Yarns and textiles for personal protective equipment

Abstract

A protective textile used for manufacturing personal protective equipment includes at least three yarns. A first composite yarn includes a tungsten core, a sheath made of a polyester filaments covering the tungsten core, and an outer layer comprising a plurality of para-aramid filaments wrapped around the sheath. A second composite yarn has a spandex core with polyester wound around it. A third yarn is made of fire-resistant spun acrylic. All three yarns are combined into a single feed to manufacture the protective textile, which can be formed into a glove or a sleeve. A fourth yarn made of a rubber core wrapped in a double covering of polyester may be used in the cuffs of the glove / sleeve for additional elasticity. A fifth yarn having a spandex core covered with fire-resistant spun acrylic fiber may be used in the palm of the sleeve for additional coverage and elasticity.

Description

BACKGROUND

[0001] Industrial workers require personal protective equipment (PPE) to keep them safe from the dangers of their work environment. When it comes to providing cut resistant PPE in a flame-resistant material, the market has not provided many solutions that are designed for achieving both dexterity and comfort. Historically, cut resistant gloves and sleeves have been produced from the use of spun yarns using poly acrylic and aramid fibers which create PPE products that are thick and uncomfortable, with low dexterity. Due to this lack of comfort and dexterity, it is common for workers to want to take off their personal protective equipment as soon as the work is complete, and sometimes even before the job is finished. This creates a safety hazard, as statistics historically show that most injuries are caused through careless behavior such as removing the PPE during the work process. Considering this issue, the industry is in an endless pursuit to provide the most comfortable, high dexterity PPE, while ensuring that such PPE remains highly protective.SUMMARY OF THE INVENTION

[0002] The present invention involves a protective textile for use in making an article of personal protective equipment. In an example, the protective textile may include a first composite yarn, the first composite yarn may further include a tungsten core filament; a sheath layer having a plurality of polyester filaments covering the tungsten core filament; and a first outer layer having a plurality of para-aramid filaments wrapped around the sheath layer. In an example the protective textile may further include a second composite yarn, the second composite yarn may include a core comprising spandex; and a second outer layer comprising filament polyester that is wound around the core. The protective textile may include a third yarn, the third yarn comprising spun fire-resistant acrylic. In an embodiment, the tungsten core filament of the first composite yarn may be 0.02 um in diameter. The plurality of polyester filaments covering the tungsten core filament may be about 30 Denier. The plurality of para-aramid filaments may be about 200 Denier.

[0003] The protective textile of the present invention may be formed in the shape of a glove. The protective textile of the present invention may be formed in the shape of a sleeve.

[0004] In one embodiment, the first composite yarn, the second composite yarn, and the third yarn each have a thickness that enables them to be fed into any of a 13-gauge knitting machine, 15-gauge knitting machine, 18-gauge knitting machine, or 21-gauge knitting machine.

[0005] In an embodiment, the protective textile may further include a fourth yarn. The fourth yarn may include a rubber core; a first layer; and a second layer, and each of the first layer and the second layer may include polyester surrounding the rubber core. In an example, the protective textile may further include a fifth yarn. The fifth yarn may include a spandex core and a third outer layer comprising fire-resistant spun acrylic surrounding the spandex core.

[0006] In another embodiment, the present invention comprises a method for producing a protective textile for use in manufacturing an article of personal protective equipment. The method may include: manufacturing a first composite yarn having a tungsten core filament; a sheath layer comprising a plurality of polyester filaments covering the tungsten core filament; and a first outer layer comprising a plurality of para-aramid filaments wrapped around the sheath layer. The method may further include manufacturing a second composite yarn comprising: a core made from spandex; and a second outer layer comprising polyester that is spun around the core. The method may include manufacturing a third yarn comprising fire-resistant spun acrylic. The method may include knitting the first composite yarn, the second composite yarn, and the third yarn into a single feed to manufacture the protective textile.

[0007] In an example embodiment, the method may further include forming the protective textile in the shape of a glove. The method may further include manufacturing a fourth yarn comprising a rubber core; and a first layer and a second layer, wherein each of the first layer and the second layer comprise polyester surrounding the rubber core. In the example, the step of forming the protective textile in the shape of the glove further includes knitting the first composite yarn, the second composite yarn, the third yarn, and the fourth yarn into a cuff of the glove.

