Embossed Foamed Opacifying Layer for Patterned Light-Blocking Fabrics
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Solution Overview
Problem
Current light-blocking materials, such as those using carbon black, face challenges including high manufacturing complexity, energy usage, and potential for fugitive carbon, which can lead to uneven light blocking and aesthetic issues, while lacking tunability and tactile appeal.
Innovation Solution
A method involving a fabric with a foamed aqueous opacifying composition applied to its back side, followed by embossing to create a densified layer with a visible relief pattern, allowing for customizable light blocking and aesthetic appeal by blocking light in recessed regions and allowing it in raised regions, using porous particles and a binder matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If carbon black is used in light-absorbing foamed layers, then light blocking is achieved, but manufacturing complexity and energy usage increase due to multiple coating operations
Solution Approach 1:
The patent combines the light-absorbing function and the structural framework into a single foamed layer containing carbon black particles, eliminating the need for separate light-absorbing and reflective layers. This merging reduces manufacturing complexity while maintaining light-blocking performance.
Solution Approach 2:
The invention uses a composite foamed layer comprising carbon black particles dispersed in a foamed matrix material, creating a single-layer composite structure that integrates light absorption and structural support functions, thereby simplifying the manufacturing process.
2Illumination intensity
If multiple coating operations are used to create light-blocking layers, then light blocking performance is improved, but energy usage and water usage increase
Solution Approach 1:
The patent merges multiple coating operations into a single coating process that applies a foamed layer containing carbon black particles, significantly reducing energy consumption and water usage associated with multiple drying and coating cycles.
3Illumination intensity
If carbon black is used in foamed layers, then light blocking is achieved, but carbon black can become fugitive and soil other layers
Solution Approach 1:
The patent embeds carbon black particles within the foamed matrix structure before final assembly, creating a protective framework that prevents carbon black from becoming fugitive during subsequent handling, sewing, or laundering operations.
Solution Approach 2:
The foamed layer structure provides a porous yet cohesive matrix that traps carbon black particles, preventing them from migrating or becoming fugitive while maintaining the light-absorbing properties of the carbon black.
4Illumination intensity
If fabric is coated with light-blocking material, then light blocking is provided, but tunability of light blocking degrees cannot be designed
Solution Approach 1:
The patent enables tunability by varying parameters such as carbon black particle concentration, particle size distribution, and foamed layer density, allowing different degrees of light blocking to be achieved within a single-layer structure.
Solution Approach 2:
The invention allows different regions of the fabric to have different light-blocking properties by locally adjusting the carbon black content or foamed layer characteristics, enabling customized and tunable light blocking patterns across the fabric surface.
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 method produces patterned light-blocking elements that provide aesthetically pleasing backlit displays with tunable light blocking, reducing manufacturing complexity and energy use, while maintaining a tactile appeal similar to fabric, and allowing for customizable designs.
Implementation Method 1
A backlit sign may consist of laser-cut panel(s) made of wood or metal and backing material of light diffusing acrylic... when light strikes a surface, some light may be reflected, some absorbed, some scattered, and the rest transmitted
Implementation Method 2
backing material of light diffusing acrylic... some light may be reflected, some absorbed, some scattered, and the rest transmitted
Implementation Method 3
D) embossing and densifying the dried foamed opacifying layer to reduce its thickness by at least 20% compared to its original thickness, while the dried foamed opacifying layer and the i) fabric are in intimate contact between a pair of pressure rollers
Data Source
AI summary
Patterned light-blocking elements are prepared using a method having operations A′) through F′), or a method having operations A″) through G″). Such methods include providing an ii) embossed and densified foamed opacifying layer on the back side of a i) fabric and a iii) non-foamed function composition on the ii) embossed and densified foamed opacifying layer. Embossing can be carried out using any suitable embossing means including a continuous embossing belt or web or an embossing roller or sleeve. The embossing operation provides a visible relief pattern in the ii) embossed and densified foamed opacifying layer that can be viewed from the face side of the patterned light-blocking element when appropriately backlit as a transmissive display in a darkened environment. Such elements can be used as window treatments as well as decorative fabrics in various environments.