Three-Layer Woven Blackout Curtain Structure to Eliminate Light Leaks

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing blackout curtain technologies fail to achieve 100% light-proofing, are costly, and suffer from issues like artificial feel, chemical separation, and surface deformations, while current methods like weaving, coating, and lamination have limitations in achieving complete blackout and durability.

Innovation Solution

A three-layered blackout curtain structure with specific knitting techniques and connection points, using high filament and black colored weft yarns in the middle layer, and diagonal connections to prevent light leaks, ensuring 100% blackout and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If coating process is used to achieve light-proof properties, then blackout effect is improved, but manufacturing cost increases and process complexity increases

Engineering Contradiction:

Improveblackout effectVSAvoidmanufacturing cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The curtain is divided into three separate fabric layers (first, second, and third layers) that are woven independently and then joined together. Each layer is constructed with specific knitting patterns and yarn types to optimize light blocking while maintaining manufacturing simplicity and cost-effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite fabric construction combining different yarn types (high filament content yarns, black chip yarns) and different knitting structures (double-faced satin knits, plain knits) within a single woven fabric layer, achieving superior blackout performance without requiring chemical coatings.

Inventive Principle:

Principle #40Composite materials

2Illumination intensity

If coating process is used to ensure light-proof properties, then blackout effect is improved, but device complexity increases

Engineering Contradiction:

Improveblackout effectVSAvoidprocess complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

3Illumination intensity

If lamination technology is used to achieve light-proof properties, then blackout effect is improved, but manufacturing cost increases

Engineering Contradiction:

Improveblackout effectVSAvoidmanufacturing cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If single-layer fabric structure is used, then ease of manufacture is improved, but blackout effect deteriorates

Engineering Contradiction:

Improveease of manufactureVSAvoidblackout effect

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Three separate fabric layers with different knitting structures and yarn compositions are merged together through connection points to create a composite curtain structure that achieves 100% blackout effect, combining the advantages of each individual layer.

Inventive Principle:

Principle #5Merging (Combining)

5Illumination intensity

If connection points are added to join fabric layers, then blackout effect is improved, but device complexity increases

Engineering Contradiction:

Improveblackout effectVSAvoidstructure complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Connection points serve as intermediary elements that join the first, second, and third fabric layers together, preventing light leakage at the joints while maintaining the structural integrity and relative simplicity of the overall design.

Inventive Principle:

Principle #24Intermediary (Mediator)

6Illumination intensity

If dark color is used to increase blackening rate, then blackout effect is improved, but product range deteriorates

Engineering Contradiction:

Improveblackening rateVSAvoidproduct range

Core Design Contradiction:

Illumination intensityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The fabric uses black chip yarns specifically in strategic locations (weft yarns in the second layer) where they provide maximum light blocking benefit, while other areas can use varied yarn colors and types to maintain aesthetic appeal and product variety.

Inventive Principle:

Principle #3Local quality

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 a 100% blackout curtain that is washable, ironable, and resistant to light leaks, with a natural feel and long-lasting structure, overcoming the limitations of existing methods.

Implementation Method 1

high filament and black colored weft yarns in the middle layer

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 2

black colored weft yarns

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentEP4579016A1A new blackout curtain that provides complete blackout

Publication Date: 2025.07.02 BERTEKS TEKSTIL SANAYI VE TICARET ANONIM SIRKETI

Figure 1

AI summary

The invention relates to a new blackout curtain that does not transmit light to the interior environment, which can be used in any environment where it is desired to prevent light from entering such as home, office, hotel, photo studios, motion picture theaters. The invention particularly relates to a curtain structure that provides 100% blackout by minimizing the light transmittance rate, which protects the privacy of private life and protects against the disturbing effect of light and UV rays.