[0008] In an example embodiment, the method may further include forming the protective textile in the shape of a sleeve. The method may further include manufacturing a fifth yarn comprising: a spandex core and a third outer layer comprising fire-resistant spun acrylic surrounding the spandex core. In the example, the step of forming the protective textile in the shape of the sleeve further includes knitting the first composite yarn, the second composite yarn, the third yarn, and the fourth yarn into a cuff of the sleeve; and knitting the first composite yarn, the second composite yarn, the third yarn and the fifth yarn into a palm of the sleeve.

[0009] In an example embodiment, the tungsten core filament of the first composite yarn is 0.02 um in diameter. In an example, the plurality of polyester filaments of the first composite yarn is about 30 Denier. In an example, the plurality of para-aramid filaments of the first composite yarn is about 200 Denier. In an example, the rubber core and each of the first layer and the second layer of polyester of the fourth yarn are about 100 Denier.

[0010] In an example embodiment, the knitting the first composite yarn, the second composite yarn, and the third yarn into a single feed to manufacture the protective textile further comprises feeding the first composite yarn, the second composite yarn, and the third yarn into a single feed of any of: a 13-gauge knitting machine; a 15-gauge knitting machine; an 18-gauge knitting machine; or a 21-gauge knitting machine.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1A is an elevated view of an example first yarn which may be incorporated into a textile for use in personal protective equipment.

[0012] FIG. 1B is an elevated partial front detail view of the example first yarn illustrated in FIG. 1A, showing a partial construction of the example first yarn.

[0013] FIG. 2 is a front perspective view of an example second yarn which may be incorporated into a textile for use in personal protective equipment.

[0014] FIG. 3 is a front perspective view of an example third yarn which may be incorporated into a textile for use in personal protective equipment.

[0015] FIG. 4A is an elevated view of an example fourth yarn which may be incorporated into a textile for use in personal protective equipment in a first configuration.

[0016] FIG. 4B is an elevated view of an example fourth yarn which may be incorporated into a textile for use in personal protective equipment in a second configuration.

[0017] FIG. 5 is a front perspective view of an example fifth yarn which may be incorporated into a textile for use in personal protective equipment.

[0018] FIG. 6 is an illustration of an example knitting assembly diagram for manufacturing a textile for use in personal protective equipment according to an example implementation of the invention.

[0019] FIG. 7 is an illustration of an example method for preparing a covered yarn.DETAILED DESCRIPTION OF THE INVENTION

[0020] Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the claims. Furthermore, in the detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.

[0021] Generally speaking, various embodiments provide for a textile for use in PPE and a method to produce PPE textiles that are thinner, lighter, and more comfortable while maintaining high levels of cut and flame resistance, towards increasing worker safety by reducing the likelihood of PPE removal during work. The PPE textile with a composite yarn comprising a tungsten core and para-aramid filament is advantageous over the products currently in the flame resistant and cut resistant market. Instead of using an older spun yarn technology (which may feel scratchier than heavy cotton), the current embodiment features flame resistant and cut resistant products produced from aramid yarns that are produced from a process called filament spinning to create aramid filament yarns.

[0022] Filament extruding technology has enabled the creation of new products which offer higher safety compliance and lower reportable accidents. This is due to the products developed and described in this patent application as being thinner and lighter in weight. Therefore, in order to impart higher cut resistance properties to flame resistant products while decreasing material thickness, the invention uses aramid filament yarns in a specific construction.

[0023] The materials as described in this specification utilizing filament yarn are thinner than conventional PPE textiles in the market today, but they still achieve ANSI Level A6 cut resistance, Level 4 flame resistance, and Level 2 Heat contact. This yarn and textile comprising the yarn achieves added dexterity and comfort as well as cut resistance, flame resistance, and heat contact properties which in turn may decrease the need, want, or desire for workers to remove PPE before work is completed. This may translate into greater worker safety across the workforce which is required to use cut and flame-resistant PPE.

[0024] FIG. 1A of the drawings discloses a first yarn 10 (“Yarn One 10”) to be used in manufacturing a textile or fabric for use in PPE. Yarn One 10 features a core 12 around which is spun or wrapped a covering layer 14. Core 12 may be made of 40 Denier spandex, which provides elasticity and flexibility. Surrounding spandex core 12 is outer covering 14, which may comprise polyester, specifically 75 Denier polyester. As one example, outer covering 14 may comprise thirty-six filament strands of said 75 Denier filament polyester. This construction may ensure that Yarn One 10 maintains stretchability while offering flame resistance, making it suitable for applications requiring both flexibility and safety.

