U.S. patent application number 17/570609 was filed with the patent office on 2022-04-28 for fabric having a backing material for a covering for an architectural opening.
The applicant listed for this patent is Hunter Douglas, Inc.. Invention is credited to David Lynch, Erick A. Phillips, Paul G. Swiszcz, Stephen T. Wisecup.
Application Number | 20220127904 17/570609 |
Document ID | / |
Family ID | 1000006075604 |
Filed Date | 2022-04-28 |
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United States Patent
Application |
20220127904 |
Kind Code |
A1 |
Lynch; David ; et
al. |
April 28, 2022 |
FABRIC HAVING A BACKING MATERIAL FOR A COVERING FOR AN
ARCHITECTURAL OPENING
Abstract
An architectural covering with an operable vane having a fabric
backing is provided. The vane may include a vane fabric and a
backing material connected to the vane fabric by a layer of
adhesive. The backing material may increase a machine-direction
stiffness of the vane while slightly affecting a cross-direction
stiffness of the vane. As such, the vane may have increased
stiffness in its machine direction while simultaneously remaining
flexible in its cross direction.
Inventors: |
Lynch; David; (Centennial,
CO) ; Phillips; Erick A.; (Denver, CO) ;
Swiszcz; Paul G.; (Niwot, CO) ; Wisecup; Stephen
T.; (Niwot, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hunter Douglas, Inc. |
Pearl River |
NY |
US |
|
|
Family ID: |
1000006075604 |
Appl. No.: |
17/570609 |
Filed: |
January 7, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15738887 |
Dec 21, 2017 |
11242711 |
|
|
PCT/US2016/039335 |
Jun 24, 2016 |
|
|
|
17570609 |
|
|
|
|
62185326 |
Jun 26, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 5/26 20130101; E06B
9/24 20130101; B32B 5/12 20130101; B32B 2307/54 20130101; B32B
2262/0276 20130101; B32B 7/12 20130101; B32B 5/024 20130101; B32B
2307/414 20130101; E06B 9/42 20130101; B32B 2305/188 20130101; B32B
2419/00 20130101; B32B 5/04 20130101; B32B 2262/04 20130101; B32B
27/12 20130101; B32B 2262/0253 20130101; B32B 5/02 20130101; B32B
5/24 20130101; B32B 27/36 20130101; B32B 2307/546 20130101; E06B
2009/2405 20130101; B32B 7/03 20190101; B32B 2262/14 20130101; B32B
7/022 20190101; E06B 9/386 20130101; B32B 2307/718 20130101; B32B
5/08 20130101; B32B 2305/20 20130101; B32B 2262/062 20130101; E06B
2009/1516 20130101; B32B 2367/00 20130101; E06B 9/262 20130101;
B32B 2250/03 20130101; B32B 2398/20 20130101; E06B 9/264 20130101;
E06B 9/266 20130101; E06B 9/34 20130101; B32B 2262/0246 20130101;
B32B 27/304 20130101 |
International
Class: |
E06B 9/262 20060101
E06B009/262; B32B 7/12 20060101 B32B007/12; E06B 9/386 20060101
E06B009/386; B32B 5/02 20060101 B32B005/02; B32B 27/12 20060101
B32B027/12; E06B 9/266 20060101 E06B009/266; E06B 9/42 20060101
E06B009/42; E06B 9/24 20060101 E06B009/24; E06B 9/264 20060101
E06B009/264; B32B 7/03 20060101 B32B007/03; B32B 5/04 20060101
B32B005/04; E06B 9/34 20060101 E06B009/34; B32B 7/022 20060101
B32B007/022; B32B 5/12 20060101 B32B005/12; B32B 27/36 20060101
B32B027/36 |
Claims
1-41. (canceled)
42. A fabric laminate for an architectural covering, the fabric
laminate comprising: a fabric material portion having a first
stiffness in a first direction, and a second stiffness in a second
direction transverse to said first direction; and a backing
material portion adhesively bonded to said fabric material portion
such that said backing material portion and said fabric material
portion form discrete layers of the fabric laminate, wherein said
backing material portion increases said first stiffness, said
backing material portion increasing said second stiffness less than
said first stiffness so as to increase a stiffness ratio between
said first stiffness and said second stiffness; wherein: said
backing material portion comprises a plurality of fibers or
filaments oriented substantially along said first direction; and
said backing material portion has a basis weight of less than 20
grams per square meter (gsm).
43. A fabric laminate according to claim 42, wherein: said first
direction extends along a machine direction of said fabric material
portion; and said second direction extends along a cross direction
of said fabric material portion.
44. A fabric laminate according to claim 42, wherein: said fabric
material portion has a first stiffness ratio biased in one of said
first direction or said second direction; and said backing material
portion causes said fabric laminate to have a second stiffness
ratio biased in the other of said first direction or said second
direction.
45. A fabric laminate according to claim 42, wherein said stiffness
ratio is greater than approximately 1.5:1.
46. A fabric laminate according to claim 42, wherein said backing
material portion comprises a non-woven web.
47. A fabric laminate according to claim 46, wherein said nonwoven
web comprises a spunbond web, a meltblown web, a carded web, a
hydroentangled web, an airlaid web, a wetlaid web, or a coform
web.
48. A fabric laminate according to claim 42, wherein said backing
material portion comprises a woven material.
49. A fabric laminate according to claim 42, wherein said backing
material portion has a basis weight of less than 17 gsm.
50. A fabric laminate according to claim 42, wherein said fabric
material portion has an elongation in said first direction and
wherein said backing material portion bonded to said fabric
material portion decreases said elongation in said first direction
at least about 20%.
51. A fabric laminate according to claim 42, wherein the backing
material portion bonded to said fabric material portion increases
an opacity of said fabric material portion by less than about
30%.
52. A fabric laminate according to claim 51, wherein said fabric
material portion has an optical density (opacity) of from about 0.2
to about 2.
53. A fabric laminate according to claim 42, wherein said fabric
material portion comprises one of a woven material, a non-woven
material, or a knit material.
54. A fabric laminate for an architectural covering, the fabric
laminate comprising: an outer material having a first stiffness in
a first direction, and a second stiffness in a second direction
transverse to said first direction; and a backing material portion
formed directly on said outer material, said backing material
portion comprising a plurality of substantially unidirectionally
oriented fibers or filaments applied directly on a surface of said
outer material, said backing material portion having a basis weight
of less than 20 grams per square meter (gsm); wherein said backing
material portion increases said first stiffness, said backing
material portion increasing said second stiffness less than said
first stiffness so as to increase a stiffness ratio between said
first stiffness and said second stiffness.
55. A fabric laminate according to claim 54, wherein: said first
direction extends along a machine direction of said outer material;
and said second direction extends along a cross direction of said
outer material.
56. A fabric laminate according to claim 54, wherein: said outer
material has a first stiffness ratio biased in one of said first
direction or said second direction; and said backing material
portion causes said fabric laminate to have a second stiffness
ratio biased in the other of said first direction or said second
direction.
57. A fabric laminate according to claim 54, wherein said stiffness
ratio is greater than approximately 1.5:1.
58. A fabric laminate according to claim 54, wherein said backing
material portion increases the first stiffness in the first
direction at least about 1.5 times greater than an effect on said
second stiffness in said second direction.
59. A fabric laminate according to claim 54, wherein said backing
material portion comprises a non-woven web formed directly on said
outer material,
60. A fabric laminate according to claim 54, wherein said outer
material comprises one of a woven material, a non-woven material,
or a knit material.
61. A fabric laminate according to claim 54, wherein said backing
material portion has a basis weight of less than 15 gsm.
Description
RELATED APPLICATIONS
[0001] The present application is based upon and claims priority to
U.S. Provisional Patent Application Ser. No. 62/185,326, filed on
Jun. 26, 2015, and claims priority to PCT application No.
PCT/US2016/039335, filed on Jun. 24, 2016 which is incorporated
herein by reference.
TECHNICAL FIELD
[0002] This invention relates generally to coverings for
architectural openings, and more specifically to a fabric having a
backing material for a covering for an architectural opening.
BACKGROUND
[0003] Coverings for architectural openings, such as windows,
doors, archways, and the like, have taken numerous forms for many
years. The fabrics used for the coverings have presented various
challenges associated with a given operation of the covering.
