Abstract:
A blackout and thermal drapery and drapery lining and method therefor having a metalized film which is capable of providing a barrier to light, heat and cold in an environmentally and ecologically sound way.

Description:
RELATED APPLICATION  
       [0001]    This application claims priority to a corresponding provisional application U.S. Serial No. 60/272,728, filed Mar. 1, 2001 in the name of the applicant of this application. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates generally to draperies and drapery linings and, more specifically, to a blackout and thermal drapery and drapery lining and method therefor utilizing a metalized film and being capable of providing a barrier to light, heat and cold.  
         BACKGROUND OF THE INVENTION  
         [0003]    Conventional draperies are often designed for style and appearance, being made from various types of fabrics to create a desired visual effect. Such draperies, although providing a level of privacy, are generally not effective in preventing a substantial amount of light penetration into a room from outside sources. It is often the case, however, that certain people need to sleep during daylight hours, necessitating a drapery capable of blacking out natural light to create an atmosphere conducive to sleeping. Additionally, many people are interested in a blackout drapery in order to prevent outsiders from looking into their home.  
           [0004]    For this purpose, several blackout draperies and blackout drapery linings have been created to deal with these problems. Many blackout draperies are in use both in residences as well as in the commercial hotel industry. To achieve the blackout effect, most blackout draperies are created by coating a drapery fabric with an acrylic latex coat that has been mixed with a black pigment, usually carbon black. Carbon black, however, represents a significant sink in the global carbon cycle, affects earth&#39;s radiative heat balance, is a carrier for organic pollutants, and is relatively resistant to degradation. Therefore, carbon black presents several serious environmental and ecological problems.  
           [0005]    Additionally, by having an outer layer of acrylic latex, rather than a fabric, many current blackout draperies and drapery linings are more likely to wear after repeated cleanings. An outer layer of acrylic latex, as opposed to a fabric, also prevents the drapery from being printed on, dyed, or otherwise decorated.  
           [0006]    Although current blackout draperies and blackout drapery linings do provide some thermal barrier effect, they are principally designed to be a barrier to light, not heat or cold. To also provide a thermal barrier effect, specially designed fabrics are currently used to provide this energy savings.  
           [0007]    A need therefore existed for a blackout drapery and blackout drapery lining capable of achieving a blackout effect in an environmentally and ecologically sound way while at the same time providing a thermal barrier effect.  
         SUMMARY OF THE INVENTION  
         [0008]    An object of the present invention is to provide a blackout drapery having a metalized film capable of providing a blackout effect while at the same time creating a thermal barrier effect in a way that is both environmentally as well as ecologically sound.  
           [0009]    It is a further object of the present invention to provide a blackout drapery lining having a metalized film capable of being coupled to a drapery fabric and providing a blackout effect while at the same time creating a thermal barrier effect in a way that is both environmentally an well as ecologically sound.  
           [0010]    It is still a further object of the present invention to provide a method for manufacturing a blackout drapery having a metalized film capable of providing a blackout effect while at the same time creating a thermal barrier effect in a way that is both environmentally as well as ecologically sound.  
           [0011]    It is yet a further object of the present invention to provide a method for manufacturing a blackout drapery lining having a metalized film capable of being coupled to a drapery fabric and providing a blackout effect while at the same time creating a thermal barrier effect in a way that is both environmentally as well as ecologically sound.  
           [0012]    It is yet a further object of the present invention to provide a blackout and thermal barrier drapery having an outer layer of fabric which can be decorated.  
           [0013]    It is yet a further object of the present invention to provide a blackout and thermal barrier drapery lining having an outer layer of fabric which can be decorated.  
         BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS  
         [0014]    In accordance with one embodiment of the present invention, a blackout and thermal drapery lining is disclosed, comprising, in combination, a metalized film having a first side and a second side, a first layer of acrylic latex having a first side and a second side, the second side of the first layer of acrylic latex is coated to the first side of the metalized film, and a second layer of acrylic latex having a first side and a second side, the first side of the second layer of acrylic latex is coated to the second side of the metalized film.  
           [0015]    In accordance with another embodiment of the present invention, a blackout and thermal drapery is disclosed, comprising, in combination, a metalized film having a first side and a second side, a fabric having a first side and a second side, the second side of the fabric is coupled to the first side of the metalized film, and a layer of acrylic latex having a first side and a second side, the first side of the layer of acrylic latex is coated to the second side of the metalized film.  
