 30 wt%, or 5 to 25 wt%.

[0086] In one embodiment, the coating solution may include at least one coating component of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber, as well as a solvent. In one embodiment, the coating solution may further include a conductive material.

[0087] In one embodiment, the coating solution may include 5 to 60 wt% of a coating component, 1 to 30 wt% of a conductive material, and 5 to 70 wt% of a solvent, based on the total weight of the coating solution. Within these ranges, the coating solution may exhibit excellent miscibility and dispersibility, provide superior mechanical properties in the coated part, and easily ensure conductivity.

[0088] In one embodiment, the coating solution may further include a conductive material. In one embodiment, the conductive material may include at least one of conductive carbon, graphite, and acetylene black. The conductivity of the coated glove may be easily achieved by including the conductive material.

[0089] In one embodiment, the conductive material may be included in an amount of 1 to 30 wt% based on the total weight of the coating solution. Within this range, miscibility and dispersibility may be excellent, and conductivity may be effectively imparted. For example, the content may be 2 to 25 wt%, 5 to 20 wt%, or 5 to 10 wt%.

[0090] In another embodiment, the coating solution may further include at least one additive of a crosslinking agent, a dispersant, an emulsifying stabilizer, and a thickener. The additive may be included in an amount of 0.1 to 20 wt% based on the total weight of the coating solution. For example, the content may be 0.1 to 15 wt%, 0.1 to 10 wt%, or 0.5 to 5 wt%.

[0091] In another specific example, the step of manufacturing coated gloves may further include a step of applying a conductive coating solution to at least a portion of the coated part, which is formed by applying the coating solution on at least a portion of the knitted fabric and curing the same, to form a conductive coating layer.

[0092] The conductive coating solution may include at least one conductive material of conductive carbon, graphite, and acetylene black, as well as a solvent. For example, the conductive coating solution may include 1 to 50 wt% of a conductive material and 50 to 99 wt% of a solvent. Within these ranges, the coating solution may exhibit excellent miscibility and dispersibility, provide superior mechanical properties in the conductive coating layer, and easily ensure conductivity.

[0093] In one embodiment, the coating solution may have a viscosity of 10 to 1000 cPs at 25 °C. Under these conditions, the workability may be excellent.

[0094] In one embodiment, a coated glove may be manufactured by forming the coated part, followed by processes such as washing (scouring) and drying (curing). For example, the coated glove may include a coated work glove.

[0095] The curing (drying) process may be performed at 50 to 200 °C but is not limited thereto. For example, it may be performed at 100 to 150 °C.

[0096] During the coated glove manufacturing process, when the yarn includes a low-melting-point polyester staple fiber component, thermal bonding of the low-melting-point polyester component may occur. In the coating process, the glove knit mounted on a mold is dipped into a bath containing a coating solution such as PU, NBR, and latex, and then passed through scouring (washing) and drying equipment in a continuous process. Under standard conditions, typically around 120 °C for 60 minutes, thermal bonding of the low-melting-point polyester component may occur. When nitrile butadiene rubber (NBR) is used, curing does not occur at temperatures of 100 °C or below, so the temperature must be at least 100 °C. However, temperatures above 150 °C should be avoided, particularly when the glove lining is made of nylon or similar materials, as discoloration or changes in physical properties may result. Although drying the coating agent alone takes only about 20 minutes, an additional scouring (washing) process is required after coating, and since the glove must be fully dried after this step, the total drying time may be around one hour.Upcycled coated gloves manufactured by method for manufacturing upcycled coated gloves using waste fibers

[0097] Another aspect of the present invention relates to upcycled coated gloves manufactured by a method for manufacturing upcycled coated gloves using waste fibers.

[0098] FIG. 2 shows one side of an upcycled coated glove using waste fibers according to one embodiment of the present invention, and FIG. 3 shows the coated opposite side of the upcycled glove. Referring to FIGS. 2 and 3, the upcycled glove 100 includes a glove part 10 comprising a knitted fabric; and a coated part 20 formed on at least a portion of the surface of the glove part 10.

[0099] For example, the coated part 20 may be formed on the finger and palm areas of the glove part 10.