Generally, it is desirable for the fabric of the covering to
present an aesthetically pleasing appearance. For instance, it may
be desirable for the covering to have a generally uniform contour,
without undulations, puckering, or other contour irregularities
caused by the manner in which the fabric is falling, lays, or
otherwise hangs in position (in contrast with surface texture or
other features of the fabric itself). Different coverings operate
in different manners which move the fabric forming the covering
element into extended or retracted positions (respectively covering
or uncovering the architectural opening) in different manners. For
instance, different coverings fold the fabric of the covering
element along a given direction to retract the covering. More
particularly, some coverings include operable vanes that are
movable between open and closed positions. Current trends demand
the use of fabrics not previously used in vane construction (e.g.,
lightly woven fabrics and fabric constructions that have an
inherent high level of drape or other physical characteristics not
amenable to the operable vane or a desired end use). Current
manufacturing methods for making operable vanes of these desired
fabrics have not proven sufficient to provide a consistent,
preferably smooth appearance of the vane. For example, some vanes
have inherent physical properties that offer poor support for
uniformity and flatness in appearance. This creates a vane
appearance, with creases, puckering or other undesirable
non-uniform undulations and can increase the risk of significant
capital investment in an unsuccessful product, and may lead to
reduced quality and/or market share of the covering.
BRIEF SUMMARY
[0004] The present disclosure generally provides a fabric that has
a backing so that the backed fabric offers improvements or an
alternative to existing arrangements of the fabric of the shade
portion of a covering for an architectural opening (herein
"architectural opening covering" for the sake of convenience
without intent to limit). More particularly, the present disclosure
generally provides a fabric with a backing coupled thereto to
modify the stiffness of the fabric along at least a first direction
of the fabric to facilitate use of the fabric in a selected shade
configuration. In one embodiment, the backing modifies the
stiffness of the fabric to permit bending of the fabric about a
first axis more readily than about a second axis perpendicular to
the first axis. The backing may or may not modify the stiffness
about the second axis.
[0005] In one embodiment, the fabric may be used to form an
architectural opening covering having a shade employing movable
vanes. The vanes formed in accordance with principles of the
present invention include an outer fabric and an inner backing
material connected together. The backing material is designed such
that the backing material satisfies the stiffness requirements for
use in a vane by, for example, increasing the stiffness of the vane
along the length of the vane (extending across the width of the
architectural opening covering) while negligibly affecting the
stiffness of the vane perpendicular to the axis about which the
vane is to bend to open and close the vane to allow viewing through
the shade. Thus, according to the present disclosure, the vane is
stiffer along its length but remains flexible about its height,
thereby providing a flexible vane that has a consistent, preferably
smoothly contoured appearance.
[0006] This summary of the disclosure is given to aid
understanding, and one of skill in the art will understand that
each of the various aspects and features of the disclosure may
advantageously be used separately in some instances, or in
combination with other aspects and features of the disclosure in
other instances. Accordingly, while the disclosure is presented in
terms of embodiments, it should be appreciated that individual
aspects of any embodiment can be claimed separately or in
combination with aspects and features of that embodiment or any
other embodiment.
[0007] The present disclosure is set forth in various levels of
detail in this application and no limitation as to the scope of the
claimed subject matter is intended by either the inclusion or
non-inclusion of elements, components, or the like in this summary.
In certain instances, details that are not necessary for an
understanding of the disclosure or that render other details
difficult to perceive may have been omitted. It should be
understood that the claimed subject matter is not necessarily
limited to the particular embodiments or arrangements illustrated
herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated into and
constitute a part of the specification, illustrate embodiments of
the disclosure and, together with the general description above and
the detailed description below, serve to explain the principles of
these embodiments.
[0009] FIG. 1 is a front perspective view of a covering in
accordance with an embodiment of the present disclosure.
[0010] FIG. 2 is a front perspective view of a vane of the covering
of FIG. 1 and in an open configuration in accordance with an
embodiment of the present disclosure.
[0011] FIG. 3 is a front perspective view of a vane without a
fabric backing and in an open configuration.
[0012] FIG. 4 is an enlarged detail view of the vane of FIG. 2 in
accordance with an embodiment of the present disclosure.
[0013] FIG. 5 is an enlarged, exploded detail view of the vane of
FIG. 2 in accordance with an embodiment of the present
disclosure.
[0014] FIG. 6 is a comparative view of a vane having a backing
material and a vane without a backing material in accordance with
an embodiment of the present disclosure. The two vanes are shown in
a flat, or closed, configuration.
[0015] FIG. 7 is a schematic view of a method of manufacturing a
vane in accordance with an embodiment of the present
disclosure.
DETAILED DESCRIPTION
[0016] It is to be understood by one of ordinary skill in the art
that the present discussion is a description of exemplary
embodiments only, and is not intended as limiting the broader
aspects of the present disclosure.
[0017] In the figures that follow, one embodiment of the present
disclosure is described that comprises a shade including a support
sheet and a plurality of horizontally-extending vanes that can move
relative to the support sheet. It should be understood, however,
that the figures are provided for purposes of explanation and in no
way limit the different embodiments of the present disclosure. The
present disclosure, for instance, is applicable to any suitable
window covering product. For instance, roman-type shades, honeycomb
shades, vertical shades, blinds, and the like, can also be made in
accordance with the present disclosure. For example, in one
embodiment, the present disclosure is directed to a shade comprised
of a cover fabric in conjunction with a backing material in
accordance with the present disclosure as described above.
[0018] FIG. 1 is a front perspective view of an illustrative
embodiment of a covering 100 utilizing a backed fabric formed in
accordance with principles of the present disclosure. As
illustrated, the covering 100 is shown in a fully-extended, open
configuration in accordance with some embodiments of the present
disclosure. The illustrative covering 100 includes a head rail 102,
a bottom rail 104, and a shade 106 extending between the head rail
102 and the bottom rail 104. The illustrative shade 106 includes a
vertically-extending support sheet 108 and a plurality of
horizontally-extending vanes 110 connected to the support sheet
108. The support sheet 108 in the illustrative embodiment of FIG. 1
is in the form of a flexible sheet of fabric, which may be of a
substantially rectangular configuration having top and bottom edges
107a, 107b, and left and right side edges 109a, 109b. As shown, the
support sheet 108, which may be constructed of knit, woven, or
nonwoven materials of various levels of transparencies, is
vertically-suspended from the head rail 102 along its top edge
107a. In some embodiments, the support sheet 108 may be suspended
from a generally cylindrical roller rotatably mounted within the
head rail 102 for selective reversible rotary movement about a
horizontal central axis. The structure of the roller may allow the
shade 106 to be retracted around and unwound from the roller as the
roller is reversibly rotated. The structure from which the shade
106 is suspended, retracted, and extended may take on forms other
than the roller in the head rail 102 as described above. Attached
to the bottom edge 107b of the support sheet 108 is the bottom rail
104, which is an elongate member that may be weighted and generally
maintains the shade 106 in a taut condition at its desired level of
extension.
[0019] With continued reference to FIG. 1, each of the plurality of
vanes 110 is suspended generally horizontally across a front face
112 of the support sheet 108 at vertically-spaced locations such
that the length of the vane 110 extends along the width W of the
shade 106. As shown, each vane 110 is made from resiliently
flexible material or fabric, which may be light-transmissive or
light blocking. In the illustrative embodiment of FIG. 1, each vane
110 includes a first edge 114 (e.g., an upper edge) and a second
edge 116 (e.g., a lower edge) opposite the first edge 114. The
first edge 114 of each vane 110 is attached to the front face 112
of the support sheet 108 across the width W of the support sheet
108 and at vertically-spaced locations such that the plurality of
vanes 110 hang substantially parallel to the longitudinal axis
L.sub.HR of head rail 102. The second edge 116 of each vane 110
hangs freely such that the second edge 116 of vane 110 is movable
relative to the first edge 114 of vane 110 along the front face 112
of the support sheet 108. The position of the second edge 116
relative to the first edge 114 is variable based on the desired
actuation and aesthetics of each vane 110 as it moves from its
closed to open positions.
[0020] In the closed position, each vane 110 is substantially flat
and generally parallel with the support sheet 108. In the open
position, each vane 110 has a substantial teardrop shape
cross-section and extends forwardly of the support sheet 108. In
the embodiment of FIG. 1, the vanes 110 may be positioned in any
configuration between the fully open and the fully closed
configurations to achieve substantially any desired light blocking
or occluding characteristics of the shade 106. To achieve the
desired aesthetic effect when in the closed and/or open positions,
each vane 110 includes bending properties in at least two
directions, as described below.
