DESC:FIELD OF INVENTION
[0001] The present disclosure relates to fabrics. In particular, the present disclosure relates to a composite fabric provided with both radiation and conductive barriers in a monolithic solution for efficient thermal management, thereby enabling the composite fabric to prevent excessive solar radiation from heating the roof or wall surface and to provide a warmer shelter in low-temperature conditions.

BACKGROUND OF THE INVENTION
[0002] The following description of related art is intended to provide background information pertaining to the field of the disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section be used only to enhance the understanding of the reader with respect to the present disclosure, and not as an admission of prior art.
[0003] It is commonly known that global temperatures continue to rise largely due to impact of greenhouse gases. The rise in temperatures would affect people and the environment in one or more ways. In an example, human health and comfort is directly linked to heat stress, which is also linked to productivity loss.
[0004] Continuous exposure to solar radiation is a primary reason for temperature rise within infrastructure such as warehouses, production houses, poultry or dairy farms, residential houses, etc., transportation vehicles - closed and open containers, protected agriculture, and many other segments. This problem extends across countries and regions of the world, primarily in the tropical regions, but also outside of it. Various methods have been developed to address high temperature exposure primarily rely on active or passive methods. The active methods are performed through refrigeration and evaporative cooling, and are used in industrial, consumer/retail, and to some extent in live-stock farming. These methods consumes a huge amount of energy. The passive method against solar radiation primarily are relied on painting over the surface with suitable reflective pigments or integrating thick fibrous insulation below the exposure surface. The passive methods also depend on insulations, reflective coatings and fabrics, and metal alloys to create a thermal barrier.
[0005] However, the overall efficacy of such passive solutions is limited due to their inability to address the complete energy spectrum of solar radiation primarily – ultraviolet, visible, and near infrared radiation. The passive barrier would limit energy such as light and heat penetrated into a structure. Further, the amount of insulations depend on thickness required and hence can get bulkier in installation, while fibrous insulations e.g., glass wool, rock wool, etc. are extremely susceptible to loss in performance with absorption of moisture.
[0006] Further, reflective barriers in the passive methods, depend majorly either on visible or infra-red radiation reflectivity, but are unable to effectively bridge the relevant range of solar radiation wavelengths e.g., 340-2500 nm with high reflectivity. Additionally, reflective coatings based on metals and metal oxides have also been used to reduce the effect of high temperature exposure. The diffuse reflectivity of these materials is dependent on the size of the particle. In many cases, these pigments are designed to have dark colours to suit building aesthetics which compromises the reflective behaviour in the visible radiation range.
[0007] Further, composite paints in the passive methods are also used to mitigate the effect of high temperature exposure. However, the paints require extensive surface formation with multiple coating to be able to withstand long term usage. The older infrastructures are unlikely to be able to have consistent coating and are susceptible to rains. In addition, composite paints do not have an option of creating multiple emissivity ranges - higher on the surface facing ambient, lower on the surface facing roof.
[0008] Thus, there is a clear and urgent need for solutions that address exposure to high ambient temperatures as well as low temperature conditions in an effective, cost-conscious way to enable wide-spread applications.

OBJECTIVE OF THE INVENTION
[0009] An object of the present invention is to provide a composite fabric with special properties that offer protection from the environment, sun light exposure, and abnormal weather conditions.
[0010] Another object of the present invention is to provide a composite fabric that is configured to maintain the temperature within a permissible limit even in the case of heat built up inside the fully or partially covered area and during low temperature conditions.
[0011] Another object of the present invention is to provide a composite fabric with increased strength and barrier properties to withstand rigors and extended outdoor exposure.
[0012] Another object of the present invention is to provide a composite fabric that is durable, non-toxic, and environment friendly.
[0013] Another object of the present invention is to provide a composite fabric that acts as a fire retardant.
[0014] Another object of the present invention is to provide a composite fabric provided with stabilizers to stabilize the thermal management product against UV rays and high temperatures.

SUMMARY
[0015] The present disclosure relates to fabrics. In particular, the present disclosure relates to a composite fabric provided with both radiation and conductive barriers in a monolithic solution for efficient thermal management, thereby enabling the composite fabric to prevent excessive solar radiation from heating the roof or wall surface and to provide a warmer shelter in low temperature conditions.
