CARPET WITH AN ELECTROLUMINESCENT LAYER

Abstract

A carpet for a vehicle comprising at least one backing layer and a pile having a front and rear side, wherein the pile comprises yarns and/or filaments and/or staple fibers, characterised in that the carpet further comprises at least one area comprising a flexible multilayer comprising, a transparent conductive layer facing the pile, a dielectric layer, a light emitting layer comprising electroluminescent material situated directly in between the transparent conductive layer and the dielectric layer, a second conductive layer adjacent to the dielectric layer facing away from the pile and wherein the second conductive layer is not in contact with the transparent conductive layer, and wherein the flexible multilayer is connectable to means for conducting alternating electrical current (AC) such that the light emitting layer comprising electroluminescent material emits light at least through the pile in response to the alternating electrical field (AC), and wherein the at least one backing layer is a transparent or translucent impervious thermoplastic flexible layer situated between the front side of the pile and the flexible multilayer wherein at least some of the yarns and/or filaments and/or staple fibers contact the transparent or translucent impervious thermoplastic flexible layer preferably being partly embedded in the transparent or translucent impervious thermoplastic flexible layer.

Claims

1. A carpet for a vehicle comprising at least one backing layer and a pile having a front and rear side, wherein the pile comprises yarns and/or filaments and/or staple fibers, characterized in that the carpet further comprises at least one area comprising a flexible multilayer comprising, a transparent conductive layer facing the pile, a dielectric layer, a light emitting layer comprising electroluminescent material situated directly in between the transparent conductive layer and the dielectric layer, a second conductive layer adjacent to the dielectric layer facing away from the pile and wherein the second conductive layer is not in contact with the transparent conductive layer, and wherein the flexible multilayer is connectable to means for conducting alternating electrical current (AC) such that the light emitting layer comprising electroluminescent material emits light at least through the pile in response to the alternating electrical field (AC), and wherein the at least one backing layer is a transparent or translucent impervious thermoplastic flexible layer situated between the front side of the pile and the flexible multilayer wherein at least some of the yarns and/or filaments and/or staple fibers contact the transparent or translucent impervious thermoplastic flexible layer preferably being partly embedded in the transparent or translucent impervious thermoplastic flexible layer.

2. A carpet for a vehicle comprising at least one backing layer and a pile having a front and rear side, wherein the pile comprises yarns and/or filaments and/or staple fibers, characterized in that the carpet further comprises at least one area comprising a flexible multilayer comprising, a transparent conductive layer facing the pile, a second conductive layer, a dielectric light emitting layer comprising electroluminescent material situated directly in between the transparent conductive layer and the second conductive layer, and wherein the second conductive layer is not in contact with the transparent conductive layer, and wherein the flexible multilayer is connectable to means for conducting alternating electrical current (AC) such that the light emitting layer comprising electroluminescent material emits light at least through the pile in response to the alternating electrical field (AC), and wherein the at least one backing layer is a transparent or translucent impervious thermoplastic flexible layer situated between the front side of the pile and the flexible multilayer wherein at least some of the yarns and/or filaments and/or staple fibers contact the transparent or translucent impervious thermoplastic flexible layer preferably being partly embedded in the transparent or translucent impervious thermoplastic flexible layer.

3. A carpet for a vehicle according to claim 2 wherein the transparent or translucent impervious thermoplastic flexible layer has a viscosity between 3000 and 50000 mPa.Math.s, preferably between 4000 and 20000 mPa.Math.s, preferably between 5000 and 10000 mPa.Math.s measured according to ISO 11443.

4. A carpet for a vehicle according to claim 2 wherein the carpet is a tufted carpet, a needle punched carpe, a Dilour carpet, a carpet with a flocked surface.

5. A carpet for a vehicle according to claim 2 further comprising a permeable second backing layer being a primary backing and/or further comprising a permeable locking layer.

6. A carpet for a vehicle according to claim 2 wherein the transparent or translucent impervious thermoplastic flexible layer has an elastic modulus in the range of 1 to 200 MPa, preferably 20 to 150 MPa, preferably 30 to 100 MPa measured according to ISO 527.

7. A carpet for a vehicle according to claim 2 wherein the transparent or translucent impervious thermoplastic flexible layer is a viscoelastic layer.

8. A carpet for a vehicle according to claim 2 wherein a flexible substrate layer is directly connected to the second conductive layer, preferably the flexible substrate layer is impervious.