[0021] In the embodiment shown in FIG. 1, the covering 100 includes
operating elements 118 for moving the vanes 110 between open and
closed positions. Each operating element 118 extends along the
front face 112 of the support sheet 108 and is secured at spaced
locations along its length to the second edge 116 of each vane 110
such that if the operating element 118 is lifted, the second edge
116 of each vane 110 is lifted synchronously toward the first edge
114 of each respective vane 110 so as to define a gap between the
vanes 110 through which vision and/or light may pass. Because each
vane 110 is made of flexible material or fabric, movement of the
second edge 116 towards the first edge 114 causes the vane 110 to
bend or fold about a vane longitudinal axis L.sub.v and/or expand
away from the support sheet 108 as shown in FIG. 1, for instance.
Accordingly, transitioning the vanes 110 from a closed position to
an open position causes the cross-section of each vane 110 to
change from a generally planar configuration in the closed position
to a generally arcuate configuration in the open position. In the
illustrative embodiment of FIG. 1, the operating elements 118
slidably pass between the support sheet 108 and the first edge 114
of each vane 110, and in such locations, the first edge 114 is not
attached to the support sheet 108 to allow the operating elements
118 to move relatively between the first edge 114 and the support
sheet 108. The operating elements 118 are shown as monofilament
cords but can assume other various forms, including but not limited
to strips of fabric or other materials, cords of synthetic or
natural fibers, or other similar forms. The operating elements 118
may have a variety of cross-sections, including circular, oval,
rectangular, square, or other geometric shapes. The operating
elements 118 need not be attached to every vane 110, but instead
may be attached to specific vanes 110 that are desired to be
movable between open and closed positions. It will be appreciated
that instead of passing between the first edge 114 and the support
sheet 108, the operating elements 118 may pass through the support
sheet 108, or through the vane 110.
[0022] FIG. 2 is a front perspective view of an illustrative
embodiment of the vane 110 in accordance with principles of the
present disclosure. As shown in FIG. 2, the machine direction MD of
the fabric used to form the vane 110 is the direction in which the
fabric is processed during assembly. In the illustrative example of
FIG. 2, the machine direction MD thus extends along the length of
the vane 110 such that when the vane 110 is connected to the
support sheet 108 as part of the complete covering 100, the machine
direction MD extends along the length of the vane 110 and across
the width W of the support sheet 108 between the left and right
side edges 109a, 109b of the support sheet 108. In the illustrative
embodiment, the cross direction XD of the fabric used to form the
vane 110 extends transversely to the machine direction MD, and in
the illustrative example of FIG. 2, is thus along the height of the
vane 110. When the vane 110 is connected to the support sheet 108
as part of the complete covering 100, the cross direction XD of
each vane 110 extends vertically between the top and bottom edges
107a, 107b of the support sheet 108 (and between the first and
second edges 114, 116 of each vane 110). Although described above
as extending along the length of the vane 110 and across the width
W of the support sheet 108, it is contemplated that the machine
direction MD of the fabric used to form the vane 110 need not
correspond to the length of the vane 110, and could instead
correspond to, for example, the height of the vane 110, depending
on the design of the product in which the fabric is used. In other
words, the machine direction MD and the cross direction XD of the
fabric used to form the vane 110 may, in other configurations, be
oriented substantially perpendicular to respective machine and
cross directions MD.sub.SS, XD.sub.SS of the support sheet 108 (see
FIG. 1).
[0023] In the illustrative embodiment of FIG. 2, the stiffness of
each vane 110 in its machine direction MD and in its cross
direction XD is tailored to achieve a desired stiffness
characteristic, and thus the desired aesthetic effect, when the
vane 110 is in the closed and/or open positions. For example, the
vane 110 of FIG. 2 has sufficient stiffness in its machine
direction MD (i.e., machine-direction stiffness) to provide fabric
with a contour that has a consistent, preferably smooth appearance
throughout the vane 110 to reduce ripples 120 or undulations within
the vane 110, as explained below (see FIG. 3). Additionally, the
stiffness of the vane 110 of FIG. 2 in its cross direction XD
(i.e., cross-direction stiffness) permits the vane 110 to remain
flexible for resilient bending of the vane 110 during opening and
closing, as described above. In this manner, a greater variety of
fabrics may be used to construct the vane 110, including soft hand
fabrics not previously feasible for use in vane construction. Soft
hand fabrics refer to fabrics that are very flexible and soft to
the touch. A soft hand fabric may not possess good drape
characteristics when incorporated into a window covering. In the
exemplary embodiment of FIG. 2, the vane 110 includes an upper tab
122 and a lower tab 124, each optionally defined by respective
upper and lower creases 126, 128 or fold lines. Each tab 122 and
124 preferably folds rearwardly from the front surface of the vane.
The creases 126, 128 define the first and second edges 114, 116 of
the vane 110 (see FIG. 2). The upper tab 122 may be used for
attaching the first edge 114 of the vane 110 to the support sheet
108. Similarly, the lower tab 124 may be used for attaching the
second edge 116 of the vane 110 to the operating elements 118 to
allow for selective movement of the vane 110 between the open and
closed configurations. It will be appreciated that the tabs 122 and
124 are not a required feature of the vane 110, which may have only
one tab or no tabs.
[0024] FIG. 3 is a front perspective view of an alternative
embodiment of the vane 110' in accordance with principles of the
present disclosure. In substantially all respects, the vane 110' of
FIG. 3 is identical to the vane 110 of FIG. 2. However, as
illustrated in FIG. 3, the vane 110' does not have sufficient
stiffness in its machine direction MD to provide a fabric that has
a contour with a consistent, smooth, appearance throughout as
compared to the vane 110 illustrated in FIG. 2. Because of
insufficient stiffness in its machine direction MD, the vane 110'
of FIG. 3 includes regions of "puckering" or gathering of the
fabric to cause ripples 120, undulations, or waviness within the
vane 110' (e.g., on a surface of the vane 110'). This "puckering"
causes inconsistencies in appearance and performance of the vane
110 and may be undesirable for at least certain applications.
[0025] FIG. 4 is an enlarged detail view of an illustrative
embodiment of the vane 110 of FIG. 2 in accordance with principles
of the present disclosure. FIG. 5 is an enlarged exploded view of
the vane 110 of FIG. 4 in accordance with principles of the present
disclosure. As shown in FIGS. 4 and 5, the vane 110 includes a
fabric 130 and a backing material 132 connected to the fabric 130
(e.g., to a rear of the fabric 130) to enhance the desired
properties of the fabric 130 in a first direction (e.g., to enhance
stiffness along the length of the vane 110 extending about the
width W of the shade 106 which is not intended to bow or bend or
otherwise fold or bend), to reduce or eliminate any unintended or
incidental "puckering" or ripples 120 in the vane 110, and to
maintain the desired property of the fabric 130 in a second
direction (e.g., to maintain flexibility of the vane about the
bending axis of the vane so that the vane readily bends into an
open or closed configuration as desired).
[0026] The vane 110 may be formed as a laminate structure of the
fabric 130 and the backing material 132 (and adhesive), and may
alternatively be referenced as a "vane laminate." The fabric 130,
which may be referred to as a vane fabric, an outer fabric, a
fabric material portion, or a first material, and the backing
material 132 may be connected together by a layer of adhesive 134
(e.g., a thermoplastic adhesive) positioned between the fabric 130
and the backing material 132. Many different types and structures
of adhesive 134 can be used, which can be applied by spray,
gravure, roll coating, die cast extrusion, or by any other suitable
manner. Selection of adhesive type and/or structure depends upon
the desired characteristics and/or properties of the formed vane
110. For example without limitation, a crosslinking adhesive may be
used for high temperature end use applications, and a thermoplastic
adhesive may be selected for moderate temperature end use
applications. In each of the embodiments described herein, the
adhesive 134 may or may not be relatively inert to the physical
characteristics (e.g., stiffness) of the vane laminate. In the
illustrative embodiment of FIGS. 4 and 5, the layer of adhesive 134
is a melt blown adhesive sprayed onto the web structure of at least
one of the fabric 130 and the backing material 132 and solidifies
with little to no shrinkage. Although FIGS. 4 and 5 depict the
layer of adhesive 134 as a continuous layer (in both cross-section
and along its length), the layer of adhesive 134 may be a
discontinuous web or dot structure. In such embodiments, a section
view of the layer of adhesive 134 may appear discontinuous or
continuous depending on the section line. In certain embodiments,
the type of adhesive used, the manner in which the adhesive is
applied, and the amount of adhesive applied in between the backing
material in the fabric can further influence the stiffness
properties, particularly the stiffness ratio, of the resulting
laminate. For example, in one embodiment, the adhesive can also be
applied in a unidirectional manner that cooperates with the backing
material in increasing the stiffness ratio. In one embodiment, the
adhesive may be applied as fibers or filaments. For instance,
unidirectionally oriented meltblown fibers may be used as the
adhesive.
