GB2535818A

GB2535818A - Fabric for a window treatment

Info

Publication number: GB2535818A
Application number: GB1512927.3A
Authority: GB
Inventors: Peter Hamilton John
Original assignee: Whyte And Ivory Ltd
Current assignee: Whyte And Ivory Ltd
Priority date: 2015-07-22
Filing date: 2015-07-22
Publication date: 2016-08-31
Anticipated expiration: 2035-07-22
Also published as: GB201512927D0; GB2535818B; WO2017013423A1; EP3325709A1

Abstract

A fabric for use as a lining for a window treatment comprising a metallised fabric layer 102 and a coating layer 104 abutting the metallised layer 102 comprising a blackout coating. The coating 104 may comprise a flock application. There may be a plurality of coating layers. The metallised fabric 102 may comprise metallised and standard yarns woven together. Included are also claims to a window treatment comprising a lining made of such a fabric which may be integrally attached to the main curtain fabric or may be removably attached such that the metallised layer 102 may face either towards or away from the curtain fabric. Also included are claims to a fabric panel for use with a window treatment or as a standalone curtain comprising the above lining and a method of making such a fabric lining comprising extruding metallised and standard yarns, weaving a fabric from both yarns and coating the substrate with a coating layer 104 which may comprise flock.

Description

Fabric for a Window Treatment

Field of Invention

The present invention relates to a fabric for a window treatment. In particular, the present invention relates to an energy reflecting "blackout" or "thermal" fabric. In the following description it is noted that the term "window treatment" refers to curtains or blinds.

Prior Art:

The majority of heat lost or gained by a room or building passes out or into its windows, a fact demonstrated by numerous technical developments in the field of glazing and by building legislation setting minimum levels of insulating and heat reflecting properties for different glazing applications.

There are two specific issues to be addressed; 1) Heat gain through sunlight hitting a window. This is often controlled by air conditioning, which is expensive to install, maintain and run, because of the energy consumed.

2) Heat loss from a warmer room to a colder exterior. Typically compensated for by the consumption of additional room heating energy.

Heat Gain: In some warmer climate countries, shutters are used to add insulation and shading to window openings, but these are cumbersome and expensive to fit retrospectively and represent a net addition to a building. In countries where curtains or blinds are common window treatments, then closing the window treatments will help to shade a room and its contents from sunlight hitting a window. This sunlight will heat the room and damage its contents, but conventional linings and fabrics will still allow some light and significant radiant heat to pass through them.

Heat Loss: In climates where it is necessary to heat rooms because of colder outside ambient temperatures, the windows of the room are the greatest source of heat loss, through heat transfer and draughts. Conventional curtain linings, fabrics and blinds provide only limited defence against this heat loss as they allow draughts to pass through them.

Whilst the fashion for and choice of window treatments vary across the world, curtains and blinds are a common feature of hotels in most countries. In most cases, it will be a legal requirement that the fabrics and linings are flame retardant.

For new buildings, there are a number of architectural features, such as Brise Soleil, design techniques and material specifications that can be employed to help building and window insulation. However, these features tend to focus either on heat loss or heat gain alone, so cannot easily be "switched" from one mode to another. In the case of a South facing room in a building located in country with cold winters, it is quite possible for that room to overheat in the summer because of sunlight, but require heating in the winter.

In an existing building with glazing in place, to whichever specification, and with replacement to a higher specification a very significant cost, the options for improving the window insulation are limited. Reflecting films can be applied to windows, but are fixed and tend to focus on reflecting solar heat away from the room, rather than insulating from heat loss. Conventional window treatments offer limited benefit and even with the addition of so called "Thermal Lining" and insulating "Interlining", such window treatments tend to simply trap an insulating layer of air, the additional features intended to trap more air making the window treatments thick, heavy and cumbersome. The design fashion in homes and hotels has also tended towards minimalism, making such heavy window treatments less desirable, but the retrospective application of new layers such as interlining is also not practical.

"Thermal" is a name given to linings with a single layer of coating, the idea being that the coat prevents the movement of draughts through the fabric. However, this is a historically generic term used in the curtain industry and is not regarded as describing any thermal properties of the window treatment/window treatment lining.

"Blackout" is the name given to window treatment linings with one or more coats of light blocking coating, commonly used in bedrooms and hotel rooms.

