Blackout Material

Abstract

A blackout material is provided and includes a woven fabric including a weft set and a warp set, the weft set being black. More than 50% of a first surface of the woven fabric comprises the warp set. The blackout material further comprises a light excluding coating on the outer surface of the woven fabric, the light excluding coating including at least one black layer. A method of making a blackout material is provided and includes weaving a woven fabric including a weft set and a warp set, the weft set being black. More than 50% of a first surface of the woven fabric comprises the warp set. The method further comprises applying a light excluding coating on the outer surface of the woven fabric.

What is claimed is: 
     
         1 . A blackout material comprising:
 a woven fabric including a weft set including a plurality of black weft yarns and a warp set including a plurality of warp yarns, the woven fabric having a first surface and a second surface; and   a light excluding coating on the second surface of the woven fabric, the light excluding coating including at least one black layer, wherein more than 50% of the second surface comprises the weft set.   
     
     
         2 . The material of  claim 1 , wherein more than 80% of the second surface comprises the weft set. 
     
     
         3 . The material of  claim 1 , wherein each of the warp yarns floats over four weft yarns before passing under one of the weft yarns. 
     
     
         4 . The material of  claim 1 , wherein at least one of the weft set or the warp set are flame retardant treated or inherently flame retardant. 
     
     
         5 . The material of  claim 4 , wherein at least one of the weft set or the warp set are made of polyester. 
     
     
         6 . The material of  claim 1 , wherein each pair of adjacent warp yarns passes under only non-adjacent weft yarns. 
     
     
         7 . The material of  claim 1 , wherein the light excluding coating includes at least one additional layer. 
     
     
         8 . The material of  claim 1 , wherein the light excluding coating is flame retardant. 
     
     
         9 . The material of  claim 8 , wherein the light excluding coating comprises acrylic. 
     
     
         10 . The material of  claim 1 , further comprising:
 a flock layer on an outer surface of the light excluding coating.   
     
     
         11 . The material of  claim 1 , further comprising:
 a water repellant agent on the second surface of the woven fabric.   
     
     
         12 . The material of  claim 1 , further comprising:
 a topical flame retardant agent on the second surface of the woven fabric.   
     
     
         13 . A method of making a blackout material comprising:
 weaving a woven fabric including a weft set and a warp set, the weft set being black, the woven fabric including a first surface and a second surface;   applying a light excluding coating on the second surface of the woven fabric; and   binding the light excluding coating to the woven fabric, wherein more than 50% of the second surface comprises the weft set.   
     
     
         14 . The method of  claim 13 , wherein weaving includes floating each of the warp yarns over four weft yarns before passing under one of the weft yarns. 
     
     
         15 . The method of  claim 13 , wherein applying a light excluding coating comprises applying a first black coating layer and applying a second coating layer. 
     
     
         16 . The method of  claim 13 , wherein binding includes exposing the woven fabric and light excluding coating to a calendar operation. 
     
     
         17 . The method of  claim 13 , further comprising:
 applying a flock layer to an outer surface of the light excluding coating.   
     
     
         18 . The method of  claim 17 , wherein the flock layer is electrostatically applied to the outer surface of the light excluding coating. 
     
     
         19 . The method of  claim 13 , further comprising:
 applying a water repellant agent to the woven fabric before applying the light excluding coating.   
     
     
         20 . The method of  claim 13 , further comprising:
 applying a topical flame retardant agent to the woven fabric before applying the light excluding coating.