[0027] Applying the adhesive in a discontinuous manner may, in some
embodiments, better preserve the flexibility of the resulting
laminate. For example, as described above, the adhesive may be
applied in a discontinuous pattern, such as a dot pattern. In this
embodiment, the adhesive may cover less than 80%, such as less than
about 70%, such as less than about 60%, such as less than about
50%, such as less than about 40%, such as less than about 30% of
the surface area of the fabric. The adhesive generally covers
greater than about 10% of the surface area, such as greater than
about 20% of the surface area, such as greater than about 30% of
the surface area.
[0028] According to the present disclosure, almost any type of
fabric 130, particularly fabrics with a soft hand, regardless of
its inherent properties, may be used for a desired purpose (e.g.,
any of a variety of shades 106 or vanes 110 with different bending
and/or draping requirements) by application of the backing material
132 thereto to modify the stiffness (and stabilize elongation to
improve manufacturing versatility) of the fabric 130 in the desired
manner without otherwise significantly affecting the other
properties of the fabric 130, such as thickness, weight, and/or
light transmissivity of the fabric 130. Thus, the backing material
132 may be applied to a variety of fabrics 130 to modify the
stiffness ratio of the fabric 130 to achieve a desired flexibility
and stiffness characteristics of the laminate for the ultimate
application and use of the fabric, such as, without limitation, as
a vane in a shade. It is contemplated that the backing material 132
may modify or enhance, based on its inherent physical properties
and application, the properties of the fabric 130 in substantially
any direction based on a desired end use of the vane laminate.
However, for ease of reference and as an illustrative example, the
present disclosure describes the stiffness and flexibility of the
fabric 130 in terms of machine direction and cross direction. As
noted above, the machine direction MD and cross direction XD
typically correspond, in the illustrative embodiment of FIG. 4, to
length and height, respectively, of the fabric 130 used to form the
vane 110. It is contemplated, however, that the machine direction
and the cross direction of the fabric 130 do not necessarily
correspond to the length and height of the vane 110, respectively,
when the vane 110 is implemented in the shade 106. Thus, it should
be appreciated that the specific orientations described herein
(e.g., machine direction and cross direction) are for illustration
purposes and for ease of reference and do not define the scope of
the present disclosure.
[0029] The fabric 130 and the backing material 132 may be made of
any suitable material, including but not limited to woven or
nonwoven fabrics of natural or man-made materials, including vinyl,
plastic, or other such materials. In the illustrative embodiments
of FIGS. 4 and 5, however, the backing material 132 is a
directional nonwoven material, although non-directional woven and
nonwoven fabrics or materials are also contemplated. The backing
material 132, which may be referred to as an inner fabric, a
backing material portion, or a second material and may be sheer,
may be formed from a plurality of fiber segments oriented primarily
along the longitudinal axis L.sub.V of the vane 110 (i.e., along
the machine direction MD of the vane 110). In some embodiments, the
backing material 132 may be formed from aligned continuous fibers,
yarns, and/or carded, aligned staple fibers that have some fiber
overlapping. Additionally or alternatively, the backing material
132 may be formed from a plurality of generally parallel rows, each
row including a plurality of longitudinal fibers substantially
oriented and overlapping along the row, the rows extending along
the longitudinal axis L.sub.V of the vane 110 with little or no
cross-linking between the rows. Thus, in the illustrative
embodiments of FIGS. 4 and 5, the backing material 132 may have a
"grain" or striated appearance in one direction (e.g., in the
machine direction MD of the vane 110) such that the fibers appear
to be in a "combed" web structure.
[0030] Accordingly, the fiber orientation of the backing material
132 enhances or increases, sometimes significantly, for instance by
multiples, the machine-direction stiffness of the vane 110 about an
axis, such as in its machine direction MD. Additionally, because
the fibers of the backing material 132 extend mainly along the
machine direction MD of the vane 110, with little cross-linking
between rows, the backing material 132 maintains as constant and/or
slightly affects the cross-direction stiffness of vane 110, thus
maintaining the bending properties of the vane 110 in its cross
direction XD. In some embodiments, the backing material 132 may be
configured with increased cross-linking between rows to achieve a
more equal machine direction to cross direction fiber distribution
such that the vane 110 achieves a desired stiffness to operate
properly for a particular application.
[0031] In one embodiment, the backing material 132 comprises a
meltspun web or a laminate containing a meltspun web. In accordance
with the present disclosure, the meltspun web includes fibers that
are oriented in one direction for increasing the stiffness of the
material in the direction of orientation. The meltspun web, for
instance, may comprise a spunbond web, a meltblown web, a
hydroentangled web, a coform web, and the like. The meltspun web
can be made exclusively from continuous filaments, can be made
exclusively from staple fibers, or can be comprised of a
combination of continuous filaments combined with staple
fibers.
[0032] In addition to meltspun webs, the backing material 132 may
comprise any other suitable nonwoven web or laminate. The nonwoven
web, for instance, may comprise a wetlaid web, an airlaid web, a
bonded carded web, and/or a crosslapped web in which the web
contains fibers that have been unidirectionally oriented.
[0033] The backing material 132 can have various different
characteristics and properties depending upon the particular
application, as long as the material is capable of being adhered to
another fabric and includes unidirectionally oriented fibers and/or
greater stiffness properties in one direction. For example, in
certain embodiments, the backing material 132 can have a relatively
light basis weight. Using a backing material with a relatively
light basis weight can provide various advantages and benefits. For
instance, a relatively light basis weight material can provide the
necessary stiffness adjustment to a fabric without significantly
interfering with the opacity characteristics of the fabric. In
addition, it was discovered that lightweight basis materials can
dramatically and unexpectedly improve the elongation properties of
a fabric. When using a relatively light basis weight material, the
backing material can have a basis weight of generally less than
about 20 gsm, such as less than about 17 gsm, such as less than
about 15 gsm, such as less than about 13 gsm, such as less than
about 10 gsm, such as less than about 8 gsm, such as less than
about 5 gsm, such as even less than about 3 gsm. The backing
material generally has a basis weight greater than 1 gsm.
[0034] In an alternative embodiment, the backing material can also
have a relatively heavy basis weight. For instance, the basis
weight of the backing material can be greater than about 20 gsm,
such as greater than about 30 gsm, such as greater than about 40
gsm, such as greater than about 50 gsm, such as greater than about
60 gsm. The basis weight of the backing material is generally less
than about 150 gsm, such as less than about 120 gsm. Heavier basis
weight materials may be desired in certain applications, especially
when producing laminates that are designed to block light.
[0035] The backing material 132 can also be produced from various
different fibers and filaments. In one embodiment, for instance,
the backing material is made exclusively from synthetic fibers,
filaments, or a combination of fiber and filaments. For example,
the backing material can be made from polyester, a polyolefin such
as polyethylene or polypropylene, an acrylic, or mixtures thereof.
The backing material can also contain other fibers, including
cellulose fibers, regenerated cellulose fibers such as rayon,
cotton fibers, and the like.
[0036] One example of a suitable backing material 132 includes
MILIFE.RTM. T-Grade MD-only nonwoven, a 100% polyester nonwoven
material manufactured by JX Nippon. MILIFE.RTM. T-Grade MD-only
nonwoven comes in a variety of grades, including T10, which has a
basis weight of 10 g/m.sup.2 and a tensile strength of 50 N/50 mm.
Other fabrics or materials may be utilized for the backing material
132 depending on the particular application, including fabrics
having a variety of ratios between machine direction and cross
direction fiber distributions operable to affect the physical
properties of the vane 110 in a low profile manner.