[0025] FIG. 1B of the drawings discloses a partial detail view of Yarn One 10, illustrating an example partial construction of Yarn One 10. Illustrated in FIG. 1B, core 12 of Yarn One 10, comprising 40 Denier spandex, may include one filament or strand of 40 Denier spandex in one example, and in another example core 12 may include multiple strands of 40 Denier spandex aligned in a substantially parallel or linear orientation. Covering 14 of Yarn One 10 may include, for example, one filament or strand of 75 Denier polyester. In another example, covering 14 may include multiple strands or filaments of 75 Denier polyester.

[0026] Using existing machinery, covering 14 including 75 Denier polyester may be spun or wound around core 12 according to a specified pitch 16. Pitch 16 of covering 14 may be measured in turns-per-inch, or winding angle at which covering 14 turns around core 12 with respect to the longitudinal axis of core 12. In an example, covering 14 may be wound around core 12 at a pitch of twelve turns per inch. In an example, pitch 16 of covering 14 may be increased or decreased, which may consequently increase or decrease an amount of covering 14 that is applied to core 12. It will be known that increasing or decreasing pitch 16 increases or decreases an amount of covering 14 that may be applied to core 12, and consequently may affect the cut and / or flame-retardant properties of Yarn One 10. It will also be hereafter known that coverings for any subsequent yarn in this application, the pitch of winding or spinning for any covering of any yarn may be adjusted to increase or decrease an amount of covering applied to a core yarn material, which may, in turn, affect the cut and / or flame-retardant properties of a yarn.

[0027] FIG. 2 of the drawings discloses a second yarn 20 (“Yarn Two 20”) to be used in manufacturing a textile or fabric for use in PPE. In one preferred embodiment of the invention, Yarn Two 20 may be composed entirely of fire-resistant acrylic fibers 22 spun into a single material yarn. In that preferred embodiment, acrylic fibers 22 of Yarn Two 20 may be spun to English Cotton Count (Ne) 32. In another example embodiment, acrylic fibers 22 may be spun into a different English Cotton Count (Ne) to achieve different strength and flame-resistant ratings, density, and covering provided by Yarn Two 20. For example, acrylic fibers 22 may be spun to a smaller size of English Cotton Count (Ne) 100, all the way up to a larger size of English Cotton Count (Ne) 8. When the English Cotton Count (Ne) is lower, acrylic fibers 22 are larger, leading to greater flame resistance. The construction of Yarn Two 20 may provide inherent flame resistance and durability, making it ideal for protective textiles.

[0028] FIG. 3 of the drawings discloses a third yarn 30 (“Yarn Three 30”) to be used in manufacturing a textile or fabric for use in PPE. Yarn Three 30, in one example preferred embodiment, is constructed with a core 32 of tungsten metal. In that example preferred embodiment, core 32 may be constructed from a 0.02 um filament of tungsten metal, tungsten being known for its high cut resistance. In an example, core 32 may be constructed from a different diameter tungsten filament selected from a range between 0.015 um to 0.04 um. It will be understood that changing the diameter of the tungsten filament may affect the cut resistance, fire resistance, and other performance measures of the yarn, while also affecting the thickness of the resulting yarn.

[0029] In an example, tungsten core 32 may be wrapped with an intermediate layer or sheath 34 of filament polyester. In one example preferred embodiment, sheath 34 may be constructed from 30 Denier polyester and may include many strands or filaments of 30 Denier polyester. In that example preferred embodiment, filament polyester sheath 34 may be wound or spun around core 32, and filaments of sheath 34 may be substantially parallel or longitudinally aligned with core 32. The polyester filaments of sheath 24 may provide additional cut and flame resistance. In an example, filament polyester sheath 34 may be wound or spun around core 32 at 800 turns per inch in the “S” direction of twist. In an example, the pitch of sheath 34 may be increased or decreased, which may consequently increase or decrease an amount of sheath 34 that is applied to core 32.

[0030] Yarn Three 30 may also include an outer-layer or covering 36. In one example preferred embodiment, covering 36 may include 200 Denier para-aramid filament. For example, covering 36 may include 133 strands or filaments of 200 Denier para-aramid filament. The para-aramid filament of covering 36 may provide additional cut and flame resistance. The multi-layered construction of Yarn 3, comprising a tungsten core 32, an intermediate layer sheath 34, and an outermost layer 36, serves to provide a higher degree of protection while maintaining a manageable thickness of Yarn Three 30. In an example, covering 36 including 200 Denier para-aramid filament may be twisted or turned at 200 turns per inch in a “Z” direction of twist. In an example, the pitch of covering 36 may be increased or decreased, which may consequently increase or decrease an amount of covering 36 that is applied to core 32 over sheath 34.

