Foamed and foamable compositions containing solid polymeric particles
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Solution Overview
Problem
Existing light-blocking materials, such as blackout curtains, require multiple coating operations and can be prone to fugitive carbon black spreading, leading to increased manufacturing costs and reduced durability, especially when using porous polymeric particles.
Innovation Solution
A foamable aqueous composition with nonporous polymeric particles, a binder material, additives, and an opacifying colorant is used to create a foamed opacifying layer with improved light-blocking properties, minimizing the need for porous particles and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If porous polymeric particles are used in foamed compositions, then light-blocking capability is improved, but manufacturing complexity and cost increase due to multiple coating operations
Solution Approach 1:
The patent combines multiple functions (light scattering, light absorption, and foam structure formation) into a single nonporous polymeric particle system. The particles are incorporated into a foamed composition that achieves blackout performance through the synergistic effect of the foam matrix and dispersed particles, eliminating the need for separate porous particle layers and multiple coating operations.
Solution Approach 2:
The patent changes the physical state of polymeric particles from porous to nonporous, and controls their size distribution (0.1-10 micrometer range) to optimize light scattering while maintaining simplicity in the coating process. The foam density and particle concentration are adjusted to achieve effective light blocking in a single layer.
2Illumination intensity
If porous polymeric particles are used, then light scattering is enhanced, but durability decreases due to fugitive carbon black spreading
Solution Approach 1:
The patent reverses the conventional approach by using nonporous particles instead of porous ones. The nonporous polymeric particles provide light scattering through their refractive index difference with the foam matrix, while their nonporous nature prevents carbon black migration and maintains durability during sewing and laundering.
Solution Approach 2:
The patent creates a composite system where nonporous polymeric particles are dispersed within a foamed matrix containing light-absorbing materials. This composite structure achieves both light scattering (from particles) and light absorption (from foam), while preventing fugitive carbon spread through the nonporous particle architecture.
3Object-affected harmful factors
If multiple coating operations are performed, then light-blocking performance is improved, but productivity decreases and manufacturing costs increase
Solution Approach 1:
The patent develops a universal foamed composition that performs multiple functions simultaneously: the foam matrix provides light absorption, nonporous particles provide light scattering, and the single-layer structure eliminates the need for multiple coating operations. This multi-functional formulation achieves blackout performance in one application step.
Solution Approach 2:
The patent segments the light-blocking function into two components within a single layer: light-absorbing foam matrix and light-scattering nonporous particles. This segmentation allows each component to perform its specific function optimally while being applied together in one coating operation, improving productivity.
4Object-affected harmful factors
If carbon black is used for light absorption, then light-blocking capability is improved, but harmful fugitive carbon spread occurs during sewing and laundering
Solution Approach 1:
The patent converts the harmful effect of carbon black migration into a benefit by using nonporous particles that physically contain the carbon black. The nonporous structure acts as a barrier that prevents carbon migration, while still allowing the carbon to perform its light-absorbing function effectively.
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 solution provides a cost-effective, durable, and simplified method for producing light-blocking materials with minimal opacifying colorant exposure and enhanced flexibility, while maintaining light-blocking and scattering capabilities.
Implementation Method 1
an opacifying colorant different from all of the (c) two or more additives, which opacifying colorant absorbs electromagnetic radiation having a wavelength of at least 380 nm and up to and including 800 nm
Implementation Method 2
at least one of these two or more additives being a foaming agent and another of these two or more additives being a foam stabilizing agent
Implementation Method 3
nonporous polymeric particles, each nonporous polymeric particle having a mode particle size of at least 2 μm and up to and including 50 μm
Data Source
AI summary
Foamable and foamed aqueous compositions can be used to provide foamed, opacifying elements for use as light-blocking window shades, curtains, or other materials. These light-blocking articles can also have a printable outer surface that accepts ink for making printed images that are not observable from the opposite surface. Such foamable and foamed aqueous compositions comprise nonporous polymeric particles.