[0037] In an alternative embodiment, the backing material 132
comprises a unidirectionally oriented hydroentangled web. In one
embodiment, the hydroentangled web can have a relatively low basis
weight such as less than about 20 gsm, such as less than about 17
gsm, such as less than about 15 gsm, such as less than about 13
gsm, such as less than about 10 gsm, such as less than about 8 gsm.
The basis weight is generally greater than about 2 gsm, such as
greater than about 5 gsm, such as greater than about 7 gsm.
[0038] In one embodiment, the hydroentangled web is made from a
precursor web comprising a spunbond web made from continuous
polymeric filaments. The precursor or spunbond web is placed on a
foraminous surface and subjected to the hydroentangling process.
Hydroentanglement is affected by application of high pressure
liquid streams to the web. Filaments of the web are rearranged on
the fabric forming surface of the device. In one embodiment, the
forming surface and the liquid streams act in conjunction to
rearrange the filaments of the web and to create a unidirectionally
oriented web that has sufficient integrity and strength for
handling. In order to form the web, filaments can be used having a
really low denier. For instance, the filaments can have a denier of
less than about 3.0, such as less than about 2.5, such as less than
about 2.0, such as less than about 1.5, such as less than about
1.0, such as less than about 0.8, such as less than about 0.5. The
denier of the filaments is generally greater than about 0.2, such
as greater than about 0.5, such as greater than about 1.0.
[0039] In one embodiment, the spunbond precursor web comprises a
web that has been lightly bonded which allows the high pressure
fluid streams to break or disrupt the bonds without breaking the
continuous filaments. As a consequence, a relatively low basis
weight web can be formed made from substantially continuous
filaments that have been unidirectionally oriented. If desired,
after hydroentangling, the spunbond and hydroentangled web can be
subjected to further bonding processes, such as thermal
bonding.
[0040] In an alternative embodiment, a unidirectionally oriented
hydroentangled web may be used as the backing material which
comprises two or more webs that have been hydroentangled together.
For example, in this embodiment, a unidirectionally oriented
nonwoven web can be hydroentangled with one or more other nonwoven
webs to result in a unidirectionally oriented structure that has
sufficient strength and integrity for handling and incorporation
into fabric laminates.
[0041] The unidirectionally oriented web that is subjected to
hydroentangling can be made using different processes and
techniques. In one embodiment, for instance, the web may comprise a
meltspun web, such as a spunbond or meltblown web, that has been
stretched in one direction for unidirectionally orienting the
fibers. The nonwoven web can be stretched, for instance, using
rollers that operate at different speeds. Alternatively, stretching
can occur on a tenter frame. The draw ratio of the unidirectionally
oriented nonwoven fabric, for instance, can be from about 5 to
about 20, such as from about 8 to about 12. The nonwoven web can be
made from staple fibers, continuous filaments, or mixtures thereof.
The fibers and filaments can have a denier of from about 0.01 to
about 10, such as from about 0.03 to about 5.
[0042] The unidirectionally oriented web is then hydroentangled
with at least one other nonwoven web. The nonwoven web can comprise
any suitable fiber web or nonwoven fabric. For instance, in one
embodiment, the unidirectionally oriented web is hydroentangled
with a carded web. The carded web can be made from staple fibers
having any of the denier ranges described above. The two webs are
then hydroentangled together in order to produce a nonwoven
material not only having unidirectionally oriented fibers but also
having sufficient integrity and strength to be later processed. The
resulting nonwoven material can have a basis weight of from about 8
gsm to about 150 gsm. In one embodiment, for instance, the material
has a relatively light basis weight of less than about 25 gsm, such
as less than about 20 gsm, such as less than about 15 gsm, such as
less than about 12 gsm, such as less than about 10 gsm. The basis
weight is generally greater than about 3 gsm, such as greater than
about 5 gsm.
[0043] In yet another embodiment of the present disclosure, the
backing material 132 may be formed directly on one side of the
fabric 130. For example, any suitable nonwoven web having
unidirectionally oriented fibers or filaments may be applied
directly to the fabric 130 in accordance with the present
disclosure. The nonwoven web, for instance, may comprise a spunbond
web, a meltblown web, a coform web, or the like. By applying the
backing material 132 directly to the fabric 130, the backing
material can have a very low basis weight. For instance, the
backing material 132 can have a basis weight of less than about 15
gsm, such as less than about 12 gsm, such as less than about 10
gsm, such as less than about 8 gsm, such as less than about 5 gsm,
such as even less than about 3 gsm. In one embodiment, for
instance, unidirectionally oriented fibers, filaments, or mixtures
thereof can be applied directly to the fabric 130 in a manner that
produces little to no crossover points that are typically present
in nonwoven webs.
[0044] The above described backing materials when attached to a
fabric are all capable of adjusting the stiffness of the fabric in
one direction. In particular, the stiffness is increased in a first
direction without significantly affecting the stiffness in a second
and perpendicular direction. In the figures, the first direction is
the machine direction, while the second direction is the
cross-direction. It should be understood, however, that the
stiffness of a fabric can be increased in any suitable direction
depending upon the particular application. In the illustrative
embodiments of FIGS. 4 and 5, the ratio between the
machine-direction stiffness and the cross-direction stiffness
(i.e., stiffness ratio) of the vane 110 having the backing material
132 attached thereto is between about 1.5:1 and about 18:1. In
various embodiments, the stiffness ratio of laminates made
according to the present disclosure (first direction to second
direction) can generally be greater than about 2:1, such as greater
than about 3:1, such as greater than about 4:1, such as greater
than about 6:1, such as greater than about 8:1, such as greater
than about 10:1, such as greater than about 12:1, such as greater
than about 14:1. The stiffness ratio is generally less than about
50:1, such as less than about 40:1, such as less than about 30:1,
such as less than about 20:1. Certain fabrics or materials have
stiffness ratios within the range mentioned above without the use
of the backing material 132. However, the backing material 132 can
be used on substantially any type of fabric or material, including
but not limited to densely or lightly wovens or nonwovens,
lightweight woven sheers, lightweight nonwovens, and lightweight
knits, to enhance its respective stiffness ratio. For example, the
backing material 132 is not only able to enhance materials having a
poor stiffness ratio, the backing material 132 may also be used to
selectively enhance and support materials that have a desired
stiffness ratio but do not have a desired stiffness in general. For
example without limitation, for fabrics 130 having a stiffness
ratio equal to or greater than 1:1, the backing material 132 may
include less machine direction orientation compared to a backing
material 132 used for a fabric 130 having a stiffness ratio less
than 1:1. Additionally or alternatively, for fabrics 130 having a
desired stiffness ratio but lacking stiffness in general, the
backing material 132 may be unbiased such that the backing material
132 has an equal machine direction to cross direction fiber
distribution (see FIG. 5), resulting in a more balanced enhancement
of the stiffness of the vane 110 in both its machine direction MD
and its cross direction XD. For fabrics having a desired stiffness
ratio, the backing material 132 may have a relatively light basis
weight that may desirably influence the elongation properties of
the fabric without significantly impacting the opacity of the
fabric. For instance, the backing material, in this embodiment, can
have a basis weight of less than about 12 gsm, such as less than
about 10 gsm, such as less than about 8 gsm, such as less than
about 6 gsm, such as less than about 4 gsm. The basis weight of the
backing material is generally greater than about 1 gsm.
[0045] Illustrative examples of increases in stiffness ratio with
respect to various fabrics or materials are shown below in Tables
1-3. The various fabrics or materials shown in Tables 1-3 below
were tested using a Handle-O-Meter testing machine, developed by
Johnson & Johnson and now manufactured by Thwing-Albert, that
measures the combination of surface friction and flexibility of
sheeted materials (i.e., the handle of the fabric). All of the
materials were tested face side down on the testing machine.
Although the various fabrics and materials in Tables 1-3 were
tested using a Handle-O-Meter testing machine, any suitable
stiffness measurement technique for fabrics would suffice in
comparing the relative machine-direction stiffness and cross
direction-stiffness of the vane 110 so long as the measurement
technique is capable of distinguishing measurements at least
between machine direction and cross direction.