[0031] FIGS. 4A-4B of the drawings discloses a fourth yarn 40 (“Yarn Four 40”) to be used in manufacturing a textile or fabric for use in PPE. As illustrated in FIG. 4A, in one example preferred embodiment, Yarn Four 40 may include a core 42 made of 100 Denier rubber, which may provide elasticity to Yarn Four 40. In an example, such as the one illustrated in FIG. 4A, core 42 may include a single strand or ribbon of 100 Denier rubber. In the example, core 42 may have an elliptical shape. In an example, core 42 may have a ribbon or rectangular shape. In an example, the size of core 42, and thus of the rubber, may be increased or decreased, which may in turn affect the elasticity or stretchability of the resulting Yarn Four 40. Core 42 may include one strand or filament of 100 Denier rubber in an example. FIG. 4B illustrates Yarn Four 40 in a second example configuration. In that example, core 42 of Yarn Four 40 may include a single end of 100 Denier rubber. It will be known by those skilled in the art that altering the mass or thickness of rubber present in core 42 may affect the total thickness of Yarn Four 40 and may affect other properties of Yarn Four 40 such as cut and flame resistance, as well as elasticity of a resulting textile or fabric constructed from Yarn Four 40.

[0032] As illustrated in FIGS. 4A-4B, rubber core 42 may be wrapped with a first covering 44 and subsequently with a second covering 46. In one example, first covering 44 and second covering 46 may both include 100 Denier polyester. In an example, the two layers of polyester may provide enhanced flame resistance. In an example, a pitch 44P of first covering 44 may be in a direction that is opposite or the inverse of a pitch 46P of second covering 46. In the example, the dual-layer construction may provide added flexibility to Yarn Four 40.

[0033] FIG. 5 of the drawings discloses a fifth yarn 50 (“Yarn Five 50”) to be used in manufacturing a textile or fabric for use in PPE. As illustrated in FIG. 5, in an example, Yarn Five 50 includes a core 52, which may be constructed of 40 Denier spandex, which may provide stretch and flexibility. In an example, such as the example illustrated in FIG. 5, core 52 may include multiple strands or filaments of 40 Denier spandex. In an example preferred embodiment, core 52 may only include a single strand or filament of spandex. In that example, core 52 is wrapped with a covering 54. In the example illustrated in FIG. 5, covering 54 is constructed from spun acrylic fiber, specifically spun acrylic fiber having an English Cotton Count (Ne) of 32. Covering 54 is constructed from acrylic fiber, and thus offers additional durability and flame resistance, which may make this yarn suitable for applications requiring both elasticity and fire as well as cut protection.

[0034] FIG. 6 illustrates a system in which yarn packages or bobbins 604 each contain different yarns 602, such that feeds 606A-D each contain a yarn 602 of different composition, and courses 608A-D contain stitches comprised of yarns 602 having different compositions, such that the textile or fabric produced has a varying composition and exhibits varying properties according to the properties of each different yarn 602 composition. In the example, a textile or fabric may exhibit all of the properties or qualities of each different yarn 602A-D stitched together in the textile or fabric.

[0035] FIG. 7 illustrates an example schematic of a knitting assembly 60. In the example, Yarn One 10, as described above, is wound on yarn package, or bobbin 610. Likewise, yarn package, or bobbin, 620 contains Yarn Two 20, as described above, and yarn package or bobbin 630 contains Yarn Three 30, as described above Accordingly, yarn packages or bobbins 610, 620, 630 store Yarn One 10, Yarn Two 20 and Yarn Three 30, respectively, until they are transferred into, for example, feed 602 which supply yarn into course 604. Each course 604 represents a series of stiches, where each stitch contains the same continuous strand of combined yarns composed of Yarn One 10, Yarn Two 20 and Yarn Three 30, as fed, for example, from feed 602.

[0036] With this configuration, each course 604 of fabric or textile material produced by the knitting assembly contains each yarn 10, 20, 30, and exhibits the properties of each yarn 10, 20, and 30. In the example, the knitting assembly 60 can be set to use Yarn One 10, Yarn Two 20, and Yarn Three 30 in every course or feed for the main body of a glove, ensuring a balance of elasticity, flame resistance, and cut resistance.

