Textured surface coating for gloves and method of making
There is provided, in accordance with the principles of the present invention, a glove having a textured surface or textured foam coating produced by embedding a layer of discrete particles, such as a salt, into a previously formed liquid layer, gelling or curing the layer and dissolving the discrete particles to leave a textured or textured foamed surface.
1. A process for making a cured textured glove, the process comprising:
providing a support layer of a dip-coated, gelled latex or of a non-latex material on a former;
dip-coating the former with the support layer in a coagulatable aqueous latex emulsion composition to form an ungelled outer layer of emulsion composition;
applying discrete particles of multi-faceted salt to the ungelled outer layer of emulsion composition;
coagulating the ungelled outer layer of emulsion composition where the particles of multifaceted salt are in contact with the ungelled outer layer of emulsion composition to form a gelled outer layer so that impressions replicating the multi-faceted shape of the particles of salt are formed in the gelled outer layer;
dissolving the particles of multi-faceted salt;
heat curing the gelled outer layer after the step of dissolving to form a cured outer layer; and
stripping the support layer and the cured outer layer from the former to form the cured textured glove comprising the impressions replicating the multi-faceted shape of the particles of salt.
2. The process of claim 1 , wherein the step of providing the support layer comprises treating the former with a coagulant; forming the support layer of latex by dip-coating the former in a coagulatable aqueous latex emulsion composition; and gelling the first layer of latex by the destabilization of the latex emulsion by said coagulant.
3. The process of claim 1 , wherein the step of providing the support layer comprises applying a woven or knitted layer of non-latex material to the former.
4. The process of claim 3 , further comprising forming an inner layer of gelled latex between the support layer of non-latex material and the ungelled outer layer.
5. The process of claim 1 , wherein the step of forming the ungelled outer layer comprises using a foamed latex emulsion.
6. The process of claim 1 , wherein the support layer of the dip-coated, gelled latex, the coagulatable aqueous latex emulsion composition, or both comprises a natural latex, a polyurethane latex, a nitrile latex, or a polychloroprene latex.
7. The process of claim 1 , wherein the discrete particles are sized in the range of 50 to 2000 microns.
8. The process of claim 7 , wherein a mean particle size is 400 microns.
9. The process of claim 1 , wherein the step of applying discrete particles of multi-faceted salt to the ungelled outer layer comprises dipping the former in a fluidized bed of salt.
10. The process of claim 1 , wherein the step of applying discrete particles of multi-faceted salt to the ungelled outer layer comprises spraying the particles onto the outer layer of latex.
11. The process of claim 1 , wherein the discrete particles of salt comprise sodium chloride, potassium chloride, calcium chloride, magnesium chloride, zinc chloride, calcium nitrate, or zinc nitrate.
12. The process of claim 1 , wherein the particles of multi-faceted salt are dissolved in water.
13. A process for making a cured textured glove, the process comprising:
treating a former with a coagulant;
dip-coating the former in a coagulatable aqueous latex emulsion composition to form a gelled support layer of latex;
washing the gelled support layer of latex to remove residual surface syneresis products;
drying the gelled support layer to remove excess water on the gelled support layer;
dip-coating the former with the gelled support layer in a coagulatable aqueous latex emulsion composition to form an ungelled outer layer of emulsion composition;
applying discrete particles of multi-faceted salt to the ungelled outer layer of emulsion composition;
coagulating the ungelled outer layer of emulsion composition where the particles of multifaceted salt are in contact with the ungelled outer layer of emulsion composition to form a gelled outer layer so that impressions replicating the multi-faceted shape of the particles of salt are formed in the gelled outer layer;
dissolving the particles of multi-faceted salt;
heat curing the gelled outer layer after the step of dissolving to form a cured outer layer; and
stripping the support layer and the cured outer layer from the former to form the cured textured glove comprising the impressions replicating the multi-faceted shape of the particles of salt.
14. The process of claim 13 , wherein the coagulatable aqueous latex emulsion is coagulatable by sodium chloride.
15. The process of claim 13 , wherein the coagulatable aqueous latex emulsion composition for the gelled support layer of latex has a first viscosity and the coagulatable aqueous latex emulsion composition for the ungelled outer layer has a second viscosity.
16. The process of claim 15 , wherein the first viscosity is in the range of 20 to 40 cps and the second viscosity is in the range of 100 to 2000 cps.
17. The process of claim 13 , wherein the particles of multi-faceted salt are dissolved in water.
18. The process of claim 13 , further comprising providing a knitted liner on the former before treating the former with the coagulant.