[0016] The present disclosure provides a composite fabric for mitigating the effects of the heat exposure by providing effective thermal management. The composite fabric includes a substrate and a coating over one or more surfaces of the substrate. The coating is made of an additive that is a homogenous mixture of the insulating material and plastisol/organosol. When the solar radiation incidents on the said composite fabric, the major extent of the radiation gets reflected from the surface of the composite fabric. The remaining radiation may get absorbed by the composite fabric. The insulating part of the composite fabric delays the absorbed radiations in the conductive transmission. This dual mechanism of reflection and absorption would reduce the heat incident on the surface of the roof where the composite fabric is configured, thereby reducing temperature inside the roof surface.
[0017] In an aspect, the present disclosure provides a composite fabric for efficient thermal management. The composite fabric includes a substrate and a coating over one or more surfaces of the substrate. The coating is made of an additive that is a homogenous mixture of an insulating material and at least one of plastisol and organosol.
[0018] In an embodiment, the coating may include a first portion over one surface of the substrate and a second portion over another surface of the substrate.
[0019] In an embodiment, the coating may include fillers added with the at least one of the plastisol and the organosol to increase the weight of the fabric.
[0020] In an embodiment, the additive may be coated over the one or more surface of the substrate by any one of spread coating, screen coating, wire coating, spray coating, zimmer coating.
[0021] In an embodiment, the composite fabric may include bonding agents to provide good adhesion to the plastisol/organosol.
[0022] In an embodiment, the insulating material may be selected from a group comprising poly vinyl chloride (PVC), polyurethane (PU), polyethylene (PE), polypropylene (PP), high density polyethylene (HDPE), low density polyethylene (LDPE), ethyl vinyl acetate (EVA), poly vinyl alcohol (PVA).
[0023] In an embodiment, the coating may include pigments to produce the composite fabric in the desired colours.
[0024] In an embodiment, the composite fabric may possess thermal conductivity, reflectivity, and emissivity.
[0025] In an embodiment, the composite fabric may include a self-adhesive layer laminated/coated on over the coating. The self-adhesive layer may be made of a material selected from a group of materials comprising rubber, acrylic, polyurethane.
[0026] In an embodiment, the composite fabric may include one or more stabilizers to prevent decomposition of the at least one of the plastisol and the organosol against UV rays and high temperature conditions.

BRIEF DESCRIPTION OF DRAWINGS
[0027] The accompanying drawings, which are incorporated herein, and constitute a part of this invention, illustrate exemplary embodiments of the disclosed methods and systems in which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that invention of such drawings includes the invention of electrical components, electronic components or circuitry commonly used to implement such components.
[0028] FIG. 1 illustrates an exemplary schematic block diagram showing a method for producing a composite fabric, in accordance with embodiments of the present disclosure.
[0029] FIG. 2 illustrates an exemplary representation of a sectional view of the composite fabric, in accordance with embodiments of the present disclosure.
[0030] The foregoing shall be more apparent from the following more detailed description of the invention.

BRIEF DESCRIPTION OF INVENTION
[0031] In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
[0032] The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth.
[0033] Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits, systems, networks, processes, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[0034] Also, it is noted that individual embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination can correspond to a return of the function to the calling function or the main function.
[0035] The word “exemplary” and/or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and/or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive—in a manner similar to the term “comprising” as an open transition word—without precluding any additional or other elements.
[0036] Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0038] In an embodiment, the term “coated fabric” or “composite fabric” may refer to a fabric over which a coating is applied. Alternatively or additionally, the term “coated fabric” or “composite fabric” may also refer to a fabric over which a film is laminated. The coating may be applied by various methods such as but not limited to knife coating, spray coating, extrusion coating, knife on roll, knife on air, kiss roller coating, screen coating, transfer paper coating and so on. The lamination may be performed by various methods such as but not limited to film to film lamination, film to fabric lamination e.g., wet and dry heat lamination, hot melt lamination, stitching, adhesive or extrusion lamination, thermoforming, profile extrusion etc.