[0100] The coated part includes at least one of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber.

[0101] In one embodiment, the synthetic rubber may include at least one of acrylonitrile-butadiene rubber (ABR), nitrile-butadiene rubber (NBR), Buna-N rubber, and chloroprene.

[0102] When the coated part is formed, the glove may exhibit excellent slip resistance and mechanical properties. For example, the glove may include a work glove.

[0103] In one embodiment, the coated part may further include a conductive material. In one embodiment, the conductive material may include at least one of conductive carbon, graphite, and acetylene black. When the conductive material is included, the coated glove may exhibit excellent conductivity.

[0104] The coated part may include 50 to 99 wt% of at least one coating component of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber, and 1 to 50 wt% of a conductive material. Under these conditions, the coated glove may exhibit excellent conductivity, slip resistance and mechanical properties.

[0105] In one embodiment, a conductive coating layer may be further formed on at least a portion of the surface of the coated part. The conductive coating layer may be applied to areas such as the fingertips and palm region of the coated part.

[0106] The conductive coating layer may include at least one conductive material of conductive carbon, graphite, and acetylene black. Under these conditions, conductivity may be easily achieved.

[0107] The knitted fabric is manufactured by knitting yarn (or raw material) including waste staple fibers and reinforcing staple fibers. For example, the yarn may include 10 to 40 wt% of waste staple fibers and 60 to 90 wt% of reinforcing staple fibers. The waste staple fibers and reinforcing staple fibers may be of the same types as described above.

[0108] In one embodiment, the waste staple fibers may be included in an amount of 10 to 40 wt% based on the total weight of the yarn. When the waste staple fibers are included within this range, the reduction in manufacturing costs and economic efficiency may be excellent, glove fabric manufacturing may be facilitated, and the mechanical properties of the coated glove may be superior. For example, the content may be 15 to 30 wt%. For example, the waste staple fibers may be included in an amount of 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 wt%, based on the total weight of the yarn.

[0109] In one embodiment, the reinforcing staple fibers may be included in an amount of 60 to 90 wt% based on the total weight of the yarn. Within this range, glove fabric manufacturing may be facilitated, and the coated glove may exhibit superior mechanical properties. For example, the content may be 65 to 80 wt%. In another example, the content may be 70 to 85 wt%. For example, the reinforcing staple fibers may be included in an amount of 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, or 90 wt%, based on the total weight of the yarn.

[0110] In one embodiment, the raw material may further include low-melting-point polyester staple fibers. When the low-melting-point polyester staple fibers are included, pilling may be prevented and the mechanical properties of the coated glove may be improved.

[0111] In one embodiment, the low-melting-point polyester staple fiber may have a length of 10 to 70 mm. Under this length condition, the yarn may be easily manufactured. For example, the length may be 15 to 50 mm.

[0112] The low-melting-point polyester staple fiber may be included for the purpose of being fused with the waste staple fibers and reinforcing staple fibers, thereby improving the mechanical properties and uniformity of the yarn and preventing the occurrence of pilling.

[0113] In one embodiment, the low-melting-point polyester staple fiber may include a core comprising a polyester fiber having a melting point of 250 °C or higher, and a sheath formed on the outer surface of the core and comprising a low-melting-point polyester having a melting point of 110 to 200 °C. For example, the core may include polyester fibers having a melting point of 250 to 320 °C or 250 to 270 °C.

[0114] When a sheath including a low-melting-point polyester with a melting point of 110 to 200 °C is applied, the raw material exhibits excellent adhesiveness, thereby facilitating yarn production, improving uniformity, and minimizing pilling.

[0115] In one embodiment, the yarn may be formed so that at least a portion of the low-melting-point polyester staple fibers (or the core of the low-melting-point polyester staple fibers) is fused with the waste staple fibers and reinforcing staple fibers.

[0116] In one embodiment, the low-melting-point polyester staple fiber may be included in an amount of 5 to 15 wt% based on the total weight of the yarn. When the low-melting-point polyester staple fiber is included within this range, the raw material may exhibit excellent adhesiveness, which facilitates yarn production, prevents an excessive increase in yarn hardness, improves the ease of knitting or weaving, and provides a superior texture. In addition, it may enhance yarn uniformity, prevent the occurrence of pilling, and ensure excellent stiffness and durability of the yarn. For example, the content may be 5 to 10 wt%. For example, the low-melting-point polyester staple fiber may be included in an amount of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 wt%, based on the total weight of the yarn.