[0046] Table 1 below shows Handle-O-Meter test results using
"Polyester Woven A" as the fabric 130. Polyester Woven A is a
mid-weight (100 gsm-150 gsm), plain weave, 100% polyester, woven
construction. In row 1, Polyester Woven A was tested without the
backing material 132. In row 2, Polyester Woven A was tested with
the backing material 132 applied thereto. Rows 3-4 illustrate test
data of Polyester Woven A with various conventional backing
materials applied thereto for comparison with the backing material
132. Although Table 1 illustrates test results using Polyester
Woven A, similar results can be achieved for substantially any
woven material whose stiffness ratio is heavily biased towards one
direction (e.g., its cross-direction stiffness).
TABLE-US-00001 TABLE 1 "Polyester Woven A" Handle-O-Meter Test
Results Machine- Cross- Direction Direction Stiffness Stiffness
Stiffness Material Description (Ave.) (Ave.) Ratio 1 Polyester
Woven A - without 15.5 46.8 0.33:1 backing material 132 2 Polyester
Woven A - with 75.2 44.5 1.69:1 backing material 132 3 Polyester
Woven A - with 80.6 78.2 1.03:1 20 gsm Unitika spun bound nonwoven
4 Polyester Woven A - with H&V 69.0 82.0 0.84:1 17 gsm smooth
calendered nonwoven
[0047] Table 2 below shows Handle-O-Meter test results using
"Polyester Woven B" as the fabric 130, and shows stiffness testing
with and without the backing material 132 of the present disclosure
applied thereto. Polyester Woven B is a heavy-weight (greater than
150 gsm), plain weave, 100% polyester, woven construction. In row
1, Polyester Woven B was tested without the backing material 132.
In row 2, Polyester Woven B was tested with the backing material
132 applied thereto in accordance with the present disclosure.
TABLE-US-00002 TABLE 2 "Polyester Woven B" Handle-O-Meter Test
Results Machine- Cross- Direction Direction Stiffness Stiffness
Stiffness Material Description (Ave.) (Ave.) Ratio 1 Polyester
Woven B - without 17.6 45.6 0.39:1 backing material 132 2 Polyester
Woven B - with 84.7 55.1 1.54:1 backing material 132
[0048] Table 3 below shows Handle-O-Meter test results using
"Polyester Woven C" as the fabric 130, and shows stiffness testing
with and without the backing material 132 of the present disclosure
applied thereto. Polyester Woven C is a lightweight (less than 100
gsm), plain weave woven composed of 100% polyester woven material.
In row 1, Polyester Woven C was tested without the backing material
132. In row 2, Polyester Woven C was tested with the backing
material 132 applied thereto in accordance with the present
disclosure.
TABLE-US-00003 TABLE 3 "Polyester Woven C" Handle-O-Meter Test
Results Machine- Cross- Direction Direction Stiffness Stiffness
Stiffness Material Description (Ave.) (Ave.) Ratio 1 Polyester
Woven C - without 13.7 2.2 6.23:1 backing material 132 2 Polyester
Woven C - with 57.8 3.7 15.62:1 backing material 132
[0049] As shown in Tables 1-3 above, the stiffness ratio of each of
the tested fabrics or materials was substantially increased through
the application of the backing material 132 to the fabric 130. In
fact, for the tested fabrics or materials, the backing material 132
selectively increases the machine-direction stiffness at least
about 1.5 times greater, and more preferably at least about 2 times
greater, and more preferably approximately 5 times greater, than
the effect of the backing material 132 on the cross-direction
stiffness. For example, with reference to Table 1, application of
the backing material 132 to the Polyester Woven A fabric 130
resulted in an approximate 5% decrease in cross-direction stiffness
but also an approximate 385% increase in machine-direction
stiffness, or an approximate 77 times greater effect on the
machine-direction stiffness than the effect on the cross-direction
stiffness of the vane 110. Similar results are shown in Table 2,
which provides an approximate 18 times greater effect on the
machine-direction stiffness than the effect on the cross-direction
stiffness of the Polyester Woven B fabric 130. Similarly, Table 3
shows an approximate 5 times greater effect on the
machine-direction stiffness than the effect on the cross-direction
stiffness of the Polyester Woven C fabric 130. In contrast as shown
in Table 1 above, use of conventional backing materials, such as 20
gsm 100% polyester Unitika spun bound nonwoven, Hollingsworth &
Vose 17 gsm 100% polyester smooth calendered nonwoven (5-pressure),
and Hollingsworth & Vose 17 gsm 100% polyester smooth
calendered nonwoven (10-pressure), increases both the
machine-direction stiffness and the cross-direction stiffness of
the vane 110 without the selective bias towards significantly
increasing only the machine-direction stiffness while only slightly
affecting (increasing or decreasing) the cross-direction stiffness
of the vane 110 as with the backing material 132 of the present
disclosure. As can be seen in Tables 1-3, use of the backing
material 132 increases the stiffness of the vane 110 in its machine
direction MD while maintaining the flexibility of the vane 110 in
its cross direction XD, unlike use of conventional backing
materials as shown in Table 1. As illustrated in Tables 1 and 2,
for fabrics 130 having a stiffness ratio less than 1:1, the backing
material 132 may be operable to "flip" the stiffness ratio by
significantly increasing machine-direction stiffness while
marginally affecting cross-direction stiffness, or vice-versa.
Thus, according to an embodiment of the present disclosure,
strength and/or stiffness deficiencies of the fabric 130 can be
overcome through application of the backing material 132 to the
fabric 130.
[0050] As indicated by the tables above, a backing material 132 can
be selected so as to influence the stiffness properties of the
fabric in a manner desired for a particular application. In
general, the backing material, when applied to a fabric, can
increase the stiffness of the fabric in a first direction by
greater than about 2 times, such as greater than about 3 times,
such as greater than about 4 times, such as even greater than about
5 times the original stiffness of the fabric. In contrast, the
stiffness in the second direction can remain substantially
unaffected. For instance, applying the backing material to the
fabric can increase the stiffness in the second direction by less
than about 2 times, such as less than about 1.5 times, such as less
than about 1 times, such as less than about 0.5 times the original
stiffness of the fabric. In addition, as described above, the
stiffness ratio of the fabric after the backing material is applied
can increase at least about 1.5 times greater, such as at least
about 2 times greater, such as at least about 2.5 times greater,
such as at least about 3 times greater, such as at least about 3.5
times greater, such as at least about 4 times greater, such as at
least about 4.5 times greater, such as at least about 5 times
greater, such as at least about 5.5 times greater, such as at least
about 6 times greater than the original stiffness ratio of the
fabric. The stiffness ratio is generally increased less than 50
times greater, such as less than about 40 times greater, such as
less than about 30 times greater, such as less than about 20 times
greater than the original stiffness ratio of the fabric.
[0051] With continued reference to FIGS. 4 and 5, depending on the
physical characteristics of the fabric 130, the backing material
132 may be selected and/or the properties of the backing material
132 may be tailored to produce a variety of vanes 110 that behave
similarly in the covering 100. For example, through targeted
selection of respective backing materials 132, a variety of fabrics
130 each having different physical characteristics may be used to
produce respective vanes 110 that have similar properties (e.g.,
weight, machine-direction stiffness, cross-direction stiffness).
Thus, fabrics 130 not having desired stiffness characteristics
alone may be used for a particular purpose (e.g., any of a variety
of shades 106 or vanes 110 with different bending and/or draping
requirements) by application of the backing material 132 thereto to
achieve the desired stiffness of the resulting vane laminate to
suit the needs of a particular end use. In the embodiments
described herein, the backing material 132 may modify the bending
and draping characteristics of the fabric 130 without otherwise
significantly affecting other properties of the fabric 130, such as
but not limited to thickness, basis weight, and/or the opacity of
the fabric 130.
[0052] With reference to FIG. 5, the fabric 130 includes a machine
direction MD.sub.VF and a cross direction XD.sub.VF. Similarly, the
backing material 132 includes a machine direction MD.sub.BF and a
cross direction XD.sub.BF. As shown, the respective machine
directions MD.sub.VF, MD.sub.BF of the fabric 130 and the backing
material 132 extend parallel to each other and parallel to the
machine direction MD of the vane 110. Similarly, the respective
cross directions XD.sub.VF, XD.sub.BF of the fabric 130 and the
backing material 132 extend parallel to each other and parallel to
the cross direction XD of the vane 110. In an alternative
embodiment, however, the machine direction of the fabric 130 and
the machine direction of the backing material 132 may be arranged
perpendicular to each other depending upon the construction of the
different fabric materials. Similarly, the cross direction of the
fabric may be perpendicular to the cross direction of the backing
material. In the illustrative embodiment of FIG. 5, the backing
material 132 may be sized identically to the fabric 130. In some
embodiments, the fabric 130 may have relatively greater dimensions
such that an upper portion and/or a bottom portion of the fabric
130 may be folded over the backing material 132 toward the support
sheet 108 to respectively form the upper and lower tabs 122, 124
and the upper and lower creases 126, 128 of the vane 110 (see FIG.
