Foamed, opacifying elements with thermally transferred images
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Solution Overview
Problem
Traditional blackout materials for draperies are multi-layered, unsuitable for thermal transfer printing, prone to off-gassing, delamination, and poor image quality due to the absorption of heat by carbon black, which acts as a heat sink during sublimation processes.
Innovation Solution
A foamed, opacifying element with a single dry opacifying layer on a porous substrate, where thermal transfer images are applied on the external surface, avoiding carbon black and minimizing opacifying colorant usage to prevent heat-related issues and enhance transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multi-layered blackout materials with carbon black are used, then light-blocking properties are improved, but thermal transfer printing quality deteriorates due to heat sink effect
Solution Approach 1:
The patent removes carbon black and other heat-absorbing pigments from the blackout drapery composition, extracting the harmful heat sink effect while retaining the light-blocking functionality through alternative opacifying mechanisms that do not interfere with thermal transfer printing
Solution Approach 2:
The invention uses a composite formulation combining acrylic polymer emulsion with specific opacifying agents and foam stabilizers that create an opaque, light-blocking foam structure without carbon black, enabling both blackout functionality and thermal transfer compatibility
2Illumination intensity
If traditional blackout materials are used, then light-blocking is achieved, but delamination occurs during thermal transfer process
Solution Approach 1:
The patent modifies the chemical composition parameters of the foamable composition, using acrylic polymer emulsion with specific glass transition temperatures and foam stabilizers that maintain layer integrity at thermal transfer temperatures, preventing delamination while achieving blackout performance
3Illumination intensity
If carbon black is used for opacification, then light-blocking is improved, but noxious fumes are generated during heating
Solution Approach 1:
The patent eliminates carbon black and replaces it with alternative opacifying mechanisms using foam structure and safe pigments, converting the harmful off-gassing issue into a benefit by using materials that do not generate noxious fumes during thermal processing while maintaining effective light blocking
4Illumination intensity
If multiple layers are used for blackout, then light-blocking performance is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions (blackout, foamability, opacification, and thermal transfer compatibility) into a single integrated foamable composition, eliminating the need for separate layers and simplifying the overall material structure while maintaining effective light blocking performance
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 self-lined, durable, and flexible blackout drapery with improved light-blocking properties, reduced noxious fumes, and efficient thermal colorant transfer, maintaining image quality without delamination or off-gassing.
Implementation Method 1
The inks used for preparing the printed pattern contain colorants that are selected to sublime at a temperature that does not compromise the integrity of the fabric or textile substrate. The inks can be applied to an inert, transfer donor support, conventionally paper, by any number of printing processes known in the art... The preprinted transfer donor element and the fabric to be printed are brought into contact under controlled conditions of time, temperature and pressure such that the colorant of the image is sublimed and transferred from the transfer donor element to the fabric substrate
Implementation Method 2
The foamable aqueous composition is aerated to provide a foamed aqueous composition having a foam density of at least 0.1 g/cm³
Implementation Method 3
The binder material is an acrylic polymer emulsion... The foamed aqueous composition is disposed onto a porous substrate and the binder material is cured to form a durable film
Data Source
AI summary
A foamed, opacifying element can be prepared to have a thermal colorant image on either an opposing external surface and an internal surface of a porous substrate. The internal surface has a dry foamed composition disposed thereon as a dry opacifying layer that comprises: (a) 0.1-40 weight % of porous particles; (b) at least 10 weight % of an at least partially cured binder material; (c) at least 0.2 weight % of one or more additives comprising a surfactant; (d) less than 5 weight % of water; and (e) at least 0.002 weight % of an opacifying colorant different from all of the one or more (c) additives, which opacifying colorant absorbs predetermined electromagnetic radiation. The thermal colorant image is derived from thermal colorant transfer of sublimable colorants from a thermal donor element.