Light weight metallised synthetic fabric has been used in window treatments, but in countries where there is a culture of making quality window treatments and in hotel applications, this type of fabric has been considered inadequate and unattractive as the lining itself, expensive, inconvenient and unfamiliar as an interlining. The light metallised fabric does not block out light, was found to lose its reflective coating when washed and was not available in wider width.

Other metallised fabrics have been produced by laminating a metallic foil layer to a textile substrate, but the results have been stiff and unsuitable for curtains. The curtain market is conservative and so unfamiliar fabrics and techniques are difficult to introduce with any broad acceptance.

It is an object of the present invention to provide a window treatment and/or window treatment lining with improved thermal performance properties which overcomes or substantially mitigates the above mentioned problems with the prior art.

Disclosure:

Embodiments of the present invention provide a fabric suitable for window treatments with the following characteristics.

* Active reflection of heat energy.

* Blocking out of light which cannot pass through the fabric. This is termed "Blackout".

* Attractive as a curtain lining, whilst acceptably thin, light and draping, and compatible with existing curtain constructions and hanging systems.

* Suitable to be cut and sewn using existing systems and equipment.

* Suitable for use in blinds.

* Washable, whilst retaining all its properties.

* Attachable to an existing curtain retrospectively or can be hung separately on its own mechanism.

* Offering a flame retardant option for the hotel and contract sectors.

* Available in wide width for seamless applications in larger windows and hotels.

The active reflection of heat energy is achieved through metallisation of the substrate or through the production of the substrate using metallised components. These components must also satisfy the key curtain and blind market's fabric requirements listed above.

It is also noted that existing production technology available for heat reflecting fabrics is largely restricted to "narrow width" (140-150cm) production, whereas window treatment producers for larger windows and hotels prefer "wide width" (280-300cm) fabrics, so that window treatments can be produced without seams between panels. This is particularly important where the window treatment is a blackout as seams allow unsightly and distracting lines of light to pass through a window treatment intended to black out a room. Embodiments of the present invention also address this issue.

According to a first aspect of the present invention there is therefore provided a practical window treatment or window treatment lining comprising the characteristics of energy reflection and light blocking (blackout), without compromising the essential aesthetic and manufacturing characteristics of conventional linings. In the case of the present invention, this is achieved through the application of one or more layers of light and draught blocking coating to an energy reflective substrate textile.

The fabric according to the first aspect of the present invention is referred to herein as an Energy Reflecting Fabric (ERF).

According to a further aspect of the present invention there is provided a window treatment comprising a main face fabric and a lining according to the first aspect of the invention. The lining may conveniently be integral to the window treatment, e.g. by being sewn in.

The lining may also be used as a stand-alone fabric (e.g. without a main face fabric) without restriction of its performance.

Conveniently, the lining may also be constructed as a separate panel, the curtain lining being removeably attached to the main curtain fabric such that it can be mounted in a first configuration in which a first side of the lining faces away from the main curtain fabric and a second configuration in which the first side of the lining faces toward the main curtain fabric. The fabric according to embodiments of the present invention has been shown to be effective in reflecting energy from both the metallic side and, to a lesser extent the coated side, so need not be reversible to be effective. If the fabric is fixed in orientation in the window, it would be then be recommended to face the metallic side to the window if heat ingress were the priority issue, or to the room if heat loss were the main priority.

The Energy Reflecting Fabric (ERF) uses metallised and standard yarns to produce a woven or knitted substrate fabric which is then coated with one or more layers of a thin, continuous coating, to create a fabric with the properties listed above. Regardless of the number of coats, the final coat has an application of flock (fine short staple fibres) applied whilst the coat is still adhesive. This has the combined effects of softening the fabric, enhancing the feel of the fabric and preventing it from sticking to itself when rolled and stored under pressure from rolls above.

The present invention comprises a woven fabric with metallised synthetic warp yarns and standard synthetic weft yarns, providing energy reflecting characteristics to both sides of the fabric. One or more coats of coating are then applied to the fabric to add the characteristics of light and draught exclusion. It is the combination of these characteristics in one fabric specifically suitable for window treatments which represent the invention. The components may be arranged as shown in Figures 1 & 2.

