Laminate Architecture for Architectural Coverings
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Solution Overview
Problem
Existing architectural coverings for structures, such as windows and doors, face challenges in being lightweight, cost-effective, and maintaining excellent drape characteristics without creases or puckering, while also providing a uniform and aesthetic appearance.
Innovation Solution
A laminate comprising a nonwoven base layer with fibers oriented in one direction and a layer of filaments oriented perpendicularly, combined with optional yarn layers, to achieve high tear strength, stiffness, and softness, enhancing drape characteristics and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If woven or knitted fabrics are used for architectural coverings, then the covering has good drape characteristics and aesthetic appearance, but the material becomes heavy and expensive to produce
Solution Approach 1:
The patent applies composite materials by combining a nonwoven base layer with a filament layer to create a laminate structure. This composite construction provides the necessary strength and drape characteristics for architectural coverings while maintaining lightweight properties, as nonwoven materials are inherently lighter than traditional woven or knitted fabrics.
2Weight of moving object
If nonwoven materials are used for architectural coverings, then the material becomes lightweight and cost-effective, but the covering produces creases, puckering, and poor drape characteristics
Solution Approach 1:
The patent combines a nonwoven base layer with a filament layer to create a laminate that maintains the lightweight advantage of nonwoven materials while adding the drape characteristics and crease resistance of filament structures. The filament layer provides tensile strength and structural stability that prevents puckering and improves overall drape performance.
Solution Approach 2:
The patent merges two different material systems - nonwoven fabric and filament layer - into a single laminate structure. This combination allows the covering to simultaneously exhibit the lightweight, cost-effective properties of nonwoven materials and the excellent drape characteristics, uniform appearance, and crease resistance of filament structures.
3Ease of manufacture
If nonwoven laminates are used for architectural coverings, then the material allows desired light transmission and is inexpensive to produce, but the covering lacks uniform appearance and aesthetic quality
Solution Approach 1:
The patent uses a composite laminate structure where the filament layer is laminated to the nonwoven base layer. This combination enhances the uniform appearance and aesthetic quality of the covering while maintaining the cost-effectiveness and light transmission properties of the nonwoven material. The filament layer provides a more uniform surface texture and visual appearance.
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 offers a lightweight, cost-effective solution with excellent drape properties, preventing creases and puckering, and providing a balanced stiffness and softness for architectural coverings like window shades and blinds.
Implementation Method 1
The binder fibers, for instance, can be conjugate fibers having a core and sheath structure. The sheath of the conjugate fibers can be made from a polymer having a lower melting point for thermally bonding two adjacent fibers when heated under pressure.
Data Source
AI summary
The present disclosure is generally directed to a fabric laminate for architectural coverings. The laminate generally includes a nonwoven layer laminated to oriented filaments. The nonwoven layer can be a wet laid nonwoven layer. The filaments can comprise continuous spunbond filaments. Optionally, the laminate can include a third layer of oriented yarns. In one aspect, the yarns can be oriented in the length direction while the polymer filaments can be oriented in the width direction.