U.S. patent application number 16/951551 was filed with the patent office on 2021-03-11 for blackout material.
The applicant listed for this patent is L&P Property Management Company. Invention is credited to Tony Spencer.
Application Number | 20210071324 16/951551 |
Document ID | / |
Family ID | 1000005226038 |
Filed Date | 2021-03-11 |
United States Patent
Application |
20210071324 |
Kind Code |
A1 |
Spencer; Tony |
March 11, 2021 |
Blackout Material
Abstract
A blackout material is provided and includes a woven fabric
including a weft set and a warp set, the weft set being black. More
than 50% of a first surface of the woven fabric comprises the warp
set. The blackout material further comprises a light excluding
coating on the outer surface of the woven fabric, the light
excluding coating including at least one black layer. A method of
making a blackout material is provided and includes weaving a woven
fabric including a weft set and a warp set, the weft set being
black. More than 50% of a first surface of the woven fabric
comprises the warp set. The method further comprises applying a
light excluding coating on the outer surface of the woven
fabric.
Inventors: |
Spencer; Tony; (Conover,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
L&P Property Management Company |
South Gate |
CA |
US |
|
|
Family ID: |
1000005226038 |
Appl. No.: |
16/951551 |
Filed: |
November 18, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15711543 |
Sep 21, 2017 |
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16951551 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 15/513 20210101;
D03D 13/004 20130101; D02G 3/36 20130101; D03D 1/0017 20130101 |
International
Class: |
D03D 1/00 20060101
D03D001/00; D02G 3/36 20060101 D02G003/36; D03D 15/12 20060101
D03D015/12; D03D 13/00 20060101 D03D013/00 |
Claims
1. A blackout material comprising: a woven fabric including a weft
set including a plurality of black weft yarns and a warp set
including a plurality of warp yarns, the woven fabric having a
first surface and a second surface; and a light excluding coating
on the second surface of the woven fabric, the light excluding
coating including at least one black layer, wherein more than 50%
of the second surface comprises the weft set.
2. The material of claim 1, wherein more than 80% of the second
surface comprises the weft set.
3. The material of claim 1, wherein each of the warp yarns floats
over four weft yarns before passing under one of the weft
yarns.
4. The material of claim 1, wherein at least one of the weft set or
the warp set are flame retardant treated or inherently flame
retardant.
5. The material of claim 4, wherein at least one of the weft set or
the warp set are made of polyester.
6. The material of claim 1, wherein each pair of adjacent warp
yarns passes under only non-adjacent weft yarns.
7. The material of claim 1, wherein the light excluding coating
includes at least one additional layer.
8. The material of claim 1, wherein the light excluding coating is
flame retardant.
9. The material of claim 8, wherein the light excluding coating
comprises acrylic.
10. The material of claim 1, further comprising: a flock layer on
an outer surface of the light excluding coating.
11. The material of claim 1, further comprising: a water repellant
agent on the second surface of the woven fabric.
12. The material of claim 1, further comprising: a topical flame
retardant agent on the second surface of the woven fabric.
13. A method of making a blackout material comprising: weaving a
woven fabric including a weft set and a warp set, the weft set
being black, the woven fabric including a first surface and a
second surface; applying a light excluding coating on the second
surface of the woven fabric; and binding the light excluding
coating to the woven fabric, wherein more than 50% of the second
surface comprises the weft set.
14. The method of claim 13, wherein weaving includes floating each
of the warp yarns over four weft yarns before passing under one of
the weft yarns.
15. The method of claim 13, wherein applying a light excluding
coating comprises applying a first black coating layer and applying
a second coating layer.
16. The method of claim 13, wherein binding includes exposing the
woven fabric and light excluding coating to a calendar
operation.
17. The method of claim 13, further comprising: applying a flock
layer to an outer surface of the light excluding coating.
18. The method of claim 17, wherein the flock layer is
electrostatically applied to the outer surface of the light
excluding coating.
19. The method of claim 13, further comprising: applying a water
repellant agent to the woven fabric before applying the light
excluding coating.
20. The method of claim 13, further comprising: applying a topical
flame retardant agent to the woven fabric before applying the light
excluding coating.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of U.S. patent application
Ser. No. 15/711,543 filed Sep. 21, 2017 (pending), the disclosure
of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to blackout material
and to methods of making same.
BACKGROUND OF THE INVENTION
[0003] Conventional draperies are primarily designed for style and
appearance and are generally made from premium fabrics of various
colors and designs. However, such fabrics are generally ineffective
for preventing a substantial quantity of light from penetrating
into a room. Blackout draperies and drapery linings are typically
used by hotels and motels in order to ensure that guest rooms can
be maintained substantially dark at all times of the day. Blackout
draperies are also used residentially where the amount of light
penetration into a bedroom at night may be considerable due to
sources such as street lights, light from adjacent buildings, and
automobile headlights. Blackout draperies or drapery linings are
generally made of a woven textile substrate. The substrate is also
coated with one or more layers of an acrylic latex based compound
or foam, treated with resins such as water repellent, with an
adhesive compound, or with fire-retardant materials, or with
selected combinations. For many applications, it is essential that
the blackout draperies or drapery linings are flame retardant.
