Patent Application
20070123123
The invention discloses screening material that is normally used in frames for windows, as pool enclosures and/or lanai enclosures. The screening is designed to prevent insects from entering the building or to protect outdoor areas and individuals therein from being accosted by insects.
Normally, insect screening is made by coating individual glass fiber yarns and then weaving these yarns to create a fabric which is heat set so that the points of contact in the warp and weft direction are fused together. This multi step process is complicated,.expensive and requires precise types of construction. The fabric is then dip coated in PVC.
Present construction of insect screening is an aging technology with many flaws. It doesn't meet the specific extreme needs of being strong, durable, safer and cleaner.
The aim of this invention is to create a new insect screening product for windows, doors, sun rooms, lanais and pool cages which does not exist on the market today. The screening material is lighter, stronger, safer and cleaner by using more modern polymers, thermosetting composites and polymer coatings that will improve all fabric and product performance attributes and mechanical properties. The screening product will save consumer costs during the life of the product through its construction attributes and blending of polymer technologies.
The new insect screens will add to superior construction techniques by increasing the strength of the material and by reducing wind friction and forces that are exerted on aluminum construction supports. Expensive repair and replacement costs are eliminated while reducing algae, mold and mildew growth through effective application of fiber coatings. Its performance in extreme weather conditions will be improved over typical common market insect screening. The inventive screening will perform in a superior fashion due the strength, elasticity and other modulus attributes of the fibers and coatings selected and integrated in its construction. This includes increased performance and wear in tropical storms or hurricane force winds, thus protecting lanais and pool cages. Extreme forces of lateral and vertical lift along with pressure area differentials on the inside and outside of the enclosures will be reduced if the inventive screening is employed.
The insect screening will incorporate therein fibers or yarns based on Aramid, Aramid Carbon or polymer based composite compositions or other polymer thermosetting composites as yarn fibers to be woven, knitted or otherwise fixed together through thermosetting resin technologies. The yarn is used to produce a screening by weaving, braiding, knitting or by laminating, The thus obtained fabric will be coated with PVC or Flouropolymer based film. It will be heat sealed, thermoformed, vacuum heat bonded, welded, metalized, laminated and used as hot melt adhesive.
The thus obtained screening will be stretchable in all direction, unlike known screens which are known to be non-stretchable. The stretch ability is based in the polymers used to construct the fabric. Of course, the stretch ability stays within certain limits because of the nature of where the screening is installed. Another feature of the stretch ability is, when a force is applied to the screening, it will give (stretch) but will immediately return to its original state because of the phenomenon of “plastic memory”. Such force could be created by someone leaning against the screen, high winds or other forces. The known screen materials could not withstand such forces but would tear. This does not include objects blown at the screening by high winds such as are created by hurricanes. The winds alone could not tear the screening.
Material Weights:
An all carbon fiber composite costs 3.5 times more than an all glass composite to provide the same structural stiffness at a weight savings of 76%. When a 50/50 glass carbon hybrid composite is used, however, the calculated cost ratio is reduced with a weight saving of about 58%. The results appear to be similar for glass and aramid composites.
Fabric Construction:
Thermosetting Composites. Polyester Fibers, E glass, S glass, Carbon fiber, metal fibers, Glass Composites or other Polymer Fibers Composites or Hybrids can use thermoplastic or thermosetting resins. Polymatrix composites included. Using any fiber yarns and then incorporating the same into a structure to create a fabric, which is then heat set or woven so that the points of contact in the warp or the weft direction or any applied pattern in any direction are fused together. The applied pattern includes non-wovens. The higher the numbers the tighter the construction of the fabric including the diameter of the yarns. 18×16, 18×14 and 20×20 are traditional. This is applicable for any construction.
Coatings:
PVC or NDG PVC are used primarily for outdoor applications where UV resistance and outdoor weather ability are primary concerns. These materials are usually available in both high and low volatility and in a wide range of colors. They are also available in several formula modifications depending on whether the end user is undertaking the coating. any coating thickness is applicable. A standard is 0.025 g.
Thermoplastic Film (PVA-PFA or ETEE Teflon) or Oriented Fluoropolymer films can be heat sealed, thermoformed, vacuum heat bonded, welded, metalized, laminated (combined with dozens of other materials), and used as a hot melt adhesive.