[0037] The innovative approach of the example embodiments described herein lies in the unique composition of Yarn 3 and in the combinations of Yarns 1, 2, 3, 4, and 5 to produce advanced textiles for personal protective equipment (PPE). Each of these yarns, with their distinct properties, is strategically placed in bobbins on textile knitting machines. The knitting machines are programmed to control the feeds, allowing for precise combinations of the different yarns based on the specific requirements of the PPE being produced. In an example, for areas requiring additional elasticity, such as the cuff of the glove, Yarn Four 40 may be introduced. Similarly, in an example, for the palm of a sleeve, Yarn Five 50 may be added to provide increased coverage, protection, and flexibility.

[0038] All the yarns used in this example assembly 70 may have a thickness that enables them to be knitted on certain types of knitting machines. The thickness of the yarns may allow yarns 10, 20, 30 to be combined seamlessly into a single course during the knitting process. In an example, knitting machinery used to create textiles may only accommodate yarns of a certain thickness. Knitting machines may only accept yarn of a maximum thickness where yarns exceeding that thickness cannot be fed through the openings of the knitting machine. Knitting machines may likewise only accept yarns not falling below a minimum thickness where the machine cannot feed, pick up, or otherwise handle yarns not meeting the minimum thickness.

[0039] Each yarn may have a thickness that is sufficiently sized in diameter to enable the yarn to be fed into an 18-gauge knitting machine both alone and when combined with the other yarns as disclosed. Each yarn may separately be capable of being fed into an 18-gauge flatbed knitting machine, tubular knitting machine, or other configuration knitting machine, as a result of the thickness of each yarn being such that an 18-gauge knitting machine may be able to feed, pick, up, and otherwise handle each different yarn material of the present invention. Likewise, when Yarns One 10, Two 20, Three 30, Four 40, and Five 50 are combined in any combination with one another, the combined thickness is such that an 18-gauge knitting machine may be able to feed, pick, up, and otherwise handle each different combination of yarn material of the present invention. In an example, the thickness of each yarn and any combination of Yarns One 10, Two 20, Three 30, Four 40, and Five 50 is such that the yarn or combination may be capable of being fed into a range of knitting machines. In the example, the thickness of each yarn may be an appropriate thickness to feed into any of a 13-gauge, 15-gauge, 18-gauge, or 21-gauge knitting machine. In an example, the thickness of each yarn may not only facilitate the integration of multiple yarns but also enhance the dexterity of the final textile. This may result in PPE garments that are not only highly protective but also comfortable and easy to wear, thereby reducing the likelihood of workers removing their PPE during tasks and increasing overall safety.

[0040] FIG. 7 illustrates an example method 700 for producing a covered yard. In the example, a first step may include, at block 702, providing a core for the yarn and unspooling the core from a first spool. In an example, a 0.02 um diameter tungsten core is provided for the core of the yarn.

[0041] Method 700 may further include, at block 704, unspooling a first covering yarn. In an example, a first covering yarn may be filament polyester. In an example, the first covering yarn may be a yarn other than filament polyester.

[0042] Method 700 may further include, at block 706 feeding the yarn through a first covering process. In an example, the tungsten core may be unspooled from a first spool and fed, through machinery, to a first covering station. At the first covering station, a winding machine may unspool a covering from a separate spool. In an example, filament polyester material may be unspooled from a separate spool, and then polyester sheath material may be wound or spun around the core at 800 turns per inch in the “S” direction of twist. In an example, filament polyester may be wound or spun around the core at a turns per inch of other than 800, and it will be known that varying the turns per inch may vary the surface covering, and thus other physical properties of the covered yarn, such as thickness, weight, cut resistance, fire resistance, and other properties.

[0043] Method 700 may further include, at block 708, unspooling a second covering yarn. In an example, a second covering yarn may be para-aramid filament. In an example, the first covering yarn may be a yarn other than aramid filament.

[0044] Method 700 may further include, at block 710, feeding the covered core through a second covering process. In an example, the filament polyester-covered tungsten core may further be fed from the first covering step at block 706 to a second covering step, block 710. In the example, the additional covering may be twisted or turned at 200 turns per inch in a “Z” direction of twist. In an example, para-aramid filament may be wound or spun at a turns per inch of other than 200, and it will be known that varying the turns per inch may vary the surface covering, and thus other physical properties of the covered yarn, such as thickness, weight, cut resistance, fire resistance, and other properties.Glove

[0045] The glove, designed as a personal protective equipment (PPE) garment, utilizes a strategic combination of Yarns 10, 20, 30, and 40 to achieve optimal protection, comfort, and functionality. The construction process involves the following steps:Main Body

