Architectural Laminate Structure for Crease-Resistant Light Blocking
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Solution Overview
Problem
Existing architectural coverings face issues with non-uniformity and creasing due to the use of materials that lack sufficient support and flatness, particularly when employing lightly woven fabrics or metallized films for light-blocking or light-diffusing properties.
Innovation Solution
A fabric laminate comprising a polymer film with oriented nonwoven webs on either side, where the fibers in the nonwoven webs are predominantly aligned in one direction, enhancing stiffness in that direction while maintaining flexibility in the perpendicular direction, and optionally incorporating metallized layers for enhanced light-blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If metallized films or nonwoven webs are used for light-blocking or light-diffusing properties, then light control performance is improved, but physical properties such as support and flatness deteriorate, causing creases and non-uniform appearance
Solution Approach 1:
The patent applies composite materials by combining a metallized film layer with a nonwoven web layer. The metallized film provides light-blocking performance while the nonwoven web provides structural support and flatness, preventing creases. This composite structure allows both light control and physical stability requirements to be satisfied simultaneously.
Solution Approach 2:
The patent applies local quality by positioning the nonwoven web specifically at the backing layer to provide support where needed, while the metallized film is positioned at the front surface to provide light-blocking. Each layer performs its specific function optimally, with the nonwoven web compensating for the metallized film's lack of structural support.
2Shape
If lightly woven fabrics are used for architectural coverings, then aesthetic appearance is improved, but support and drape characteristics deteriorate, leading to poor performance in operable coverings
Solution Approach 1:
The patent uses a composite structure where the nonwoven web layer provides the necessary structural support and drape characteristics, while the metallized film layer provides the aesthetic appearance and light control properties. This combination allows lightly woven fabrics to maintain both appearance and functional performance.
Solution Approach 2:
The nonwoven web acts as an intermediary layer between the metallized film and the operational components of the covering system. It provides the mechanical support and drape characteristics needed for operable coverings while allowing the metallized film to maintain its aesthetic and light-control functions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The laminate provides improved drape characteristics, resistance to creasing, and uniform appearance while maintaining light-blocking or light-diffusing properties, with the nonwoven webs enhancing support and the metallized layers ensuring minimal light transmission.
Implementation Method 1
a majority of the fibers in the first nonwoven web and the second nonwoven web are oriented along the first direction. In this manner, the stiffness of the laminate in the first direction may be greater than the stiffness of the laminate in the second direction.
Implementation Method 2
at least one metallized layer positioned between one side of the film layer and a nonwoven web
Data Source
AI summary
The present disclosure is generally directed to a fabric laminate for architectural coverings. The laminate generally contains a polymer film, optionally metallized on one or more sides, with at least one layer of a nonwoven web disposed on each side of the film. In one embodiment, at least one nonwoven web on each side of the film may contain a majority of fibers oriented in one direction, and, in some cases, the orientation direction of at least one web on one side of the film coincides with the orientation direction of at least one web on the opposite side of the film. In this manner, the fabric may demonstrate improved stiffness in one direction, such as the machine direction.