[0117] In one embodiment, the yarn may include 10 to 35 wt% of waste staple fibers, 60 to 85 wt% of reinforcing staple fibers, and 5 to 15 wt% of low-melting-point polyester staple fibers.

[0118] In one embodiment, the glove part may further include a conductive part formed by knitting the yarn together with a conductive yarn in at least a portion of the glove part. When the conductive part is formed in this manner, it is possible to operate touchscreen devices while wearing the coated glove and an anti-static effect is provided, so that safe handling of oil and gas is possible. For example, the conductive part may be applied to areas such as the fingertips and palm region of the glove part.

[0119] In one embodiment, the conductive yarn may include at least one of a copper-covered yarn and a carbon-based yarn. For example, the conductive yarn may include a copper-covered yarn in which the surface of a nylon-based yarn is coated with copper (Cu). For example, the nylon-based yarn may be coated by immersing it in a copper-containing solution.

[0120] The yarn may have a fineness (count) of Ne10 / 1 to Ne40 / 1. Under this fineness condition, the yarn may have excellent durability and may be used to manufacture knitted fabrics with a superior texture.

[0121] In one embodiment, the yarn may have a twist count of 300 to 1000 twists per meter (TPM). Under this twist count condition, the glove may have a soft touch and minimize the occurrence of pilling.

[0122] In another specific example, when the yarn is a two-ply yarn, it may have a fineness of Ne20 / 2 to Ne40 / 2 and a twist count of 300 to 800 TPM. Under these fineness and twist conditions, the coated glove may have a soft touch and exhibit excellent strength and mechanical properties.

[0123] In one embodiment, the yarn may have a tensile strength of 200 to 1,100 gf, an elongation of 6 to 13%, and a tenacity of 18 to 35 g / tex. Under these conditions, the glove may have a soft touch and exhibit excellent strength and mechanical properties.

[0124] In one embodiment, the tensile strength, elongation, and tenacity of the yarn may be measured using a testing instrument. For example, these properties may be measured using a tester manufactured by USTER.

[0125] In one embodiment, the glove part may further include a double-layered knitted fabric by including a covering yarn.

[0126] For example, the glove part may include a double-layered knitted fabric having one side formed by knitting the yarn and the other side formed by knitting the covering yarn.

[0127] When the covering yarn is included, the stretchability of the glove may be further enhanced. In one embodiment, the covering yarn may include at least one of spandex yarn and nylon yarn. When the covering yarn is included, the glove may exhibit excellent stretchability and mechanical properties. For example, the nylon yarn may include nylon draw textured yarn (DTY).

[0128] The covering yarn may have a fineness of 20 to 120 denier. For example, the covering yarn may use spandex / nylon draw textured yarn under conditions such as 20d / 40d, 30d / 40d, 40d / 40d, or 40d / 70d (denier).

[0129] In another specific example, the glove fabric may be manufactured as a single layer by directly covering the upcycled yarn with spandex. The spandex may have a fineness of 40 to 70 denier.[Modes of the Invention]

[0130] Hereinafter, the configuration and operation of the present invention will be described in detail through preferred examples. However, these are provided only as exemplary examples of the present invention and should not be construed as limiting the present invention in any way. Matters not described herein may be sufficiently inferred by those skilled in the art, and thus detailed descriptions thereof will be omitted.Examples and Comparative Examples Example 1

[0131] (1) Upcycled yarn preparation: The fabric waste was introduced into a cutting machine and cut three times. The cut pieces were then put into a tearing (opening) machine, where the cut fabric waste was torn (shredded and loosened). The torn fabric waste was subsequently processed in a disintegrating machine and passed multiple times through two to eight drums, each densely mounted with multiple needles, to disintegrate the fabric waste and manufacture waste staple fibers with a length of 15 to 50 mm.

