Method of making opacifying articles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing blackout materials require multiple coating operations, increasing manufacturing costs and productivity issues, and carbon black in light-blocking layers can become fugitive during sewing or laundering, causing unwanted shading and soilage.
Innovation Solution
A method for creating opacifying articles by laminating a dry opacifying layer with porous particles and a binder to the back side of a fabric, eliminating the need for latex foam or metallized layers, and allowing for easy application without sewing an extra blackout liner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coating operations are used to create blackout materials with light-absorbing layers, then light blocking performance is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines the light-absorbing layer and light-scattering layer into a single integrated coating composition containing both carbon black and titanium dioxide pigments. This eliminates the need for separate coating operations to apply distinct light-absorbing and light-scattering layers, thereby reducing manufacturing complexity while maintaining effective light blocking performance through the synergistic interaction of both pigment types within one layer.
2Reliability
If carbon black is used in light-blocking layers, then light absorption is improved, but carbon black becomes fugitive during sewing or laundering causing soilage and shading
Solution Approach 1:
The patent creates a composite coating composition where carbon black particles are combined with titanium dioxide particles and bound within a polymer matrix. This composite structure provides two benefits: first, the combination of light-absorbing carbon black and light-scattering titanium dioxide enhances overall light blocking; second, the polymer binder encapsulates the carbon black particles, preventing them from becoming fugitive during sewing or laundering, thus eliminating the soilage and shading problems associated with loose carbon black.
3Reliability
If thick foam coatings are applied to achieve blackout effect with light scattering pigments, then light blocking is improved, but material weight increases
Solution Approach 1:
The patent changes the optical parameters of the coating by incorporating carbon black pigment, which has superior light absorption capabilities compared to light scattering pigments alone. This parameter change allows the achievement of effective blackout performance with a thinner coating layer, thereby reducing the overall material weight while maintaining or improving light blocking efficacy.
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 simplifies the production of blackout materials, reduces waste, and prevents carbon black from spreading, thus maintaining the light-colored appearance and reducing shading, while providing effective light blocking and decorative functionality.
Implementation Method 1
Light colored blackout curtains theoretically can be made by coating porous fabrics with light colored foams containing light scattering pigments such as titanium dioxide or clays
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
An opacifying article can be made using a (i) fabric having a face side and a back side and an (ii) opacifying element having a substrate that has first and second opposing surfaces; and a dry opacifying layer that has an inner surface and an outer surface. The dry opacifying layer is disposed with its inner surface in contact with the first opposing surface of the substrate. The dry opacifying layer has (a) 40-90 weight % of porous particles, each having a continuous polymeric phase and discrete pores dispersed within the continuous polymeric phase. The porous particles have a mode particle size of 2-50 μm and a porosity of 20-70 volume %. The dry opacifying layer also contains (b) 10-60 weight % of a binder material. The (ii) opacifying element is laminated to the back side of the fabric to provide the opacifying article.