[0039] The present disclosure provides a composite fabric for mitigating the effects of the heat exposure by providing effective thermal management. The composite fabric includes a substrate and a coating over one or more surfaces of the substrate. The coating is made of an additive that is a homogenous mixture of the insulating material and plastisol/organosol. When the solar radiation incidents on the said composite fabric, the major extent of the radiation gets reflected from the surface of the composite fabric. The remaining radiation may get absorbed by the composite fabric. The insulating part of the composite fabric delays the absorbed radiations in the conductive transmission. This dual mechanism of reflection and absorption would reduce the heat incident on the surface of the roof where the composite fabric is configured, thereby reducing temperature inside the roof surface. Further, the dual mechanism also facilitates maintaining of the temperature in the area enclosed by the composite fabric during the low temperature environmental conditions.
[0040] FIG. 1 illustrates an exemplary schematic block diagram showing a method for producing a composite fabric, in accordance with embodiments of the present disclosure. The composite fabric 100 may include a substrate 101 and a coating 103 over one or more surfaces of the substrate. The composite fabric 100 acts as an optimized solar radiation barrier integrated with suitable reflective and conductive properties. In an example, the composite fabric may be installed over any surface of the infrastructure such as warehouses, production houses, poultry farms, residential houses, which are exposed to the solar radiations.
[0041] In an embodiment, the emissivity of the composite fabric is closely linked with the materials used for reflective coating. The surface facing the roof or being contact with the roof, is associated with the low emissivity, whereas the surface facing the external atmosphere such as sun is associated with high emissivity.
[0042] In an exemplary embodiment, the substrate 101 can be woven or non-woven fabric. In another exemplary embodiment, the substrate can be fabrics which are closely weaved with any or a combination of polyester, nylon, polymeric synthetic yarn, cotton yarn, hessian, jute fabrics, blend of any of these yarns, fibres, films, net, sheets, and so on.
[0043] In an embodiment, the coating 103 is applied over the substrate 101 on one or more surfaces of the substrate 101. The coating may have at least one of conductive, convective, and reflective properties. In an embodiment, the coating 103 may include additives 103-1 and fillers 103-2. The additive is made of a homogenous mixture of the insulating material; and plastisol/organosol or similar type of polymer. The additive is coated over the surface of the substrate 101 using any one of spread coating, screen coating, wire coating, spray coating, zimmer coating, and any other type of coating/lamination. The spread coating is performed using either knife on air or knife on roller. The additives used in the composite fabric possess different characteristics such as flex resistance and cold resistance to the composite fabric. In an embodiment, the composite fabric may also include bonding agents as a part of the plastisol to provide good adhesion to the plastisol. The composite fabric may include a cross linker that is solvent or water based other polymers. The cross linker may be added in organosol to become the part of homogeneous mixture.
[0044] The bonding agents may include, by way of example but not limited to, Lanxess 5130 and Crosslinker – XR 5580 and so on. Primary plasticizer such as but not limited to Phthalates or Adipates e.g. DINP/DOP/DBP / DOA etc., may be mainly used for preparation of any plastisol. In some embodiments, a secondary plasticizer such as but not limited to Paraffin or Wax like CPW/CPE etc. may be used for preparation of the plastisol in a predefined amount e.g. 10/20 PHR to provide cost-effective solution.
[0045] In an embodiment, the ratio of different materials in the composition of the composite fabric can be formulated based on different characteristics or properties required in the composite fabric. In an example, for a particular application, the composite fabric with convective and reflective properties may be required, and accordingly the ratio may be varied.
[0046] In an embodiment, the insulating material can be any or a combination of poly vinyl chloride (PVC), polyurethane (PU), polyethylene (PE), polypropylene (PP), high density polyethylene (HDPE), low density polyethylene (LDPE), ethyl vinyl acetate (EVA), poly vinyl alcohol (PVA) or any other polymer resin or any other polymeric/co-polymeric compound blend. The insulating material may be either in powder, liquid, or a vapor deposited form and combination thereof.
[0047] Since the composite fabric is made of the additives, the composite fabric facilitates dual mechanism of reflection and absorption. When the solar radiation incidents on the said composite fabric, the major extent of the radiation gets reflected from the surface of the composite fabric. The remaining radiation may get absorbed by the composite fabric. The insulating part of the composite fabric delays the absorbed radiations in the conductive transmission. This dual mechanism of conducting and reflecting using the radiation barrier reduces the amount of heat incident on the surface of the roof where the composite fabric is configured, thereby reducing temperature inside the roof surface. Thus, the composite fabric acts as a thermal barrier.