2). In such embodiments, the adhesive 134 may facilitate in setting
and/or holding at least one of the upper and lower creases 126,
128. Additionally or alternatively, the backing material 132 may
help achieve better fold or crease retention in the vane 110. Also,
when the backing material 132 is applied to the fabric 130, the
vane 110 may be more easily scored and bent.
[0053] The relative dimensions of the fabric 130, the layer of
adhesive 134, and the backing material 132 are exaggerated in FIG.
5 for illustrative purposes. In practice, the layer of adhesive 134
and the backing material 132 add limited thickness and weight to
the fabric 130, although the thickness and weight of the adhesive
134 and the backing material 132 may be tailored to achieve a
desired aesthetic and/or strength characteristic. For example, in
an illustrative embodiment, the layer of adhesive 134 and the
backing material 132 contribute about 10 to about 30 grams per
square meter in weight and/or add between about 0.02 and about 0.06
mm in thickness to the vane 110. Also, although the adhesive 134 is
shown as a substantial layer in FIG. 5, the adhesive 134 may be
less substantial in practice and appear thin like a web of
interconnected adhesive fibers or a dot coated hot melt
adhesive.
[0054] FIG. 6 is a comparative view of illustrative embodiments of
a vane 110A having a backing material 132 and a vane 110B without a
backing material 132. Without the backing material 132, the vane
110B may "pucker" to create irregularities in surface contour and
topography (e.g., creating ripples 120). This "puckering" transmits
to the finished vane 110 and is visible in use. As can be seen in
FIG. 6, the backing material 132 reduces the amount of "puckering"
within the vane 110 by stabilizing the fabric 130 in at least one
direction (e.g., its machine direction MD.sub.VF). For example, the
backing material 132 is operable to prevent stretching of the
fabric 130 in the least one direction (e.g., its machine direction
MD.sub.VF). As illustrated in FIG. 6, the backing material 132
causes the fabric 130 to lie flat against, for example, a work
surface 136 as shown in FIG. 6 or against the support sheet 108 in
operation. As a result, a consistent, preferably smooth, appearance
is achieved without adversely affecting the "feel" and the look of
the fabric 130 or its function during operation, at least from a
front side view of the vane 110. In some embodiments, the backing
material 132, and in particular the fibers of the backing material
132, is not visible to a user when the vane 110 is implemented in
the shade 106 even under backlighting conditions.
[0055] In one embodiment, for instance, a backing material is
selected that does not significantly impact the opacity of the
fabric 130. Consequently, in one embodiment, the backing material
can advantageously influence the stiffness of the fabric 130
without significantly impacting the light transmission properties
of the fabric. For example, in certain embodiments, a backing
material can be selected that increases the opacity of the fabric
130 by no more than about 35%, such as no more than about 30%, such
as no more than about 25%, such as no more than about 20%, such as
no more than about 15%, such as no more than about 13%, such as no
more than about 10%, such as no more than about 8%. The opacity of
materials can be measured using an XRITE Densitometer Opacity
Tester manufactured by X-Rite, Inc. of Grandville, Mich. The above
instrument measures density which can be converted to opacity (%).
The above instrument measures a density from 0 to 5 with 0
representing 0% opacity and 5 representing approximately 100%
opacity. In the above embodiments, the density (opacity) of the
fabric 130 prior to being combined with the backing material 132
can be from about 0.2 to about 2, such as from about 0.3 to about
1.8, such as from about 0.5 to about 1.5.
[0056] In an alternative embodiment, a backing material can be
selected that substantially blocks all light from transmitting
through the laminate after the backing material is attached to the
fabric 130. For example, the backing material 132 and the fabric
130 can form a laminate having a density (opacity) of greater than
about 4, such as greater than about 4.5, such as greater than about
4.8. When selecting a backing material for blocking out light, the
backing material may have a relatively high basis weight. For
instance, the basis weight of the backing material may be greater
than about 20 gsm, such as greater than about 30 gsm, such as
greater than about 40 gsm, such as greater than about 50 gsm, such
as greater than about 60 gsm. The basis weight of the backing
material is generally less than about 150 gsm.
[0057] In addition to influencing stiffness, it was also discovered
that the backing material of the present disclosure can also have a
significant and unexpected impact on the elongation properties of
the fabric 130. Of particular advantage, the backing material of
the present disclosure can have a significant impact on the
stiffness ratio of the fabric and the elongation properties of the
fabric while only marginally impacting opacity. As described above,
the opacity of the fabric may increase by no more than about 35%,
such as no more than about 15%, such as even no more than about
10%. For example, in the direction that stiffness increases, the
backing material when applied to the fabric can decrease the
elongation of the fabric by greater than about 20%, such as greater
than about 25%, such as greater than about 30%, such as even
greater than about 35%. The elongation is generally decreased in an
amount up to about 100%, such as up to about 80%. Decreasing the
elongation of the fabric in the direction that stiffness increases
as described above can dramatically and unexpectedly improve the
handling and drape characteristics of the resulting material and
significantly improve the manufacturing versatility and durability
of the composite material. The above changes can be made to
elongation using the backing material while again only marginally
affecting opacity.
[0058] FIG. 7 is a schematic view of an illustrative embodiment of
a method of manufacturing the vane 110 in accordance with
principles of the present disclosure. As shown in FIG. 7, the
fabric 130 and the backing material 132 are bonded together in a
flatbed laminator 138 to create a laminated fabric assembly 140,
which is alternatively referred to as a "fabric laminate" and is
subsequently formed into the vane 110. Although FIG. 7 illustrates
a flatbed laminator 138, other machines can be used to create the
laminated fabric assembly 140 to similar effect, such as calenders
and drum machines. In the illustrative embodiment of FIG. 7, the
fabric 130 is wound on a first spool 142 and the backing material
132 is wound on a second spool 144. The first spool 142 and the
second spool 144 reside and rotate within a common plane in a
spaced relationship such that the fabric 130 and the backing
material 132 extend from the respective spools 142, 144 in
substantial or coextensive alignment. An alignment mechanism 146
for verifying the alignment of the fabric 130 and the backing
material 132 is also shown in FIG. 7. In some embodiments, the
alignment mechanism 146 fine-tunes the alignment of the fabric 130
and the backing material 132 before the two fabrics 130, 132 are
permanently bonded together. Before entering the flatbed laminator
138, the adhesive 134 is applied to one side of at least one of the
backing material 132 and the fabric 130. For example, the adhesive
134 may be melt blown or otherwise applied onto the backing
material 132 as the backing material 132 is unrolled from the
second spool 144. In some embodiments, the backing material 132 is
wound onto the second spool 144 with the adhesive 134 pre-applied
to the backing material 132 for later activation. Additionally or
alternatively, the adhesive 134 may take the form of a web adhesive
wound on a third spool, which may reside and rotate within the
common plane of, and in a spaced relationship with, the first spool
142 and the second spool 144. In such embodiments, the fabric 130,
the backing material 132, and the web adhesive may extend from the
respective spools 142, 144 in substantial or coextensive alignment,
with the web adhesive positioned between the fabric 130 and the
backing material 132.