9. A carpet for a vehicle according to claim 1 wherein the transparent or translucent impervious thermoplastic flexible layer comprise a polymer selected from the group consisting of polyolefin such as polypropylene (PP) or polyethylene (PE) or propylene ethylene copolymers (CoPE) or high density polyethylene (HDPE) or low density polyethylene (LDPE) or linear low density polyethylene (LLDPE) or maleic anhydride grafted polyolefin (MAPE) or maleic anhydride grafted polyolefin elastomer, polyethylene terephthalate (PET), copolyester (CoPET), polyamide (PA6, PA66, PA12), copolyamide (CoPA), thermoplastic elastomers (TPE) such as styrenic block copolymers (TPS) or polyolefin elastomers (POE), thermoplastic polyolefin elastomers (TPO or TPE-o), Thermoplastic Vulcanizates (TPE-v or TPV), Thermoplastic polyurethanes (TPU), Thermoplastic copolyester (TPC or TPE-E), Thermoplastic polyamides (TPA or TPE-A) and latex.

10. A carpet for a vehicle according to claim 2 wherein the thickness of transparent or translucent impervious thermoplastic flexible layer is between 0.2 mm and 5 mm, preferably between 0.5 mm and 3 mm, preferably between 1 mm and 2 mm.

11. A carpet for a vehicle according to claim 2 wherein at least one of the second conductive layer, flexible substrate layer or the dielectric layer is a reflective opaque layer.

12. A carpet for a vehicle according to claim 2 wherein the layers of the flexible multilayer and or at least one of the layer's transparent or translucent impervious thermoplastic flexible layer and flexible substrate layer are printed layers preferably printed by screen printing.

13. A carpet for a vehicle according to claim 2 wherein the area weight of the pile is at least 150 gsm, preferably at least 250 gsm, preferably between 400 gsm and 2000 gsm, preferably between 400 and 1200 gsm, preferably between 400 and 800 gsm.

14. A carpet for a vehicle according to claim 2 wherein at least some of the yarns comprise transparent or translucent filaments or staple fibers, preferably these yarns comprise between 5 and 60%, preferably between 10 and 50%, preferably between 20 and 40% transparent or translucent filaments or staple fibers wherein the percentage is calculated as a percentage of cross section surface area of the yarn.

15. A carpet for a vehicle according to claim 2 comprising a fibrous or foam layer and wherein the flexible multilayer is situated between the fibrous or foam layer and the pile.

16. A method of using a carpet according to claim 1 for covering any one of flooring, inner dash, side panels, instrument panel, door trim, parcel shelf, side trims, consoles, load floors, or on any other surface within the passenger compartment, and/or in the front or rear trunk.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0084] FIGS. 1 and 2 show a schematic cross section of a carpet (10) for a vehicle with the EL lamp according to the invention.

[0085] FIG. 3 shows a schematic cross section of a carpet (10) for a vehicle with the EL lamp according to the invention wherein the EL lamp is encapsulated.

[0086] FIG. 4 shows a schematic cross section of a carpet (10) with the EL lamp according to the invention.

[0087] FIG. 5 shows a schematic cross section of a carpet (10) being a tufted carpet with the EL lamp according to the invention.

[0088] FIG. 6 shows a schematic cross section of a carpet (10) being a tufted carpet with partly reduced pile height and with the EL lamp according to the invention.

[0089] FIG. 7 shows a schematic cross section of a carpet (10) with partly reduced backing layer and with the EL lamp according to the invention.

[0090] FIG. 8 shows a schematic cross section of yarn (20).

[0091] FIG. 9 shows a schematic top view of a carpet with an EL lamp in operation.

[0092] FIGS. 10A and 10B show a schematic top view of a carpet with an EL lamp in operation.

DETAILED DESCRIPTION

[0093] FIG. 1 shows a schematic cross section of a carpet (10) for a vehicle with the EL lamp according to the invention comprising a pile (1), having a front (22) and rear (23) side and a flexible multilayer (2). The front side is facing the interior when the carpet is mounted inside the vehicle. The flexible multilayer (2) consists in the example of a transparent conductive layer (4), a light emitting layer comprising electroluminescent material (5), a dielectric layer (6) and a second conductive layer (7). The transparent or translucent impervious thermoplastic flexible layer (3) bonds the flexible multilayer (2) to the pile and ensures a good light guidance and light transfer through the pile. Optionally a flexible substrate layer (8) is connected to the flexible multilayer (2) and preferably this layer is impervious to liquids and moisture. The flexible substrate layer (8) is preferably lager than the flexible multilayer (2) and laminated against the transparent or translucent impervious thermoplastic flexible layer (3) outside the area of the flexible multilayer (2) thereby encapsulating and sealing the flexible multilayer (2) from liquids and moisture. The AC power is connected to the transparent conductive layer (4) and the second conductive layer (7). The layers of the flexible multilayer (2) are preferably printed on the transparent or translucent impervious thermoplastic flexible layer (3) or the flexible substrate layer (8).