[0048] In addition to thermal barrier properties, the composite fabric may also have strength to resist tears, rips and puncture. The composite fabrics are also useful in cases where the conventional fabrics gradually lose the desired strength and barrier properties, over a period of time, and are susceptible to premature degradation as a result of extended exposure to intense sunlight. The composite fabric provides protection from the adverse effects associated with the conventional fabric for higher temperature exposure and abnormal weather conditions. In addition, the composite fabric can act a warmer shelter in low temperature conditions.
[0049] In an embodiment, the composite fabric exhibits reflecting barrier properties due to addition of metals, inorganic filler, glass bubbles, ceramics, hollow fibres, and so on, in either powder, liquid, or vapour deposition. In an embodiment, the fillers 103-2 may be added with the at least one of plastisol and organosol to increase the weight of the composite fabric. The fillers 103-2 may include, by way of example, calcium carbonate, coated or uncoated calcium carbonate or any other soap stone powder/ marble power etc. Thus, with the additives and fillers in the coating, the composite fabric is able to reflect the solar radiation and to modify the emissivity. Additionally or alternatively, the coating 103 may include pigments to produce the composite fabric in the desired colours.
[0050] In an embodiment, the composite fabric may also include a self-adhesive layer 105 that may be laminated/coated on one surface of the substrate. In another embodiment, the self-adhesive layer 105 may be configured over the coating such that the coating lies between the self-adhesive layer 105 and the substrate. The self-adhesive layer allows the substrate to configure with a flat or curved surface of a structure. The self-adhesive material for layer 105 may be selected from a group of materials comprising rubber, acrylic, polyurethane or so on.
[0051] As described above, the composite fabric is provided with an integrated conductive and reflective barrier. In an example, the composite fabric may be associated with a thermal conductivity of 0.025 W/m.K to 0.1 W/m.K, reflectivity of 0.6-0.9 in 350-2500 nm range, emissivity of 0.6-0.9 for surface facing sun, emissivity of 0.05-0.4 for surface facing the roof. The fabric composite thermal resistivity is in the range of 0.1-1 m2K/W, or can be > 1.0 m2.K/W depending on the thickness or addition of other insulations (including air gaps).
[0052] In an embodiment, the composite fabric may be installed as a single layer with a restraining net or rope. In another embodiment, the fabric may be placed as multiple layers or sheets, each joined to the other either with an adhesive, heat seal, rope, nut-bolt, or other appropriate physical and chemical methods. In another embodiment, a single sheet or multiple sheets, with an adhesive backing is installed by pasting the sheet on the roof or surface. In another embodiment, the fabric is thermoformed into a corrugated shape matching the roof or surface contour. The sheet (s) are then installed by a physical restraint or an adhesive onto the roof or surface.
[0053] In an embodiment, the composite fabric may include one or more stabilizers that may be configured to prevent decomposition of the at least one of the plastisol and the organosol against UV rays and high temperature conditions. In an embodiment, the coating may also include fire resistant chemicals to provide fire retardancy to the composite fabric.
[0054] In an embodiment, the composite fabric can be used to manufacture one or more of vehicle canopies, covers, tents, outdoor apparels, other outdoor fabrics/objects. The composite fabrics are induced to incorporate strong physical parameters and therefore can be used to make tarpaulins and other shelters.
[0055] FIG. 2 illustrates an exemplary representation of sectional view of the composite fabric, in accordance with embodiments of the present disclosure. As illustrated, the composite fabric includes a substrate 101 and a coating 103. The coating 103 may include a first portion of coating 103a and a second portion of coating 103b. The first coating 103a may be configured at the upper surface of the substrate 101, whereas the second portion of coating 103b may be configured at the lower surface of the substrate 101. In an exemplary embodiment, the first portion of coating 103a may have the same composition as of the second portion of coating 103b. In another exemplary embodiment, the first portion of coating 103a may not have the same composition of the second portion coating 103b. In an example, the first portion of coating 103a may be made of a combination of aluminium, TiO2, and PVC plastisol, whereas the second portion of coating 103b may be made of insulating material PVC foam and reflective material TiO2.
[0056] In an embodiment, there can be multiple portions of coating configured on the surface of the substrate, where each portion may have a different composition. For example, the coating may have a left portion and a right portion, configured over the same surface of the substrate horizontally. In another example, the coating may include an upper portion and a lower portion, configured such that the lower portion is configured over the surface of substrate and the upper portion is configured over the surface of the lower portion, thus substrate, upper portion, and lower portion are arranged vertically.
