Item including a laminated, metallized textile layer, in particular for sun protection, and method for grafting a metal layer in order to obtain said item
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Solution Overview
Problem
Current solar protection articles with a textile layer and metal coating struggle to achieve both high solar reflection indices (Rs >= 75%) and fire classification levels (M1 or B1) due to adhesion issues caused by plasticizers migrating between the textile and metal layers, and the use of organic binders prevents the attainment of M0 or A2s1d0 fire classifications.
Innovation Solution
A method involving a textile layer with a polymer mixed with a plasticizer, where an intermediate polymer layer forms chemical bonds with both the textile and metal layers, preventing plasticizer migration and enhancing adhesion, while using a coupling polymer to create covalent or polar bonds between the components, ensuring durable peeling strength and compliance with fire and solar reflection standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an organic binder is used to deposit metal particles on the textile layer, then the metal layer adhesion is improved, but the fire resistance classification deteriorates (cannot achieve M0 or A2s1d0)
Solution Approach 1:
The patent introduces a silane coupling agent as an intermediary substance between the textile layer and metal particles. The silane forms chemical bonds with both the textile substrate and the metal particles, creating a bridge that provides adhesion without requiring organic binders. This intermediary layer enables achieving both good adhesion and high fire resistance classification (M0 or A2s1d0) by eliminating the need for combustible organic binding materials while maintaining structural integrity.
Solution Approach 2:
The patent changes the chemical and physical parameters of the metal particle deposition process by using silane treatment on the textile surface before metal particle application. This parameter change transforms the surface properties of the textile to be more reactive and compatible with metal particles, enabling direct chemical bonding or strong physical adhesion without organic binders, thus achieving both adhesion and fire resistance.
2Illumination intensity
If a vacuum metal coating operation is used to deposit pure aluminum on the textile layer, then the solar reflection index (Rs) is improved, but the metal layer adhesion to the textile surface deteriorates
Solution Approach 1:
The patent applies silane coupling agent treatment to the textile layer surface before performing the vacuum metal coating operation. This preliminary action modifies the textile surface to create anchoring sites that will bond with the aluminum layer during vacuum deposition. The silane treatment is performed in advance to ensure the surface is properly prepared for metal adhesion, solving the adhesion problem while maintaining the high solar reflection properties of the pure aluminum coating.
3Ease of operation
If plasticizer is added to the polymer to impart flexibility to the textile article, then the flexibility is improved, but the adhesion between the textile layer and metal layer deteriorates due to plasticizer migration
Solution Approach 1:
The silane coupling agent acts as an intermediary barrier layer between the plasticizer-containing polymer and the metal layer. This intermediary silane layer has chemical affinity for both the polymer matrix and the metal particles, creating a stable interface that prevents plasticizer migration while maintaining adhesion. The silane forms a protective interface that blocks the plasticizer from reaching the metal layer, thus preserving both flexibility and adhesion over time.
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 achieves Rs values greater than 75% and M1 fire resistance, with stable peeling strength maintained over time, even after months of storage, and allows for flexibility and outdoor use of the solar protection articles.
Implementation Method 1
the textile layer is treated with a silane coupling agent prior to depositing the metal particles on the outside face of the textile layer
Implementation Method 2
improving adhesion between the metal layer and the polymer mixed with at least one plasticizer
Implementation Method 3
Depositing a layer of aluminum on the surface of the textile layer by a vacuum metal coating operation
Implementation Method 4
the plasticizer(s) present in the textile layer migrate(s) to the interface of the textile layer with the metal layer, thereby progressively destroying the adhesion
Data Source
AI summary
The present invention provides an article, in particular for solar protection, comprising at least one metal-coating layer and a textile layer having an outside face comprising at least one polymer mixed with at least one plasticizer to form a first matrix. Advantageously, the bonding between said first matrix and the metal-coating layer is provided by an intermediate polymer layer comprising at least one coupling polymer, said coupling polymer being bonded by chemical bonds firstly to the first matrix and secondly to the metal-coating layer.The present invention also provides a method of fabricating such an article including a step of metal coating by depositing metal vapor under reduced pressure.