           [0016]    In accordance with still another embodiment of the present invention, a blackout and thermal drapery is disclosed, comprising, in combination, a metalized film having a first side and a second side, a first layer of fabric having a first side and a second side, the second side of the first layer of fabric is coupled to the first side of the metalized film, and a second layer of fabric having a first side and a second side, the first side of the second layer of fabric is coupled to the second side of the metalized film.  
           [0017]    In accordance with yet another embodiment of the present invention, a method for manufacturing a blackout and thermal drapery lining is disclosed, comprising, in combination, the steps of providing a film having a first side and a second side, metalizing the first side of the film and the second side of the film, coating a first layer of acrylic latex to the first side of the metalized film, and coating a second layer of acrylic latex to the second side of the metalized film.  
           [0018]    In accordance with yet another embodiment of the present invention, a method for manufacturing a blackout and thermal drapery in disclosed, comprising, in combination, the steps of providing a film having a first side and a second side, metalizing the first side of the film and the second side of the film, providing a fabric having a first side and a second side, coupling the second side of the fabric to the first side of the metalized film, and coating a layer of acrylic latex to the second side of the metalized film.  
           [0019]    In accordance with yet another embodiment of the present invention, a method for manufacturing a blackout and thermal drapery is disclosed, comprising, in combination, the steps of providing a film having a first side and a second side, metalizing the first side of the film and the second side of the film, providing a first layer of fabric having a first side and a second side, coupling the second side of the first layer of fabric to the first side of the metalized film, providing a second layer of fabric having a first side and a second side, and coupling the first side of the second layer of fabric to the second side of the metalized film.  
           [0020]    The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    [0021]FIG. 1 is a perspective, partially exploded view of an embodiment of the blackout and thermal drapery lining of the present invention, showing the metalized film sandwiched between a first layer of acrylic latex and a second layer of acrylic latex.  
         [0022]    [0022]FIG. 2 is a perspective, partially exploded view of one embodiment of the blackout and thermal drapery of the present invention, showing the metalized film sandwiched between a layer of fabric on one side and a layer of acrylic latex on the other side.  
         [0023]    [0023]FIG. 3 is a perspective, partially exploded view of one embodiment of the blackout and thermal drapery of the present invention, showing the metalized film sandwiched between a first layer of fabric on one side and a second layer of fabric on the other side.  
         [0024]    [0024]FIG. 4 is a perspective, partially exploded view of one embodiment of the blackout and thermal drapery of the present invention, showing the metalized film sandwiched between two layers of acrylic latex with a layer of fabric coupled to one of the layers of acrylic latex.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0025]    Referring to FIG. 1, one embodiment of the blackout and thermal drapery lining, hereinafter blackout and thermal drapery lining  10 , is shown. The blackout and thermal drapery lining  10  is comprised of a metalized film  12  having a first side  14  and a second side  16 .  
         [0026]    Preferably, the film substrate of the metalized film  12  is comprised of polypropylene, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which the film substrate of the metalized film  12  is comprised of an alternative substance other than polypropylene, such as polyester film, PVC film, polyurethane film, polyethylene film, or the like.  
         [0027]    In the preferred embodiment, the metalized film  12  is metalized with aluminum, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which the metalized film  12  is metalized with an aluminum alloy, titanium, tungsten, a combination thereof or blends of other metal components so long as the metalized film  12  is capable of being either light impermeable or a thermal barrier, or both.  
         [0028]    Preferably, the aluminum or other metal used to metalize the metalized film  12  has an optical rating of between 1.5 and 4.0, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which the optical rating of the aluminum or other metal deviates, even substantially, from the preferred optical rating in either direction.  
         [0029]    In the preferred embodiment, the aluminum or other metal used to metalize the metalized film  12  has a thickness of between 0.0002 and 0.03 millimeters, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which the thickness of the aluminum or other metal deviates, even substantially, from the preferred thickness in either direction.  