[0132] Subsequently, reinforcing staple fibers (cotton fibers) with a length of 15 to 50 mm and low-melting-point polyester staple fibers with a length of 15 to 50 mm (including a core comprising polyester fibers with a melting point of 265 °C and a sheath formed on the outer surface of the core and comprising low-melting-point polyester staple fibers with a melting point of 110 to 200 °C) were prepared. After blending raw materials including 15 wt% of the waste staple fibers, 80 wt% of reinforcing staple fibers, and 5 wt% of low-melting-point polyester staple fibers together into a mass, the blended mass was unraveled and thoroughly mixed (opened), and primary removal of impurities (cleaning) from the raw fibers was performed during the blowing process.

[0133] The raw material processed through the blowing was combed (carded, aligned, and subjected to secondary impurity removal) to manufacture a sliver. Next, the slivers were introduced into a drawing machine, where five to eight strands were combined and drawn into a single sliver, allowing the thick and thin parts of each sliver to offset each other. This process equalized the thickness and adjusted the uniformity, resulting in a drawn sliver.

[0134] Afterward, the drawn sliver was introduced into a spinning machine, where it was spun and twisted to manufacture yarn (spun yarn). The resulting yarn from the spinning machine was then wound into a cheese-shaped package.

[0135] (2) Manufacture of upcycled coated work gloves: The prepared yarn was introduced into a glove knitting machine to manufacture a glove-shaped knitted fabric. Next, a coating solution (including nitrile-butadiene rubber and a solvent) was applied onto the finger and palm areas of the knitted fabric (by dipping), and the glove was washed and cured (dried) using a conventional method to manufacture upcycled coated work gloves. During the drying process, thermal bonding of the low-melting-point polyester staple fibers within the yarn occurred.Example 2

[0136] The upcycled coated glove was manufactured in the same manner as in Example 1, except that upcycled yarn manufactured using recycled polyester fiber as the reinforcing staple fiber was used.Example 3

[0137] An upcycled coated glove was manufactured in the same manner as in Example 1, except that the yarn manufactured in Example 1 and a covering yarn (spandex / nylon draw textured yarn (DTY) 20d / 40d) were introduced into the glove knitting machine. The upcycled coated glove of Example 3 includes a glove part formed as a double-layered knitted fabric, in which one side is knitted from the yarn and the other side is knitted from the covering yarn, and a coated part formed on the fingers and palm areas of the glove part.Example 4

[0138] An upcycled coated glove was manufactured in the same manner as in Example 1, except that, in the process of manufacturing the glove-shaped knitted fabric by introducing the yarn manufactured in Example 1 into the glove knitting machine, a conductive part was formed by knitting the finger area of the knitted fabric with the yarn and a conductive yarn (nylon-based yarn coated with copper (Cu)).Example 5

[0139] An upcycled coated glove was manufactured in the same manner as in Example 1, except that a coating solution (including nitrile-butadiene rubber, a conductive material (conductive carbon black), and a solvent) was applied onto the finger and palm areas of the knitted fabric of Example 1 (by dipping).Experimental Example

[0140] The physical properties of the yarns used in the upcycled coated gloves of the representative Examples 1 and 2 were evaluated as described below, and the results are shown in Table 1. (1) Tensile strength (gf), elongation (%), and tenacity (g / tex): The tensile strength, elongation, and tenacity of the yarns of Examples 1 and 2 were measured individually using a USTER measurement instrument (USTER TESTER). (2) Twist count (TPM) and fineness (Ne): The twist count and fineness of the yarns of Examples 1 and 2 were measured using standard methods. (3) Appearance: The occurrence of pilling in the yarns was observed and evaluated (⊚: Almost no pilling, o: Slight pilling, △: Considerable pilling, X: Very severe pilling). [Table 1] ClassificationExamples12Tensile strength (gf)300-1000500-1100Elongation (%)6-136-13Tenacity (g / tex)18-3518-35Twist count (TPM)500-1000500-1000Fineness (Ne)20 / 1-40 / 120 / 1-40 / 1Appearance○○

[0141] Based on the results in Table 1, it can be seen that Examples 1 and 2 demonstrated excellent economic efficiency through the use of recycled waste fibers. In addition, the yarns exhibited superior mechanical strength including tensile strength, elongation, and tenacity, as well as excellent uniformity and significantly less pilling compared to conventional spun yarns.