[0059] With continued reference to FIG. 7, the backing material 132
is laminated to one side of the fabric 130 using heat and/or
pressure applied by the flatbed laminator 138. For instance, the
flatbed laminator 138 may include a heating platen assembly 148 to
heat set the adhesive 134 applied between the fabric 130 and the
backing material 132. As shown in FIG. 7, the heating platen
assembly 148 includes an upper platen 150 and a lower platen 152
maintained at a high temperature between about 300.degree. F. and
about 350.degree. F. (e.g., about 325.degree. F.) such that as the
fabric 130 and the backing material 132 are passed therebetween,
the adhesive 134 is activated to bond the two fabrics 130, 132
together. Each of the upper platen 150 and the lower platen 152
includes a pressure surface 154 that is generally rectangular in
shape and is longer than it is wide. In some embodiments, the upper
platen 150 and the lower platen 152 press the fabrics 130, 132
together to consistently bond the backing material 132 to the
fabric 130. For instance, each of the upper platen 150 and the
lower platen 152 may apply a pressure of between about 2.5 psi and
about 25 psi (e.g., approximately 5 psi) to the fabric assembly
140. The heat and pressure settings described above are for
illustration purposes. In the illustrative embodiment of FIG. 7,
the stiffness of the fabric assembly 140 may be tailored by
adjusting the heat and/or pressure settings of the heating platen
assembly 148.
[0060] After passing through the heating platen assembly 148, the
fabric assembly 140 may pass through a cooling platen assembly 156
to reduce the temperature of the fabric assembly 140 for later
processing (e.g., to room temperature). Similar to the heating
platen assembly 148, the cooling platen assembly 156 includes an
upper chilling platen 158 and a lower chilling platen 160, each of
which applying a pressure to the fabric assembly 140 passing
therebetween (e.g., approximately 5 psi) and including a pressure
surface 162 that is generally rectangular in shape and is longer
than it is wide. Each of the upper chilling platen 158 and the
lower chilling platen 160 are water cooled to maintain the reduced
temperature of the cooling platen assembly 156. For example,
cooling water passes through the upper chilling platen 158 and the
lower chilling platen 160 at a temperature between about 52.degree.
F. and about 58.degree. F. (e.g., about 54.degree. F.). In the
exemplary embodiment of FIG. 7, the fabric 130 and the backing
material 132 are continuously passed through the heating platen
assembly 148 and/or the cooling platen assembly 156 by one or more
conveyors 164 running between about 15 and about 20 feet per minute
(e.g., about 18.5 fpm). After passing through the flatbed laminator
138, the fabric assembly 140 may undergo further processing, such
as but not limited to, cutting the fabric assembly 140 to desired
length for particular applications or products.
[0061] Although FIGS. 1-7 illustrate the backing material 132
associated with an operable vane 110 selectively attached to a
support sheet 108, the backing material 132 of the present
disclosure can be utilized on different vane structures where
bending along one axis while having stiffness along the axis is
desired. For example, the backing material 132 may be applied to
vertical vane structures, roller shades, and/or vane structures
attached to and extending between two vertically or horizontally
extending sheets of material to create either a vane or shade
structure that has a consistent, preferably smooth, appearance
throughout due at least in part to increased stiffness in a desired
direction (e.g., in a machine direction and/or in a cross direction
of the vane or shade structure).
[0062] The foregoing description has broad application. It should
be appreciated that the concepts disclosed herein may apply to many
types of shades, in addition to the shades described and depicted
herein. For example, the concepts may apply equally to Roman-type
shades, honeycomb shades, vertical shades, or any other shade
having an elongated vane that needs to bend along its width or
height. The discussion of any embodiment is meant only to be
explanatory and is not intended to suggest that the scope of the
disclosure, including the claims, is limited to these embodiments.
In other words, while illustrative embodiments of the disclosure
have been described in detail herein, it is to be understood that
the inventive concepts may be otherwise variously embodied and
employed, and that the appended claims are intended to be construed
to include such variations, except as limited by the prior art.
[0063] The present disclosure may be better understood with respect
to the following further examples.
EXAMPLES
Example 1
[0064] Physical properties of backed and unbacked fabric samples
were tested. Face fabrics from three different rolls were tested.
Each roll was made from a 175 gsm, 100% polyester jacquard weave
fabric. Backing fabrics used were a MILIFE oriented nonwoven having
a basis weight of 10 gsm and a MILIFE oriented nonwoven having a
basis weight of 15 gsm.
[0065] Machine-direction and cross-direction stiffness were tested
using a Handle-O-Meter, available from Thwing-Albert Instrument Co.
of Philadelphia, Pa. Five machine-machine direction and five
cross-direction tests were performed using samples from each roll.
The average stiffness of the five machine-direction samples and
five cross-direction samples tested for each roll is reported in
Table 4. The tests were run according to ASTM D2923.
[0066] Machine-direction and cross-direction elongation were
measured using an Instron 5969 Tensile Tester. Five machine-machine
direction and five cross-direction tests were performed using
samples from each roll. The sample test size was 2.0''.times.5.0'',
the crosshead speed was 1.5 in/min, the force exerted on the
specimen was 5 lbf, and the grip distance was 3.0''. The average
elongations of the five machine-direction samples and five
cross-direction samples tested for each roll are reported in Table
4.
TABLE-US-00004 TABLE 4 Roll 1 Roll 2 Roll 3 Face Face Face Fabric +
Fabric + Fabric + Face Backing % Face Backing % Face Backing %
Fabric Fabric Change Fabric Fabric Change Fabric Fabric Change
Alone 10 gsm -- Alone 10 gsm -- Alone 15 gsm -- MD/Warp 10 74.7 647
9.1 75.2 726 10.5 87.9 737 Direction Stiffness (gram-force) CD/Weft
32.8 35.2 7 35.1 39.1 11 40.9 50.2 23 Direction Stiffness
(gram-force) MD 76 47.4 -38 80.4 48.8 -39 68.6 34.9 -49 Elongation
(% stretch) CD 49.3 41.7 -15 -- -- -- 31.4 37.5 19 Elongation (%
stretch) Thickness 0.0123 0.0141 15 0.0129 0.0146 13 0.0123 0.0141
15 (in)
Example 2
[0067] The effect of the backing fabric on opacity was tested. Face
fabrics from Example 1 were tested for opacity alone and with a
MILIFE 10 gsm oriented nonwoven backing fabric. Face fabric from
roll 1 had a beige color and face fabric from roll 2 had a dark
brown color. Five tests were run for each sample. The average
optical density of the five samples is shown in Table 5. The tests
were run using an Xrite Densitometer Opacity Tester having a 3 mm
aperture. The X-Rite Densitometer, made by X-Rite, Inc. of
Grandville, Mich., was used to measure visible light
transmittance/opacity. This machine measured over a range of about
400-750 nm, and may be considered to provide a more accurate
measurement of human visible light transmittance than measurements
taken at a single visible light wavelength.
TABLE-US-00005 TABLE 5 Roll 1 (beige) Roll 2 (dark brown) Face Face
Face Fabric + % Face Fabric + % Fabric Backing Change Fabric
Backing Change Alone Fabric -- Alone Fabric -- Opacity 0.59 0.63 7
1.18 1.33 13 (optical density)
[0068] The foregoing discussion has been presented for purposes of
illustration and description and is not intended to limit the
disclosure to the form or forms disclosed herein. For example,
various features of the disclosure are grouped together in one or
more aspects, embodiments, or configurations for the purpose of
streamlining the disclosure. However, it should be understood that
various features of the certain aspects, embodiments, or
configurations of the disclosure may be combined in alternate
aspects, embodiments, or configurations. Moreover, the following
claims are hereby incorporated into this Detailed Description by
this reference, with each claim standing on its own as a separate
embodiment of the present disclosure.
[0069] The phrases "at least one", "one or more", and "and/or", as
used herein, are open-ended expressions that are both conjunctive
and disjunctive in operation. The term "a" or "an" entity, as used
herein, refers to one or more of that entity. As such, the terms
"a" (or "an"), "one or more" and "at least one" can be used
interchangeably herein. All directional references (e.g., proximal,
distal, upper, lower, upward, downward, left, right, lateral,
longitudinal, front, back, top, bottom, above, below, vertical,
horizontal, radial, axial, clockwise, and counterclockwise) are
only used for identification purposes to aid the reader's
understanding of the present disclosure, and do not create
limitations, particularly as to the position, orientation, or use
of this disclosure. Connection references (e.g., attached, coupled,
connected, and joined) are to be construed broadly and may include
intermediate members between a collection of elements and relative
movement between elements unless otherwise indicated. As such,
connection references do not necessarily infer that two elements
are directly connected and in fixed relation to each other.
Identification references (e.g., primary, secondary, first, second,
third, fourth, etc.) are not intended to connote importance or
priority, but are used to distinguish one feature from another. The
drawings are for purposes of illustration only and the dimensions,
positions, order and relative sizes reflected in the drawings
attached hereto may vary.
* * * * *