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 with poor support for light-blocking or light-diffusing properties, leading to undesirable undulations and puckering.
Innovation Solution
A fabric laminate comprising a polymer film with nonwoven webs on either side, where the fibers in the nonwoven webs are oriented in one direction to enhance 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 nonwoven webs are laminated to films to block or filter light, then light-blocking performance is improved, but the laminate exhibits poor support for uniformity and flatness in appearance
Solution Approach 1:
The patent applies composite materials by combining a film layer with nonwoven webs containing synthetic fibers. The film provides light-blocking performance while the nonwoven web with oriented fibers provides structural support for uniformity and flatness, resolving the contradiction between light-blocking capability and appearance quality
Solution Approach 2:
The patent applies local quality by orienting synthetic fibers in a specific direction within the nonwoven web. This directional orientation provides localized stiffness and support in the machine direction to prevent creasing and puckering, while maintaining the overall light-blocking function of the laminate structure
2Strength
If fibers in nonwoven webs are oriented along the machine direction to increase stiffness, then resistance to creasing is improved, but flexibility in the perpendicular direction may be reduced
Solution Approach 1:
The patent applies local quality by orienting fibers primarily in the machine direction to provide localized stiffness and crease resistance where needed, while the perpendicular direction retains sufficient flexibility for operational requirements. This directional fiber orientation creates anisotropic mechanical properties that satisfy both contradictory requirements
3Illumination intensity
If metallized films are used for light-blocking, then light-blocking performance is improved, but the material may exhibit poor drape characteristics
Solution Approach 1:
The patent applies composite materials by combining metallized films with nonwoven webs containing oriented synthetic fibers. The metallized film provides superior light-blocking performance while the nonwoven web layer provides structural support and improves drape characteristics, resolving the contradiction between light-blocking capability and drape quality
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 enhanced mechanical durability and aesthetic customization options.
Implementation Method 1
The binder fibers may be thermally bonded to other fibers in the 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.