Flame retardancy is usually achieved by application of a suitable
coating.
[0004] However, conventional blackout fabrics present numerous
disadvantages. For example, blackout fabrics are often bulky and
stiff due to their manufacture. Additionally, such blackout fabrics
drape poorly and have a high cost of production. Further, to
provide a blackout fabric without pin holes through which light
passes, the material must be of a plain, flat weave. This limits
the amount of design and texture of the face fabric.
[0005] Therefore, there is a need for an improved blackout material
that addresses these problems.
SUMMARY OF THE INVENTION
[0006] One objective of the present invention is to provide an
effective blackout material for preventing a desired amount of
light from passing through the material. Other objectives are to
reduce the costs of making such material and to provide a woven
textured material with surface interest.
[0007] According to one embodiment of the present invention, a
blackout material comprises a woven fabric including a weft set
including a plurality of black weft yarns and a warp set including
a plurality of warp yarns. The woven fabric has a first surface and
a second surface, and more than 50% of the first surface comprises
the warp set.
[0008] According to one embodiment of the present invention, a
method of making a blackout material comprises weaving a woven
fabric including a weft set and a warp set, the weft set being
black, the woven fabric including a first surface and a second
surface. More than 50% of the first surface comprises the warp
set.
[0009] These and other objects and advantages of the present
invention will be apparent from the following detailed description
of the embodiments which are illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a front view of a woven fabric according
to an embodiment of the present invention.
[0011] FIG. 2A illustrates a cross-sectional view of the woven
fabric taken along the line 2A-2A of FIG. 1.
[0012] FIG. 2B illustrates a cross-sectional view of the woven
fabric taken along the line 2B-2B of FIG. 1.
[0013] FIG. 3 is an interlacing diagram showing a face surface of
the woven fabric of FIG. 1.
[0014] FIG. 4 is a cross-sectional view of a coated blackout
material according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0015] Referring to the drawings, and particularly FIGS. 1-4, a
blackout material 10 is illustrated according to an embodiment of
the present invention. The blackout material 10 includes a woven
fabric 12 that includes a weft set 14 and a warp set 16. The weft
set 14 includes a plurality of weft yarns used in weaving that are
oriented in the cross machine direction of the weaving loom. The
weft set 14 includes black weft yarns that create light exclusion
properties. The warp set 16 includes a plurality of warp yarns used
in weaving that are oriented in the machine direction of the
weaving loom. The weft yarns are at a right angle relative to the
warp yarns.
[0016] With reference to FIGS. 1-3, the set of warp yarns 16 are
selectively interlaced with the set of weft yarns 14 using a
weaving system such that the woven fabric 12 is warp-faced. In
other words, the set of warp yarns 16 are selectively interlaced
with the set of weft yarns 14 such that a face surface 18 is
predominantly composed of the set of warp yarns 16 and a back
surface 20 is predominantly composed of the set of weft yarns 14.
In various embodiments, the weft set 14 may form more than 50%,
more than 60%, more than 70%, more than 80% of the back surface 20.
The woven fabric 12 includes long, floating black yarns and is
tightly paralleled. The yarn characteristics and weave structure
may create a smooth back surface 20 for improved coating adherence
and blackout quality.
[0017] Still referring to FIGS. 1-3, in an embodiment, a weaving
system includes a repeating pattern 22 that is 5 weft yarns by 5
warp yarns. The set of warp yarns 16 may be selectively interlaced
with the set of weft yarns 14 such that a first warp yarn 16a may
float over four weft yarns before passing under a first weft yarn
14a. Second and third warp yarns 16b, 16c also float over four weft
yarns before passing under second and third weft yarns 14b, 14c.
The second warp yarn 16b is adjacent to the first warp yarn 16a,
and the second weft yarn 14b is separated by two weft yarns from
the first weft yarn 14a. The third warp yarn 16c is adjacent to the
second warp yarn 16b, and the third weft yarn 14c is adjacent to
the first weft yarn 14a.
[0018] The characteristics of the weft and warp yarns may vary. For
example, the size of the weft yarn may be, without limitation, 50D,
75D, 100D, 150D, 200D, 250D, 300D, and 450D. For example, the warp
yarn sizes may include, without limitation, 50D, 75D, 100D, 150D,
200D, 250D, 300D, 450D, and 600D. Further, the warp yarn may be
dyed or printed. The fiber material or blend of the weft and warp
yarns may vary. The weft and/or warp yarn may be made of, without
limitation, polyester, cotton, linen, rayon, viscose, bamboo,
nylon, polyamide, polypropylene, or a combination thereof. The weft
and/or warp yarn may be traditional yarn, flame retardant (FR)
treated yarn, or inherently flame retardant (IFR) yarn (e.g.,
polyester).
