Method of making patterned light-blocking elements
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Solution Overview
Problem
Existing light-blocking materials require multiple coating operations, leading to increased energy and water usage, and carbon black can become fugitive during sewing or laundering, causing contamination and health concerns, while offering limited light-blocking tunability and aesthetic appeal.
Innovation Solution
A method involving a fabric with a prefabricated visible relief pattern, where a foamed aqueous opacifying composition is applied and self-embossed to create a densified layer on the backside, providing a patterned light-blocking element with adjustable light-blocking properties and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coating operations are used to create light-blocking layers, then light-blocking performance is improved, but manufacturing complexity and energy consumption increase
Solution Approach 1:
The patent combines multiple coating operations into a single application step by incorporating all necessary layers (light-blocking layer with carbon black, light-scattering layer with white pigment, and binding layer) into one composite coating composition that is applied simultaneously to the fabric substrate, thereby maintaining light-blocking performance while reducing manufacturing complexity
Solution Approach 2:
The invention uses a composite coating composition containing multiple functional components (carbon black particles for light-blocking, white pigment particles for light-scattering, and binder for adhesion) that work together in a single layer, eliminating the need for separate coating operations while achieving the required light-blocking performance
2Reliability
If carbon black is used in the light-absorbing layer, then light-blocking capability is improved, but carbon black becomes fugitive during sewing or laundering causing contamination
Solution Approach 1:
The patent creates a composite structure where carbon black particles are embedded within a matrix of binder and work together with light-scattering white pigment particles, forming a stable composite layer that prevents carbon black from becoming fugitive during sewing or laundering while maintaining light-blocking capability
Solution Approach 2:
The binder acts as an intermediary that encapsulates and secures the carbon black particles within the coating layer, preventing them from detaching and becoming contaminating fugitive material during subsequent processing or use, while still allowing the carbon black to perform its light-absorbing function
3Ease of manufacture
If standard coating methods are used, then manufacturing simplicity is maintained, but light-blocking tunability and aesthetic appeal are limited
Solution Approach 1:
The patent enables light-blocking tunability by allowing adjustment of the composition ratios of carbon black particles to white pigment particles, as well as adjusting the overall thickness of the single coating layer, providing versatile light-blocking control while maintaining manufacturing simplicity through a single application process
Solution Approach 2:
The invention allows different regions of the fabric to have different light-blocking properties by varying the composition or thickness of the coating in specific areas, enabling localized optimization for different aesthetic or functional requirements while using the same single-coating manufacturing process
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 method results in a patterned light-blocking element that offers tunable light-blocking capabilities, reduced manufacturing complexity, and maintains aesthetic appeal while avoiding fugitive carbon black issues, suitable for various lighting conditions and applications.
Implementation Method 1
self-embossing and densifying the dried foamed opacifying layer to reduce its thickness by at least 20% compared to its original thickness while the dried foamed opacifying layer and the fabric are in intimate contact between a pair of pressure rollers, wherein the prefabricated visible relief pattern of the face side embosses the foamed opacifying layer on the back side
Implementation Method 2
carbon black in the light absorbing middle layer
Implementation Method 3
two foamed light scattering, white pigment-containing layers
Data Source
AI summary
Patterned light-blocking elements are prepared using a method having operations A) through F). Such method includes providing an ii) embossed and densified foamed opacifying layer on the back side of a i) fabric and a iii) non-foamed function composition on the ii) embossed and densified foamed opacifying layer. Embossing can be carried out using a specific i) fabric having a prefabricated visible relief pattern on its face side. During embossing and densification, this prefabricated visible relief pattern self-embosses the ii) embossed and densified foamed opacifying layer, thus providing a visible relief pattern in that layer that can be viewed from the face side of the patterned light-blocking element when appropriately backlit as a transmissive display in a darkened environment. Such elements can be used as window treatments as well as decorative fabrics in various environments.