Method and system for making light-blocking articles

Abstract

A foamed, opacifying element having a target light blocking value (LBVT) and a target porous substrate is prepared by determining the light blocking value (LBVS) of the target porous substrate; calculating the LBVT-S difference; choosing a foamable aqueous composition; determining a dry coating weight for the chosen foamable aqueous composition (when foamed); and using the dry coating weight to form the single dry opacifying layer as the only layer disposed on the target porous substrate, such that the single dry opacifying layer has light blocking value that is equal to LBVT-S, ±10%. The chosen foamable aqueous composition comprises the essential components (a) through (e) described herein. The desired foamable aqueous composition can be chosen from a set of similar compositions to achieve the desired LBVT with the noted target porous substrate using suitable mathematical formula relating dry coating weight to light blocking value and a suitable data processor.

Description

RELATED APPLICATIONS[0001]Reference is made to the following copending and commonly assigned patent applications:[0002]U.S. Ser. No. 15 / 144,893, filed May 3, 2016, titled “FOAMED, OPACIFYING ELEMENTS,” by Brick et al., that is a continuation-in-part of commonly assigned U.S. Ser. No. 14 / 730,280, filed Jun. 4, 2015, now abandoned.[0003]U.S. Ser. No. 15 / 144,875, filed May 3, 2016, titled “FOAMED AQUEOUS COMPOSITION,” by Pyszczek et al., recently allowed, that is a continuation-in-part of commonly assigned U.S. Ser. No. 14 / 730,269, filed Jun. 4, 2015, now abandoned;[0004]U.S. Ser. No. 15 / 144,911, filed May 3, 2016, titled “METHOD OF MAKING FOAMED, OPACIFYING ELEMENTS,” by Brick et al., that is a continuation-in-part of commonly assigned U.S. Ser. No. 14 / 730,280, filed Jun. 4, 2015, now abandoned;[0005]U.S. Ser. No. 15 / 239,915, filed Aug. 18, 2016, titled “FORMABLE AND FOAMED AQUEOUS COMPOSITIONS,” by Pyszczek et al.;[0006]U.S. Ser. No. 15 / 239,938, filed Aug. 18, 2016, titled “LIGHT-BLO...

AI Technical Summary

Benefits of technology

The present invention allows for the creation of a single-layer foamed, opacifying element that can save money or provide a more premium feel to a lighter-weight substrate based on the desired economic or aesthetic values. The various factors can be carefully balanced to achieve a customer's needs. Additionally, the invention allows for the creation of foamable aqueous compositions that can block light to a specific level based on its thickness. These compositions can be designed to provide a desired light blocking value while minimizing material costs. The patent text also describes a method to formulate these compositions based on various factors and provide a set of dry coating weights for a set of possible foamable aqueous compositions.

Problems solved by technology

Thus, when a blackout material such as a blackout curtain is hung over a window, it generally blocks substantially all external light from entering the room through that window.

However, very thick foam coatings will be needed to create blackout curtains through which the sun is not visible in a darkened room using only these pigments.

When an electromagnetic radiation blocking coating has, as it often does, a strongly light absorbing material containing black pigments such as carbon black, between two reflective layers, it has at least two distinct problems.

First, such materials require three separate coating operations that reduce manufacturing productivity and increase unit costs.

Secondly, carbon black in the light absorbing middle layer can become “fugitive” (or non-enclosed) from some puncture or tear occurring during sewing or laundering, and soil other layers such as the reflective layers, which is highly objectionable.

Additionally, the stitches generated in the materials during sewing can cause the fugitive carbon from the light absorbing layer to spread over a larger area thereby increasing the area of objectionable shading of the light colored surface.