[0142] Additionally, it can be seen that Examples 1 and 2, by manufacturing upcycled coated work gloves with discarded waste fibers, minimized waste clothing disposal costs, resulting in excellent economic efficiency and eco-friendliness by preventing environmental pollution, and the gloves also demonstrated excellent strength and uniformity, minimized the occurrence of pilling, and had excellent sensory properties with a soft touch.

[0143] The present invention has been described so far with reference to examples. Those skilled in the art will understand that the prevent invention can be implemented in modified forms without departing from the essential characteristics of the invention. Therefore, the disclosed examples should be considered from a descriptive perspective rather than a limiting perspective. The scope of the present invention is defined by the patent claims rather than the foregoing description, and all variations within the equivalent scope thereof should be construed as being included in the present invention.

Claims

1. A method for manufacturing upcycled coated gloves using waste fibers, comprising: a step of cutting and disintegrating fabric waste to manufacture waste staple fibers; a blowing step of mixing a raw material including the waste staple fibers and reinforcing staple fibers, and removing impurities; a carding step of manufacturing a sliver using the raw material that has undergone the blowing step; a drawing step of combining and stretching a plurality of slivers to manufacture a single sliver; a spinning step of manufacturing yarn using the drawn sliver; a knitting step of knitting the yarn to manufacture a glove-shaped knitted fabric; and a step of applying a coating solution onto at least a part of the knitted fabric, followed by curing, wherein the coating solution includes one or more of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber.

2. The method of claim 1, wherein the raw material further includes low-melting-point polyester staple fibers, and the low-melting-point polyester staple fiber includes a core comprising a polyester fiber having a melting point of 250 °C or higher and a sheath formed on an outer surface of the core and comprising low-melting-point polyester having a melting point of 110 to 200 °C.

3. The method of claim 1, wherein the yarn has a fineness of Ne10 / 1 to Ne40 / 1 and a twist count of 300 to 1000 twists per meter (TPM), when the yarn is a two-ply yarn, a fineness is Ne20 / 2 to Ne40 / 2 and a twist count is 300 to 800 TPM, and the yarn has a tensile strength of 200 to 1,100 gf, an elongation of 6 to 13%, and a tenacity of 18 to 35 g / tex.

4. The method of claim 1, wherein the reinforcing staple fiber includes one or more of polyester fibers, cotton fibers, viscose rayon fibers, wool fibers, and acrylic fibers.

5. The method of claim 1, further comprising a roving step of stretching and twisting the sliver between the drawing step and the spinning step.

6. The method of claim 1, wherein the step of manufacturing the glove-shaped knitted fabric includes knitting the yarn together with a conductive yarn to form a conductive part in at least a portion of the knitted fabric.

7. The method of claim 1, wherein the coating solution further includes a conductive material.

8. An upcycled coated glove using waste fibers, comprising: a glove part including a knitted fabric; and a coated part formed on at least a portion of the surface of the glove part, wherein the coated part includes one or more of latex, polyurethane, polyvinyl chloride, natural rubber, and synthetic rubber, and the knitted fabric is manufactured by knitting yarn including waste staple fibers and reinforcing staple fibers.

9. The upcycled coated glove of claim 8, wherein the yarn further includes low-melting-point polyester staple fibers.

10. The upcycled coated glove of claim 8, wherein the glove part further includes a conductive part formed by knitting the yarn together with a conductive yarn in at least a portion of the glove part.

11. The upcycled coated glove of claim 8, wherein the coated part further includes a conductive material.

12. The upcycled coated glove of claim 8, wherein the yarn has a fineness of Ne10 / 1 to Ne40 / 1 and a twist count of 300 to 1000 twists per meter (TPM), when the yarn is a two-ply yarn, a fineness is Ne20 / 2 to Ne40 / 2 and a twist count is 300 to 800 TPM, and the yarn has a tensile strength of 200 to 1,100 gf, an elongation of 6 to 13%, and a tenacity of 18 to 35 g / tex.

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