[0046] In an example, yarns 10, 20, and 30 are integrated, using knitting equipment, into every course and feed throughout the main body of the glove. This combination ensures a balanced blend of properties. Yarn 10 provides elasticity and flexibility due to its spandex core, while the polyester outer covering offers flame resistance. Yarn Two 20 is composed of fire-resistant acrylic, which adds inherent flame resistance and durability to the glove. Yarn Three 30 features a tungsten core for high cut resistance, an intermediate layer of filament polyester for additional protection, and an outer layer of aramid filament for enhanced cut and flame resistance. By combining these multiple layers of Yarn Three 30, and by integrating these three yarns in every course, the glove achieves greater cut and flame resistance while maintaining flexibility and comfort.

[0047] For the cuff of the glove, Yarn Four 40 is introduced to increase elasticity and ensure a secure fit around the wrist. Yarn Four 40 consists of a rubber core wrapped with two layers of polyester, providing both flexibility and flame resistance. The addition of Yarn Four 40 in the cuff area enhances the glove's ability to conform to the wrist, preventing it from slipping off during use and ensuring that the glove remains securely in place.Overall Construction

[0048] The integration of these yarns, which when combined have a gauge thickness ranging from 13-gauge to 21-gauge, allows for a seamless textile. In one example, each yarn may have a thickness that enables them to be knitted on an 18-gauge knitting machine. In an example, each yarn may have a different thickness, enabling them to be knitted on knitting machines ranging between 13-gauge and 21-gauge. In another example some yarns may have a thickness that enables them to be knitted on knitting machines that are smaller than 21-gauge. The fine gauge contributes to the glove's dexterity, making it comfortable to wear for extended periods. The combination of high cut resistance, flame resistance, and flexibility ensures that the glove provides comprehensive protection without compromising on comfort or usability.TABLE 1Comparison Between Prior Art versus New Yarn ThreeCut Resistant, Flame Technology Used in a GloveMetricNEW Aramid Filament GloveExisting Spun Yarn Glove-Machine TypeGlove Knitting MachineGlove Knitting MachineMachine GG18gg13ggYarn DetailsPara-aramid filament: 200 DAcrylic / Para-Aramid SpunFR acrylic fiber: Ne32Yarn BlendTungsten: 0.02 umPolyester: 75 DSpandex: 20 DWeight* (gsm)357367Thickness* (mm).048.098Cut Resistance LevelA6A5(ASTM F2992-16)Flame Resistance LevelLevel 4N / A(EN 407:2020)Contact HeatLevel 2Level 5(ANSI F1060)*tested at back of hand for glove.

[0049] In an example, the yarn composition used in the construction of the glove may have a thickness of 0.048 mm and may weigh 357 grams per square meter. In the example, the yarn composition used in the glove may be less thick than conventional yarn compositions, which may traditionally have a thickness of 0.098 mm or greater. In the example, the yarn composition may be lighter than conventional yarn composition, which may traditionally weigh 367 grams per square meter or greater.

[0050] In summary, the glove's construction leverages the unique properties of yarns 10, 20, 30, and 40 to create a PPE garment that is both highly protective and comfortable, thereby reducing the likelihood of workers removing their PPE during tasks and increasing overall safety.Sleeve

[0051] The sleeve, designed as a personal protective equipment (PPE) garment, may employ a combination of yarns 10, 20, 30, 40, and 50 to deliver superior protection, comfort, and functionality. The construction process is as follows:Main Body

[0052] Yarns 10, 20, and 30 are utilized in every course and feed throughout the main body of the sleeve. This combination ensures a comprehensive blend of essential properties:

[0053] Yarn One 10 provides elasticity and flexibility due to its spandex core, while the filament polyester outer covering offers flame resistance. Yarn Two 20, composed of fire-resistant acrylic, this yarn adds inherent flame resistance and durability to the sleeve. Yarn Three 30 features a tungsten core for high cut resistance, an intermediate layer of filament polyester for additional protection, and an outer layer of para-aramid filament for enhanced cut and flame resistance. By combining these multiple layers of Yarn Three 30, and by integrating these three yarns in every course and feed, the sleeve achieves a high level of cut and flame resistance while maintaining flexibility and comfort. Additionally, it can be noted that one additional end of Yarn Two 20 can be added to each stitch to provide added Heat Contact performance without significantly increasing the thickness of the sleeve material.Cuff