[0057] In an embodiment, the composite fabric is provided with closed-cell insulation or the open cell insulation with a reflective barrier in visible and infrared radiation, where the closed cell insulation offers much higher energy absorption capability compared to open-cell or fibrous structures. The closed cell insulation refers to insulation made of chemically foamed material, which does not absorb liquid such as water. The cellular structure of the such material is closed with air/ gas bubbles. The open cell insulation refers to insulation made of basically mechanical frothing/ foaming which absorbs liquid such as water. In an embodiment the closed cell insulations formed with foaming material and primarily polyurethane or polyisocyanate, have been used in infrastructural applications but they tend to be of high thickness – generally greater than 1 inch.
[0058] Thus, the present disclosure provides a composite fabric that offers protection from the environment, sunlight exposure, and abnormal weather conditions. In particular, the composite fabric maintains the temperature of the area that is fully or partially covered with the composite fabric, within a permissible limit. In addition, the composite fabric also has high strength and barrier properties to withstand rigors and extended outdoor exposure.
[0059] While considerable emphasis has been placed herein on the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiments of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter to be implemented merely as illustrative of the invention and not as limitation.

ADVANTAGES OF THE INVENTION
[0060] An object of the present invention is to provide a composite fabric with special properties that offer protection from the environment, sun light exposure, and abnormal weather conditions.
[0061] The present disclosure provides a composite fabric that is configured to maintain the temperature within a permissible limit even in the case of heat built up inside the fully or partially covered area or during low temperature conditions.
[0062] The present disclosure provides a composite fabric with increased strength and barrier properties to withstand rigors and extended outdoor exposure.
[0063] The present disclosure provides a composite fabric that is durable, non-toxic, and environment friendly.
[0064] The present disclosure provides a composite fabric that acts as a fire retardant.
[0065] The present disclosure provides a composite fabric provided with stabilizers to stabilize the thermal management product against UV rays, high temperatures, and low temperature conditions.
[0066] The present disclosure provides a composite fabric with a self-adhesive layer laminated/coated on one surface of the fabric for easy installation on a flat or curved surface.

,CLAIMS:1. A composite fabric (100) comprising:
a substrate (101); and
a coating (103) over one or more surfaces of the substrate (101), wherein the coating is made of an additive (103-1) that is a homogenous mixture of an insulating material and at least one of plastisol and organosol.
2. The composite fabric (100) as claimed in claim 1, wherein the coating (103) comprises a first portion (103a) over one surface of the substrate (101) and a second portion (103b) over another surface of the substrate (101).
3. The composite fabric (100) as claimed in claim 1, wherein the coating (103) comprises fillers (103-2) added with the at least one of the plastisol and the organosol to increase the weight of the fabric.
4. The composite fabric (100) as claimed in claim 1, wherein the additive is coated over the one or more surface of the substrate (101) by any one of spread coating, screen coating, wire coating, spray coating, zimmer coating.
5. The composite fabric (100) as claimed in claim 1, wherein the composite fabric (100) comprises bonding agents to provide good adhesion to the plastisol/organosol.
6. The composite fabric (100) as claimed in claim 1, wherein the insulating material is selected from a group comprising poly vinyl chloride (PVC), polyurethane (PU), polyethylene (PE), polypropylene (PP), high density polyethylene (HDPE), low density polyethylene (LDPE), ethyl vinyl acetate (EVA), poly vinyl alcohol (PVA).
7. The composite fabric (100) as claimed in claim 1, wherein the coating (103) includes pigments to produce the composite fabric in the desired colours.
8. The composite fabric (100) as claimed in claim 1, wherein the composite fabric (100) possess thermal conductivity, reflectivity, and emissivity.
9. The composite fabric (100) as claimed in claim 1, wherein the composite fabric (100) comprises a self-adhesive layer (105) laminated or coated on over the coating (103), wherein the self-adhesive layer (105) is made of a material selected from a group of materials comprising rubber, acrylic, polyurethane.
10. The composite fabric (100) as claimed in claim 1, wherein the composite fabric (100) comprises one or more stabilizers to prevent decomposition of the at least one of the plastisol and the organosol against UV rays and high temperature conditions.