Method and system for making light-blocking articles

A method for providing a foamed, opacifying element having a target light blocking value (LBVT) and required physical properties, the foamed, opacifying element comprising a textile fabric substrate having a first supporting side and an opposing second supporting side,

• the method comprising:
• providing a textile fabric substrate;
• determining a light blocking value (LBVS) of the textile fabric porous substrate;
• choosing a target light blocking value (LBVT) of at least 3 and greater than LBVS;
• calculating LBVT-S as a difference between LBVT and LBVS;
• choosing a foamable aqueous composition that provides the required physical properties in the foamed, opacifying element;
• using an empirical mathematical formula to determine a dry coating weight of a single dry opacifying layer derived from the chosen foamable aqueous composition, of at least 40 g/m2 and up to and including 300 g/m2, in order to achieve the calculated LBVT-S;
• foaming the chosen foamable aqueous composition to form a foamed aqueous composition having a foam density of at least 0.1 g/m3 and up to and including 0.4 g/cm3;
• applying an amount of the foamed aqueous composition to the first supporting side of the textile fabric substrate,
• drying the applied foamed aqueous composition to provide the dry coating weight and a dry thickness of a dry layer;
• and
• densifying the dry layer at a crushing pressure of at least 5 pounds per linear inch and up to and including 800 pounds per linear inch such that the dry layer dry thickness is reduced by at least 20%,
• to form the single dry opacifying layer disposed on the first supporting side of the textile fabric substrate, such that the single dry opacifying layer has a light blocking value that is equal to LBVT-S, +/−15%, thereby forming the foamed, opacifying element having the target light blocking value (LBVT)+/−15%.