[0094] FIG. 2 shows a schematic cross section of a carpet (10) according to the invention similar to the carpet as shown in FIG. 1. In FIG. 2 the light emitting layer comprising electroluminescent material and the dielectric layer is replaced by a dielectric light emitting layer comprising electroluminescent material (9) wherein the functions of the two layers are combined in one layer. Otherwise the layers and numbering are the same as in FIG. 1.

[0095] FIG. 3 shows a schematic cross section of a carpet (10) according to the invention. The layers of the flexible multilayer (2) are printed one by one to a flexible substrate layer (8) and the transparent or translucent impervious thermoplastic flexible layer (3) is bonding the flexible multilayer (2) to the carpet and the pile (1). Both the flexible substrate layer (8) and the transparent or translucent impervious thermoplastic flexible layer (3) extends further than the flexible multilayer (2) and are laminated together and encapsulating the flexible multilayer (2) and thereby protecting the EL lamp from liquids and moisture. The flexible multilayer (2) is situated between the pile (1) and a decoupling layer (11) being a porous foam layer or a porous felt layer.

[0096] FIG. 4 shows a schematic cross section of a carpet (10) with the EL lamp according to the invention. The pile (1) comprises staple fibers (12), and wherein the carpet further comprises a locking layer (19), indicated by the thick dashed line. The locking layer is preferably permeable and the transparent or translucent impervious thermoplastic flexible layer can penetrate through the locking layer during production and the staple fibers of the pile (1) are contacting the transparent or translucent impervious thermoplastic flexible layer (3) and are even partly embedded in the transparent or translucent impervious thermoplastic flexible layer (3). The flexible multilayer (2) is situated between the transparent or translucent impervious thermoplastic flexible layer (3) and a flexible substrate layer (8). Since the staple fibers are partly contacting and being partly embedded into the transparent or translucent impervious thermoplastic flexible layer (3) the light from the flexible multilayer (2) is efficiently transmitted through the carpet pile (1) from the rear (23) side to the front (22) side of the pile (1). The height (15) of the pile (1) is measured from the backing closest to the front side of the pile.

[0097] FIG. 5 shows a schematic cross section of a carpet (10) being a tufted carpet with the EL lamp according to the invention. The pile (1) comprises yarns (14) and wherein the carpet further comprises a locking layer (19), indicated by the thick dashed line. The locking layer is preferably permeable and the transparent or translucent impervious thermoplastic flexible layer can penetrate through the locking layer during production and the yarns or filament or staple fibers of the pile (1) are contacting and are even partly being embedded in the transparent or translucent impervious thermoplastic flexible layer (3). The carpet further comprises a primary backing layer (13) situated between locking layer (19) and the front (22) side of the pile (1). The flexible multilayer (2) is situated between the transparent or translucent impervious thermoplastic flexible layer (3) and a flexible substrate layer (8). Since the yarns are contacting and are even partly embedded into the transparent or translucent impervious thermoplastic flexible layer (3) the light from the flexible multilayer (2) is efficiently transmitted through the carpet pile (1) from the rear (23) side to the front (22) side of the pile (1). The height (15) of the pile (1) is measured from backing closest to the front side, for example the primary backing (13).

[0098] FIG. 6 shows a similar carpet (10) according to the invention as shown in FIG. 5 with the only difference that the carpet has at least one area (17) with reduced pile height (16). Otherwise the layers and numbering are the same as in FIG. 5. The reduced pile height is further improving the transmittance of the light through the carpet pile.

[0099] FIG. 7 shows a similar carpet (10) according to the invention as shown in FIG. 4 wherein the carpet comprises an additional backing (27) and wherein the carpet has at least one area (18) of the additional backing (27) with reduced thickness. If the additional backing (27) is very thick and or dense it may be necessary to locally reduce the thickness of the backing where the flexible multilayer (2) is situated in order to ensure that enough light can pass through. In this area the thickness of the transparent or translucent impervious thermoplastic flexible layer (3) may, at least locally, be thicker in order to compensate for the reduced thickness of the backing.

[0100] FIG. 8 shows a schematic cross section of a yarn (20) wherein the yarn comprises filaments or staple fibers. The cross section surface area (21) of each filament or staple fiber can be calculated from the measured filaments or staple fibers diameter or [or] the linear density expressed in for example deniers, tex, or dtex value. Preferably the yarns of the carpet pile comprise transparent or translucent filaments or staple fibers and the percentage transparent filaments or staple fibers is calculated as a percentage of the total cross section surface area of the yarn. The total cross section surface area of the yarn is the total cross section surface area (21) of all filament or staple fiber forming the yarn.