[0019] The blackout material 10 may be constructed in different
configurations of warp and weft yarn and weaving techniques. For
example, the appearance of the weave may be, without limitation,
plain, box, dobby, jacquard, satin, knit, linen, brushed, textured,
etc. Further, the number of yarns per inch in each of the weft set
14 and the warp set 16 may vary with the desired fabric appearance.
Although only one weft set 14 and one warp set 16 is shown, the
blackout material 10 may include one or two weft sets 14 and one or
two warp sets 16 depending on desired surface appearances. Further,
to achieve a variety of decorative fabric surfaces, the blackout
material 10 may be woven with texture patterns or with use of warp
yarn characteristics such as slub yarn, flat yarn, brushed yarn,
yarns of varied thickness or texture, and various fiber blends. The
blackout material 10 may be used in draperies, drapery linings, or
roller shade products.
[0020] With reference to FIG. 4, in an embodiment, the blackout
material 10 is constructed with the woven fabric 12 and a light
excluding coating 24 on the surface 20 of the woven fabric 12. The
light excluding coating 24 includes a first coating layer 26 and a
second coating layer 28. The colors of the coating layers 26, 28
may vary. For example, in an embodiment, the first coating layer 26
is black. In an embodiment, the second coating layer 28 is white or
another light color, such as ivory, ecru, etc. Further, it should
be recognized that the coating layers 26, 28 may have other colors
depending on the desired appearance of the blackout material 10.
One or more layers 26, 28 of the light excluding coating 24 may
optionally be flame retardant (FR). In addition to the color, the
composition of the layers 26, 28 may differ. The material for the
light excluding coating 24 may include, without limitation, one or
more of acrylic, titanium dioxide, flame retardant agents, such as
decabromodiphenyl ethane (DBDPE) and antimony (III) oxide, and
other compound agents. Further, the material for the light
excluding coating 24 may be foam. Although two coating layers are
shown, it should be recognized that the light excluding coating 24
may include only one layer (e.g., for use in residential
applications) or more than two layers (e.g., three, four, etc.).
Each coating layer may have a weight of from 35 to 90 gsm. For
example, an initial coating layer (not shown) may be applied to the
woven fabric 12 before the black coating layer 26. The blackout
material 10 may have a reduced basis weight and thinner profile
compared to conventional blackout material, which creates an
aesthetically attractive product.
[0021] With further reference to FIG. 4, the light excluding
coating 24 may optionally be flocked. For example, a flock layer 30
may be electrostatically applied to an outer surface 32 of the
light excluding coating 24. The flock layer 30 may be made of, for
example, Rayon, polyester, cotton. The flock layer 30 may be
applied using other techniques and materials known in the art.
[0022] Still referring to FIG. 4, additional coatings 34 may be
applied to the woven fabric 12. In the illustrated embodiment, the
additional coatings 34 are applied to the face surface 18 of the
woven fabric 12. Alternatively, the additional coatings 34 may be
applied to both surfaces 18, 20 of the woven fabric 12. For
example, the woven fabric 12 may be immersed in a coating material.
The additional coatings may include, without limitation, a water
repellant treatment, soil and stain resistance treatments,
antimicrobial treatment, etc. In an embodiment, a water repellant
agent may be applied and cured before the application of the light
excluding coating 24. A suitable water repellant agent may include
silicon. For example, the coating 34 may include a fabric softener,
which provides a water repellant finish. In another embodiment,
some applications of the blackout material 10 may require a topical
FR treatment prior to applying the light excluding coating 24 in
order to meet fire or safety codes.
[0023] A method of making the blackout material 10 is now
described. The woven fabric 12 is woven using, for example, black
weft yarn and white warp yarn. The woven fabric 12 may be
constructed on typical water jet, air jet, rapier loom, or
projectile loom for example. The woven fabric 12 may optionally be
prepared for application of the light excluding coating 24 by
applying a water repelling agent 34 to woven fabric 12. For
example, a water repelling agent 34 may be topically applied to
both surfaces 18, 20 of the woven fabric 12. Depending on the
material, the additional coatings 34 may be cured. A first, black
coating layer 26 is applied to the surface 20 of the woven fabric
12, followed by application of the second, white coating layer 28.
During the application of the second coating layer 28, the blackout
material 10 is exposed to a calendar operation and curing process
to bind the coating layers 26, 28 together. The crushing effect of
the calendar and the heat and dwell time in a finishing frame
result in the binding of the woven fabric 12 to the light excluding
coating 24 and the adhering of all coating layers 26, 28 together
(i.e., the binding agents in the light excluding coating 24 are
chemically cross-linked).
[0024] Although only certain exemplary embodiments of this
invention have been described in detail above, those skilled in the
art will readily appreciate that various modifications can be made
without departing from the principles of the present invention.
Accordingly, all such modifications are intended to be included
within the scope of this invention.
* * * * *