[0054] For the cuff of the sleeve, Yarn Four 40 is introduced to enhance elasticity and ensure a secure fit around the arm. Yarn Four 4 consists of a rubber core wrapped with two layers of polyester, providing both flexibility and flame resistance. The inclusion of Yarn Four 40 in the cuff area improves the sleeve's ability to conform to the arm, preventing it from slipping off during use and ensuring that the sleeve remains securely in place.Palm

[0055] For the palm area of the sleeve, Yarn Five 50 is added to provide increased coverage, protection, and elasticity. Yarn Five 50 features a spandex core wrapped with fire-resistant spun acrylic, offering additional durability and flame resistance. This combination ensures that the palm area is both flexible and highly protective, catering to the specific needs of tasks that require enhanced dexterity and safety.Overall Construction

[0056] The integration of these yarns, which when combined have a gauge thickness ranging from 13-gauge to 21-gauge, allows for a seamless textile. In one example, each yarn may have a thickness that enables them to be knitted on an 18-gauge knitting machine. In an example, each yarn may have a different thickness, enabling them to be knitted on knitting machines ranging between 13-gauge and 21-gauge. In an example some yarns may have a thickness that enables them to be knitted on knitting machines that are smaller than 21-gauge. The fine gauge contributes to the sleeve's dexterity, making it comfortable to wear for extended periods. The combination of high cut resistance, flame resistance, and flexibility ensures that the sleeve provides comprehensive protection without compromising on comfort or usability.TABLE 2Comparison Between Older versus Newer CutResistant, Flame Resistant TechnologyMetricNew Aramid FilamentExisting Spun YarnExisting Spun YarnSleeveSleeveSleeveMachine TypeGlove KnittingTubular KnittingTubular KnittingMachineMachineMachineMachine GG18ggNANAYarn DetailsPara-aramid filament:Para-AramidYN14 / 1CRTX13:200 DSpun yarn14s 100% Para AramidFR acrylic fiber: Ne32Yarn (yellow color), ZTungsten: 0.02 umTwist, Twist TPMPolyester: 75 D440 + / − 10%,Spandex: 20 DStandardFZ / T 12023.2011+YNPARRC14S 380Denier.+Cotton 16'S KNITTUBING, 100%COTTON, NATURALWeight* (gsm)304524566Thickness* (mm)1.1082.9023.000Cut ResistanceA6A4A3Level(ASTM F2992-16)Flame ResistanceLevel 4N / AN / ALevel(EN 407:2020)Contact HeatLevel 1*Level 1Level 1(ANSI F1060)*It is anticipated thatadding more weight ofFR Acrylic yarn, suchas Ne20 or two-plyNe32s, will increasethe conductive heatresistance to Level 2.This will increase thethickness of the sleeve,but not enough tomatch the thickness ofexisting options in themarket.*Tested on main body of sleeve.

[0057] In an example, and specifically when compared to the first example “existing spun yarn sleeve” shown in Column 3 of Table 2 above, the yarn composition used in the construction of that sleeve may have a thickness of 1.108 mm and may weigh 304 grams per square meter. In the example, the yarn composition of the present invention and used in the sleeve may be less thick than conventional yarn compositions, which may traditionally have a thickness of 2.902 mm or greater, and which may traditionally weigh 524 grams per square meter or greater. In another example, when compared to the second example “existing spun yarn sleeve” shown in Column 4 of Table 2 above, the yarn composition of the present invention may be lighter than conventional yarn compositions, which may traditionally have a thickness of 3.000 mm or greater, and which may traditionally weigh 566 grams per square meter or greater. It may be noted that a thicker or larger-sized fire-resistant acrylic-based Yarn Two 20 may be added to each stitch of this construction, which will increase the thickness and weight to enable a higher heat contact rating as necessary.

[0058] In summary, the sleeve's construction leverages the unique properties of yarns 1, 2, 3, 4, and 5 to create a PPE garment that is both highly protective and comfortable, thereby reducing the likelihood of workers removing their PPE during tasks and increasing overall safety.

[0059] The foregoing disclosure describes systems and methods for manufacturing a fabric or textile to be used in personal protective equipment. However, as will be appreciated by those skilled in the art, the systems and methods of the present disclosure may be applicable to other textile manufacturing processes (e.g., fabrics or textiles for improved composite qualities). Thus, various embodiments as described herein provide a method for creating composite textiles or fabric exhibiting multiple beneficial characteristics.