[0101] FIGS. 9, 10A and 10B show schematic top views (24) of carpets with an EL lamp in operation. The figures are based on photos that have been recolored to back and white, wherein the white areas are areas where light shines through the carpet and black areas or spots are places when no light or very limited amount of light shines through the carpet pile.

[0102] FIG. 9 shows a blond tufted carpet with a pile and a primary backing layer (not shown in the figure), for example as shown in FIG. 5. The sample is divided in two areas, separated in the figure by the dashed line. The right area (25) is according to the invention wherein the EL lamp is laminated to the carpet with the transparent or translucent impervious thermoplastic flexible layer and wherein the yarns are partly embedded in the transparent or translucent impervious thermoplastic flexible layer. The left area (26) of the sample is not according to the invention and has the EL lamp connected directly to the carpet without the transparent or translucent impervious thermoplastic flexible layer. Also the right area (25) has some back spots at the edge due to delamination of the lamp during sample preparation.

[0103] The tufted carpet has a pile with an area weight of 380 gsm and a pile height of 3.5 mm and 58 stitches/10 cm in the machine direction and 5/64 stitching gauge in the cross direction. The carpet has a white 120 gsm PET/CoPET primary backing and a permeable locking layer consisting of 70 gsm latex combined with 260 gsm LDPE. The transparent or translucent impervious thermoplastic flexible layer (3), not shown in the figure, is a 2 mm modified PP layer. The elastic modulus was measured according to the current ISO 527-2, sample type 5A. The following test settings were used: clamping distance 50 mm, gauge length 20 mm, Pre-load 0.5N, E-Modulus evaluation range 0.05-0.25%, E-Modulus test speed 1 mm/min. The elastic modulus was measured to 3 MPa. The viscosity was measured to 6000 mPa.Math.s according to ISO 11443:2014.

[0104] The EL lamp is according to the invention as shown in FIG. 1, with a light emitting layer comprising electroluminescent material (5) wherein the electroluminescent material is copper doped zinc sulfide (ZnS:Cu).

[0105] As can clearly be seen in FIG. 9 the transparent or translucent impervious thermoplastic flexible layer bonding the EL lamp to the carpet increases the light passing through the carpet compared to a carpet without the transparent or translucent impervious thermoplastic flexible layer.

[0106] FIGS. 10A and 10B show a black tufted carpet with a pile and a primary backing layer (not shown in the figure), for example as shown in FIG. 5. The carpet (28) in FIG. 10A does not have the transparent or translucent impervious thermoplastic flexible layer (3) and the carpet (29) in FIG. 10B is according to the invention where the EL lamp is laminated to the carpet by the transparent or translucent impervious thermoplastic flexible layer (3) and where at least some of the yarns are partly embedded into the transparent or translucent impervious thermoplastic flexible layer (3).

[0107] The tufted carpet has a dense pile with an area weight of 1120 gsm and a pile height of 3.5 mm and 43 stitches/10 cm in the machine direction and 1/10 stitching gauge in the cross direction. The carpet has a permeable beige PP primary backing and a locking layer with total area weight of 130 gsm. The yarns of the carpet pile comprise 42% transparent PA filaments and 58% non-transparent black PA filaments. The yarns comprise 384 non-transparent filaments, with diameter 33.7 micrometres and 8 transparent filaments with diameter 200 micrometres.

[0108] The transparent or translucent impervious thermoplastic flexible layer (3), (not shown in the figure), is a 2 mm modified PP layer. The elastic modulus was measured according to the current ISO 527-2, sample type 5A. The following test settings were used: clamping distance 50 mm, gauge length 20 mm, Pre-load 0.5N, E-Modulus evaluation range 0.05-0.25%, E-Modulus test speed 1 mm/min. The elastic modulus was measured to 3 MPa. The viscosity was measured to 6000 mPa.Math.s according to ISO 11443:2014.

[0109] The EL lamp is according to the invention as shown in FIG. 1, with a light emitting layer comprising electroluminescent material (5) wherein the electroluminescent material is copper doped zinc sulfide (ZnS:Cu).

[0110] The transparent or translucent impervious thermoplastic flexible layer bonding the EL lamp to the carpet increases the light passing through the carpet compared to a carpet without the transparent or translucent impervious thermoplastic flexible layer. The effect of the transparent yarn is much more effective when the yarns are partly embedded into the transparent or translucent impervious thermoplastic flexible layer (3).