         [0030]    The blackout and thermal drapery lining  10  further comprises a first layer of acrylic latex  18  having a first side  20  and a second side  22 , although it should be understood that in addition to acrylic, urethanes or a blend of urethane and acrylic is also contemplated. The second side  22  of the first layer of acrylic latex  18  is coated to the first side  14  of the metalized film  12  The blackout and thermal drapery lining  10  further comprises a second layer of acrylic latex  24  having a first side  26  and a second side  28 . The first side  26  of the second layer of acrylic latex  24  is coated to the second side  16  of the metalized film  12 .  
         [0031]    In one embodiment, the first side  20  of the first layer of acrylic latex  18  is flocked and the second side  28  of the second layer of acrylic latex  24  is flocked, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which only the first side  20  of the first layer of acrylic latex  18  is flocked or only the second side  28  of the second layer of acrylic latex  24  is flocked, or neither layer of acrylic latex is flocked.  
         [0032]    In one embodiment, the first side  20  of the first layer of acrylic latex  18  is flame retardant and the second side  29  of the second layer of acrylic latex  24  is flame retardant, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which only the first side  20  of the first layer of acrylic latex  18  is flame retardant or only the second side  28  of the second layer of acrylic latex  24  is flame retardant, or neither layer of acrylic latex is flame retardant.  
         [0033]    Referring now to FIG. 4, the blackout and thermal drapery lining  10  is dimensioned to be lined to a fabric  30  in order to create a blackout and thermal drapery. By coupling to a fabric  30  a blackout and thermal drapery lining  10  having two layers of acrylic latex, the fabric  30  can be printed on without any discoloration. In the preferred embodiment, the fabric  30  has a width of between 36 inches and 160 inches, although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which the width of the fabric deviates, even substantially from the preferred width, in either direction. The fabric  30  is coupled to the first side  20  of the first layer of acrylic latex  18 , although it should be clearly understood that substantial benefit could be derived from an alternative configuration of the blackout and thermal drapery lining  10  in which the fabric  30  is instead coupled to the second side  28  of the second layer of acrylic latex  24 .  
         [0034]    Referring now to FIG. 2, a blackout and thermal drapery, hereinafter blackout and thermal drapery  100  is disclosed. The blackout and thermal drapery  100  is substantially the same as the blackout and thermal drapery lining  10 , except that in the blackout and thermal drapery  100  a fabric  30  replaces one of the layers of acrylic latex that is present in the blackout and thermal drapery lining  10 , making the blackout and thermal drapery  100  a drapery, instead of a drapery lining. For this reason, the same reference numbers used in describing the features of the blackout and thermal drapery lining  10  will be used when describing the identical features of the blackout and thermal drapery  100 . The blackout and thermal drapery  100  comprises a metalized film  12  having a first side  14  and a second side  16 . The blackout and thermal drapery  100  comprises a fabric  30  having a first side  34  and a second side  36 . The second side  36  of the fabric  30  is coupled to the first side  14  of the metalized film  12 . The fabric  30  may be woven or non-woven. The blackout and thermal drapery  100  further comprises a layer of acrylic latex  24  having a first side  26  and a second side  28 . The first side  26  is coated to the second side  16  of the metalized film  12 .  
         [0035]    Referring now to FIG. 3, a blackout and thermal drapery, hereinafter blackout and thermal drapery  200  is disclosed. The blackout and thermal drapery  200  is substantially the same as the blackout and thermal drapery  100 , except that in the blackout and thermal drapery  200  a second layer of fabric  38  replaces the layer of acrylic latex  24  that is present in the blackout and thermal drapery  100 . For this reason, the same reference numbers used in describing the features of the blackout and thermal drapery  100  will be used when describing the identical features of the blackout and thermal drapery  200 . The blackout and thermal drapery  200  comprises a metalized film  12  having a first side  14  and a second side  16 . The blackout and thermal drapery  200  comprises a first layer of fabric  30  having a first side  34  and a second side  36 . The second side  36  of the first layer of fabric  30  is coupled to the first side  14  of the metalized film  12 . The blackout and thermal drapery  200  comprises a second layer of fabric  33  having a first aide  40  and a second side  42 . The first side  40  of the second layer of fabric  38  is coupled to the second side  16  of the metalized film  12 . The two layers of fabric in the blackout and thermal drapery  200  allows for both sides of a drapery to be decorated, as opposed to the blackout and thermal drapery  100  in which only the one fabric side of the drapery can be decorated.  
         [0036]    While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.