Opacifying articles and methods of making

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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 staining and spreading.

Innovation Solution

A method involving an aqueous formulation with porous particles and a binder material, applied to a polymeric film substrate, which is then laminated to the back side of a fabric to create an opacifying article, eliminating the need for metalization and reducing waste by allowing for easy application and testing of decorative blackout fabrics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple coating operations are used to create light-blocking layers, then light blocking performance is improved, but manufacturing productivity decreases and costs increase

Engineering Contradiction:

Improvelight blocking performanceVSAvoidmanufacturing productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines multiple coating operations into a single lamination step by pre-assembling the opacifying element with all necessary layers (light-scattering layer, light-absorbing layer, and protective layer) bonded together. This single lamination operation replaces multiple sequential coating operations, maintaining light-blocking performance while significantly improving manufacturing productivity and reducing costs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The opacifying element is pre-assembled with all functional layers bonded together before lamination to the fabric. The light-scattering layer, light-absorbing layer, and protective layer are prepared and bonded in advance, allowing the final application to be a single lamination step rather than multiple coating operations.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If carbon black is used in light-absorbing layers, then light blocking performance is improved, but carbon black becomes fugitive during sewing or laundering causing staining

Engineering Contradiction:

Improvelight blocking performanceVSAvoidfugitive carbon black staining

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The light-absorbing layer containing carbon black is nested between two light-scattering layers. The protective layer on the outer side acts as a barrier that encapsulates the carbon black, preventing it from becoming fugitive during sewing or laundering. This nested structure maintains light-blocking performance while eliminating the harmful staining effect.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The protective layer serves as an intermediary barrier between the carbon black in the light-absorbing layer and the external environment. This protective layer prevents carbon black particles from migrating out during sewing or laundering, eliminating the fugitive staining problem while maintaining the light-blocking function.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If thick foam coatings are used with light scattering pigments, then light blocking performance is improved, but weight of the material increases

Engineering Contradiction:

Improvelight blocking performanceVSAvoidweight of blackout material

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent uses a composite structure combining light-scattering foam layers with a light-absorbing layer containing carbon black. This composite material approach achieves superior light-blocking performance with thinner overall construction compared to using thick foam coatings alone, thereby reducing the weight of the blackout material while maintaining or improving light-blocking effectiveness.

Inventive Principle:

Principle #40Composite materials

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 manufacturing costs, and prevents carbon black from becoming fugitive, ensuring consistent light blocking without staining other layers.

Implementation Method 1

coating porous fabrics with light colored foams containing light scattering pigments such as titanium dioxide or clays

Methodology Applied

Scientific EffectLight scattering: Scattering

Implementation Method 2

a light-absorbing, foamed black or grey pigment, such as a carbon black between two foamed light scattering, white pigment-containing layers

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Data Source

PatentEP3850047B1Opacifying articles and methods of making

Publication Date: 2024.01.24 EASTMAN KODAK CO

Figure 1A~1B
Figure 2A~2B
Figure 3A~3B

AI summary

An opacifying article has 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 pm 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.