Method for preparing laminated precursor rolls
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Solution Overview
Problem
Current light-blocking materials, such as blackout curtains, require multiple coating operations and can be prone to contamination due to fugitive carbon black pigments, increasing manufacturing costs and complexity, while also requiring additional layers that add weight and expense.
Innovation Solution
A method involving the application of an aqueous foamed opacifying composition to the backside of non-woven fabrics, followed by drying and optional anti-blocking material application, to create laminate precursor rolls that can be easily laminated to decorative fabrics, eliminating the need for direct coating and extra blackout liners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coating operations are used to create light-blocking materials, then light-blocking performance is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines multiple coating operations into a single application step by using a pre-coated foamable composition that contains both light-scattering pigments (titanium dioxide) and light-absorbing pigments (carbon black) in one formulation. This eliminates the need for separate coating operations to apply different pigment layers, thereby maintaining light-blocking performance while reducing manufacturing complexity
Solution Approach 2:
The invention uses a composite foamable composition containing multiple pigment types (titanium dioxide for light scattering and carbon black for light absorption) combined in a single coating material. This composite approach achieves superior light-blocking performance through the synergistic effect of both pigments while simplifying the manufacturing process by requiring only one coating operation
2Reliability
If carbon black pigment is used in light-absorbing layers, then light-blocking performance is improved, but contamination and fugitivity problems occur
Solution Approach 1:
The patent merges light-scattering titanium dioxide pigment and light-absorbing carbon black pigment into a single foamable composition that is applied in one coating operation. By combining both pigments in the same coating layer and applying them simultaneously, the carbon black is not exposed to mechanical stress from subsequent coating operations, eliminating the fugitivity and contamination problems that occur when carbon black is applied in separate layers
Solution Approach 2:
The invention performs the pigment incorporation action preliminarily by pre-mixing both light-scattering and light-absorbing pigments into the foamable composition before application. This preliminary combination ensures that carbon black particles are protected within the foam matrix from the outset, preventing them from becoming fugitive during subsequent handling and processing
3Reliability
If additional blackout liner layers are added, then light-blocking performance is improved, but weight and expense increase
Solution Approach 1:
The patent uses a composite foamable composition containing both light-scattering titanium dioxide pigment and light-absorbing carbon black pigment in a single coating layer. The synergistic interaction between these two pigments achieves superior light-blocking performance equivalent to multiple separate layers, but with significantly reduced material weight and cost since only one coating layer is required instead of multiple stacked layers
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
This approach reduces manufacturing complexity and costs by allowing for on-demand production of light-blocking decorative articles with desired weight, stiffness, and color, while avoiding the use of fugitive pigments and extra layers, resulting in cost-effective and efficient production of laminated light-blocking materials.
Implementation Method 1
coating porous fabrics with light colored foams containing light scattering pigments such as titanium dioxide
Implementation Method 2
sandwich a light-absorbing, foamed black or grey pigment, such as a carbon black between two foamed light scattering, white pigment-containing layers
Data Source
AI summary
Laminate precursors are prepared by applying an aqueous foamed opacifying composition to a non-woven fabric, drying, optionally applying an anti-blocking material to the dried aqueous foamed opacifying composition, and densifying the dry foamed opacifying layer so that it will have a thickness that is at least 20% less than its thickness before densifying. Each laminate precursor is rolled up for immediate or later use to make laminate decorative articles when the unrolled laminate precursor is laminated with back side of a decorative fabric. The applied aqueous foamed opacifying composition has 35%-70% solids and a foam density of 0.1-0.5 g/cm3. It is composed of (a) porous particles, (b) a binder material, (c) two or more additives comprising at least one foaming surfactant and at least one foam stabilizer, (d) an aqueous medium, and (e) an opacifying colorant that absorbs electromagnetic radiation having a wavelength of 380-800 nm.