The production route may be as follows (Note: FR = flame retardant; non-FR = standard coating which is not flame retardant), Extrude yarns-metallic and standard Prepare and size weaving or knitting beam Weave or knit substrate fabric Finish substrate fabric to be clean, flat and stable Prepare substrate fabric for coating Coat substrate fabric one or more times -FR or non-FR Trim, inspect and pack finished fabric The resulting product is a fabric that is acceptable for curtain and blind making, in terms of cutting, sewing, drape, construction, appearance and washing, whilst reflecting heat energy, excluding draughts and blocking out light. The fabric is reversible so as to maximise energy reflection either back into or away from the room, can be produced in a flame retardant version and can be retrospectively fitted to the back of curtains through the use of a made to measure or readymade reversible panel hung on the back of an existing curtain.

Tests were undertaken by an accredited independent laboratory in the field of glazing and window performance to established glazing energy transmittance standard EN 13363-1.

Face fabrics vary in weight and construction so significantly that it was chosen not to set a face fabric control. A single pane of clear 4mm high translucent glazing alone (Control 1), and in conjunction with a commonly used 50% Cotton, 50% Polyester lining (Control 2) were therefore set as a controls to show how much the ERF fabric reduced energy transmittance when also paired with the same 4mm glazing.

Because the glazing itself reflects some energy, the most significant reductions in energy transmittance were achieved with the metallic side of the ERF facing the energy source, (as recommended) and between the energy source and the glazing. The reduction of energy transmittance through the combination of the control lining + glazing and the ERF + glazing could then be assessed.

The reduction of energy transmittance with the glazing between the energy source and the lining or ERF were also measured, so that we could assess the ERF being used in a fixed window treatment, reflecting heat into a room in the winter AND then out of a room in the summer.

Taking the Control as 100% in each circumstance, we show below the % to which the energy transmittance was reduced by the ERF and (the °A) reduction) V's Control 1 (glazing only) 17% (83% reduction) ERF between glazing and energy source Glazing between ERF and energy source V's Control 2 (glazing + control lining) ERF between glazing and energy source Glazing between ERF and energy source 60% (40% reduction) 22% (78% reduction) 79% (21% reduction) It can be seen from the above that in the case of the ERF between the energy source and glazing, the very slight decrease in reduction when the control includes the standard control lining shows the ineffectiveness of such standard linings compared to the ERF.

The ERF can be employed in a number of ways, as a window treatment lining, as a standalone window treatment and as a separate panel to be attached to or suspended in conjunction with existing window treatments. See separate configurations explained by Figures 3, 4, 5 & 6 Advantages of the Invention: The key advantage of the ERF is that it integrates a new performance characteristic (active energy reflectance) generally not easily incorporated in curtains and blinds, with an established lining characteristic (blackout) without changing the way in which the lining can be employed. Previous solutions have involved building into the curtain or blind one or more additional components, changing the established ways of production, whilst compromising appearance and drape and adding cost.

ERF is reversible to optimise its performance by directing the metallised side to the source of heat, be it the sun or the room. Correct use of ERF will therefore allow it to be used to protect a room from the sun in the summer and from the cold in the winter, at the same time fulfilling all the requirements of a regular blackout curtain lining.

Embodiments of the present invention provide a new and important energy reflecting performance characteristic to a window treatment lining or to stand-alone window treatment using the present invention alone. Such performance characteristics are also commercially significant in that they add only incremental cost to a lining that would be employed in any case and does not add any cost to the production of the curtain or blind itself. This is considered particularly important in the hotel sector, where flame retardant blackout curtain linings are commonly used, meaning that the incremental additional cost of the ERF will be easily justifiable through savings on heating and air conditioning costs.

Variations: It is the combination of a suitable weight and construction ER property fabric with blackout property coating, which can also be flame retardant, which makes this invention unique. There are other means by which this combination of characteristics could be achieved: The ERF development fabric is based on a woven fabric constructed with metallised yarn in the warp direction and standard polyester yarn in the weft direction. This presents sufficient metallised yarn to the face of the fabric to be ER effective. Even a very low percentage content by weight of the metallic component is effective if it is applied to the surface of the yarn.

The standard yarn could be spun from other materials and it would be possible to reverse the direction of the yarns, so that the metallised yarn ran in the weft direction, or to make the fabric from 100% metallised yarn, or to alternate standard and metallised yarn in the warp and weft directions.

