Light-blocking articles with tinted functional composition

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Solution Overview

Problem

Existing light-blocking articles, such as blackout curtains and shades, face challenges with weight, flexibility, launderability, and the risk of dark opacifying agents escaping during handling or stitching, leading to unwanted shading and contamination.

Innovation Solution

A foamed, opacifying element with a substrate coated with a functional composition containing porous particles, a binder material with a low glass transition temperature, and an opacifying colorant, which minimizes sticking and static issues, and incorporates spacer particles to reduce surface contact and enhance flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If thick foam coatings with light scattering pigments are used to create light-colored blackout curtains, then light blocking performance is improved, but weight increases

Engineering Contradiction:

Improvelight blocking performanceVSAvoidcurtain weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent uses a composite structure with a white foamed layer containing light scattering pigments (titanium dioxide, clays) on the exterior surface, and a black foamed layer containing light absorbing pigments (carbon black) on the interior surface. This composite material approach achieves effective light blocking with reduced overall thickness and weight compared to using thick white foam alone.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The blackout curtain is divided into multiple functional layers: a white exterior foamed layer for light scattering and a black interior foamed layer for light absorption. This segmentation allows each layer to perform its specific function efficiently, reducing the total material required and overall weight.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If multiple coating operations are used to create light absorbing middle layer between reflective layers, then light blocking performance is improved, but manufacturing productivity decreases

Engineering Contradiction:

Improvelight blocking performanceVSAvoidmanufacturing productivity

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent combines the light scattering and light absorbing functions into a single sandwich structure applied in one coating operation. The white foamed layer and black foamed layer are applied together as an integrated unit, eliminating the need for multiple separate coating operations required by traditional approaches.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If carbon black layer is used for light absorption, then light blocking performance is improved, but risk of contamination increases

Engineering Contradiction:

Improvelight blocking performanceVSAvoidcontamination risk

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The black carbon black-containing foamed layer is positioned between the white exterior foamed layer and the fabric substrate, creating a protective barrier that prevents carbon black from migrating to and contaminating the white exterior surface during handling, sewing, and laundering operations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Object-affected harmful factors

If heavy materials are used to ensure light blocking, then light blocking performance is improved, but flexibility and launderability worsen

Engineering Contradiction:

Improvelight blocking performanceVSAvoidflexibility and launderability

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent uses thin foamed polymer layers (acrylic, vinyl, or polyurethane foam) that provide effective light blocking through their cellular structure and pigment content while maintaining flexibility and light weight, enabling the curtain to be easily handled, sewn, and laundered.

Inventive Principle:

Principle #30Flexible shells and thin films

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 lightweight, flexible, and launderable light-blocking materials with improved release properties and reduced contamination risks, maintaining effective light absorption and coloration.

Implementation Method 1

a binder material with a low glass transition temperature

Methodology Applied

Scientific EffectGlass transition temperature:

Implementation Method 2

an opacifying colorant, which minimizes sticking and static issues, and incorporates spacer particles to reduce surface contact and enhance flexibility

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 3

A foamed, opacifying element with a substrate coated with a functional composition containing porous particles

Methodology Applied

Scientific EffectLight scattering: Scattering

Data Source

PatentUS10696813B2Light-blocking articles with tinted functional composition

Publication Date: 2020.06.30 EASTMAN KODAK CO

AI summary

A foamed, opacifying element is useful as a light-blocking article, and includes a substrate; an opacifying layer disposed on the substrate, and a functional composition disposed over the opacifying layer. The functional composition comprises a tinting material comprising one or more pigments, one or more dyes, or a combination thereof to provide a desired tint or colorant to the entire foamed, opacifying element.