[0060] Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the description taken in conjunction with the accompanying figures. The figures constitute a part of this specification, include illustrative embodiments of the present disclosure, and illustrate various objects and features thereof. Any measurements, specifications and the like disclosed herein are intended to be illustrative, and not restrictive. Thus, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. While various embodiments of the new technology described herein have been described in detail, modifications and adaptations of the embodiments will occur to those skilled in the art and remain within the spirit and scope of the presently disclosed technology.

[0061] In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and / or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,”“an,” and “the” include plural references, unless the context clearly dictates otherwise. The meaning of “in” includes “in” and “on,” unless the context clearly dictates otherwise.

Claims

1. A protective textile for use in making an article of personal protective equipment, the protective textile comprising:a first composite yarn, the first composite yarn comprising:a tungsten core filament;a sheath layer comprising a plurality of polyester filaments covering the tungsten core filament; anda first outer layer comprising a plurality of para-aramid filaments wrapped around the sheath layer.

2. The protective textile of claim 1 further comprising:a second composite yarn, the second composite yarn comprising:a core comprising spandex; anda second outer layer comprising polyester that is wound around the core; anda third yarn, the third yarn comprising spun fire-resistant acrylic.

3. The protective textile of claim 1, wherein the tungsten core filament is 0.02 um in diameter.

4. The protective textile of claim 1, wherein the plurality of polyester filaments is about 30 Denier.

5. The protective textile of claim 1, wherein the plurality of para-aramid filaments is about 200 Denier.

6. The protective textile of claim 1, wherein the protective textile is formed in the shape of a glove.

7. The protective textile of claim 1, wherein the protective textile is formed in the shape of a sleeve.

8. The protective textile of claim 2, wherein the first composite yarn, the second composite yarn, and the third yarn each have a thickness that enables them to be fed into any of a 13-gauge knitting machine, 15-gauge knitting machine, 18-gauge knitting machine, or 21-gauge knitting machine.

9. The protective textile of claim 2, further comprising a fourth yarn, the fourth yarn comprising:a rubber core; anda first layer and a second layer, wherein each of the first layer and the second layer comprise polyester surrounding the rubber core.

10. The protective textile of claim 9, further comprising a fifth yarn, the fifth yarn comprising:a spandex core; anda third outer layer comprising fire-resistant spun acrylic surrounding the spandex core.

11. A method for producing a protective textile for use in manufacturing an article of personal protective equipment, the method comprising:manufacturing a first composite yarn comprising:a tungsten core filament;a sheath layer comprising a plurality of polyester filaments covering the tungsten core filament; anda first outer layer comprising a plurality of para-aramid filaments wrapped around the sheath layer;manufacturing a second composite yarn comprising:a core comprising spandex; anda second outer layer comprising polyester that is spun around the core;manufacturing a third yarn comprising fire-resistant spun acrylic; andknitting the first composite yarn, the second composite yarn, and the third yarn into a single feed to manufacture the protective textile.

12. The method of claim 11, further comprising forming the protective textile in the shape of a glove.

13. The method of claim 11, further comprising forming the protective textile in the shape of a sleeve.

14. The method of claim 12, wherein the method further comprises:manufacturing a fourth yarn comprising:a rubber core; anda first layer and a second layer, wherein each of the first layer and the second layer comprise polyester surrounding the rubber core; andwherein the step of forming the protective textile in the shape of the glove further comprises knitting the first composite yarn, the second composite yarn, the third yarn, and the fourth yarn into a cuff of the glove.

15. The method of claim 14, wherein the method further comprises:manufacturing a fifth yarn comprising:a spandex core; anda third outer layer comprising fire-resistant spun acrylic surrounding the spandex core; andwherein the step of forming the protective textile in the shape of the sleeve further comprises:knitting the first composite yarn, the second composite yarn, the third yarn, and the fourth yarn into a cuff of the sleeve; andknitting the first composite yarn, the second composite yarn, the third yarn and the fifth yarn into a palm of the sleeve.

16. The method of claim 11, wherein the tungsten core filament is 0.02 um in diameter.

17. The method of claim 11, wherein the plurality of polyester filaments is about 30 Denier.

18. The method of claim 11, wherein the plurality of para-aramid filaments is about 200 Denier.

19. The method of claim 14, wherein the rubber core and each of the first layer and the second layer of polyester are about 100 Denier.

20. The method of claim 11, wherein knitting the first composite yarn, the second composite yarn, and the third yarn into a single feed to manufacture the protective textile further comprises feeding the first composite yarn, the second composite yarn, and the third yarn into a single feed of any of:a 13-gauge knitting machine;a 15-gauge knitting machine;an 18-gauge knitting machine; ora 21-gauge knitting machine.

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