Similarly, it would be possible to produce a knitted substrate fabric with metallised and standard yarn combined, or 100% metallised yarn, with alternative constructions. Nonwoven textiles could also be used a metallised substrate.

In ERF, the blackout coating is applied directly to the substrate fabric. It would be possible to bond together through a process such as lamination both a blackout fabric and an ER fabric.

The final possible variation is to revert to the solutions attempted in the market to date, which is the building up of a curtain to achieve the desired outcome, but using separate fabrics to provide the ER and the blackout characteristics.

It is noted that embodiments of the present invention may also comprise a ready-made reversible lining that can be retrospectively hung on the back of an existing face curtain, or hung as a standalone curtain where there is no existing face curtain

Claims

CLAIMS1. A fabric for use as a lining for a window treatment, the fabric comprising: a metallised fabric layer; a coating layer.
2. A fabric as claimed in Claim 1, wherein the coating layer comprises a flock application.
3. A fabric as claimed in Claim 1 or Claim 2, comprising a plurality of coating layers, the coating layer distal to the metallised fabric layer comprising a flock application.
4. A fabric as claimed in any preceding claim, wherein the coating layer abutting the metallised fabric layer comprises a blackout coating.
A fabric as claimed in any preceding claim wherein the metallised fabric layer comprises metallised yarns and standard yarns which have been woven together.
6. A fabric as claimed in any preceding claim wherein the metallised fabric layer comprises synthetic yarns having a metallic component on the surface of the yarns.
7. A window treatment comprising a main curtain fabric and a lining wherein the lining comprises a fabric according to any one of claims 1 to 6.
8. A window treatment as claimed in Claim 7, wherein the lining is integrally attached to the main curtain fabric.
9. A window treatment as claimed in Claim 7, wherein the lining is removeably attached to the main curtain fabric such that it can be mounted in a first configuration in which the metallised fabric layer faces away from the main curtain fabric and a second configuration in which the metallised fabric layer faces toward the main curtain fabric.
10. A readymade fabric panel for use with a window treatment or as a standalone curtain element comprising a panel of fabric wherein the panel of fabric is made from the fabric according to any one of Claims 1 to 6.
11. A method of making a fabric for use as a lining for a window treatment, the method comprising: extruding metallised yarns and standard yarns; weaving a substrate fabric comprising the extruded metallised yarns and standard yarns; coating the substrate fabric with a coating layer.
12. A method of making a fabric as claimed in Claim 11, comprising applying a flock application to an outer coating layer.Amendments to the claims have been made as follows:CLAIMS1. A fabric for use as a lining for a window treatment, the fabric comprising: a metallised fabric layer; a coating layer, wherein the coating layer abutting the metallised fabric layer comprises a blackout coating.2. A fabric as claimed in Claim 1, wherein the coating layer comprises a flock application.3. A fabric as claimed in Claim 1 or Claim 2, comprising a plurality of coating layers, the coating layer distal to the metallised fabric layer comprising a flock application.4. A fabric as claimed in any preceding claim wherein the metallised fabric layer comprises metallised yarns and standard yarns which have been woven together.5. A fabric as claimed in any preceding claim wherein the metallised fabric layer comprises synthetic yarns having a metallic component on the surface of the yarns.6. A window treatment comprising a main curtain fabric and a lining wherein the lining comprises a fabric according to any one of claims 1 to 5.7. A window treatment as claimed in Claim 6, wherein the lining is integrally attached to the main curtain fabric.8. A window treatment as claimed in Claim 6, wherein the lining is removeably attached to the main curtain fabric such that it can be mounted in a first configuration in which the metallised fabric layer faces away from the main curtain fabric and a second configuration in which the metallised fabric layer faces toward the main curtain fabric.9. A readymade fabric panel for use with a window treatment or as a standalone curtain element comprising a panel of fabric wherein the panel of fabric is made from the fabric according to any one of Claims 1 to 5.10. A method of making a fabric for use as a lining for a window treatment, the method comprising: extruding metallised yarns and standard yarns; weaving a substrate fabric comprising the extruded metallised yarns and standard yarns; coating the substrate fabric with a coating layer.11. A method of making a fabric as claimed in Claim 10, comprising applying a flock application to an outer coating layer.