WO2021053616A1

WO2021053616A1 - Smart illuminated carpet and manufacturing method thereof

Info

Publication number: WO2021053616A1
Application number: PCT/IB2020/058734
Authority: WO
Inventors: André Filipe BARBOSA MOREIRA DA SILVA; Catarina Rosa FRAGA DIAS; Ana Rita BRANDÃO SILVA; Maria Cristina FERREIRA DE SÁ BARBOSA; Bruno PAIVA DA COSTA; Fernanda Maria FERREIRA DE SÁ BARBOSA; Ricardo Manuel CUNHA SILVA; Daniela Cristina RODRIGUES CAMPANHÃ; Nelson Manuel FEIO DURÃES; Bruno Guilherme Gonçalves de Matos; Maria José GOMES FERNANDES; Albertino João BRITO GOTH; Elanice DELGADO LIMA; Juliana Patrícia DA SILVA SOARES; Marta Sofia DA SILVA MIDÃO
Original assignee: Tapecarias Ferreira De Sa Lda
Current assignee: Tapecarias Ferreira De Sa Lda
Priority date: 2019-09-18
Filing date: 2020-09-18
Publication date: 2021-03-25
Anticipated expiration: 2022-03-18

Abstract

The present application describes a smart illuminated carpet, controlled remotely and/or by means of presence sensors and the manufacturing method thereof. Optical textile fibers (light conductive filaments) are used in the developed carpet, directly integrated in the textile structure, which allied to the use of an incorporated lighting and sensing system, allow to obtain a carpet with interactive and personalized lighting, without jeopardizing the appearance and comfort of a conventional carpet.

Description

SMART ILLUMINATED CARPET AND MANUFACTURING METHOD THEREOF

TECHNICAL FIELD

The present application describes a smart illuminated carpet, controlled remotely and/or by means of presence sensors and the manufacturing method thereof.

BACKGROUND

As regards the use of LED matrices and with potential for use in interactive publicity in textiles, it is known in the market the existence of some solutions, such as for example the product Luminous Carpets™, commercialized by Philips, which allows to control the information to be presented (text and/or image) via mobile phone or computer. This product simultaneously allows to light the carpets for larger areas by means of the coupling of several LED panels. However, in the referred product, the LED panel is not integrated in the material, being just placed underneath the carpet, providing an extra thickness to the product.

Another company called Experia, is a manufacturer of carpets with LED integration and rigid optical fibers, and presents products such as the Fibre Optic Carpet, the Interactive LED Circle Carpet and the Interactive LED and Carpet. These products use a light source that is external to the carpet where the LED integration is executed manually. The products Interactive LED Circle Carpet and the Interactive LED and Carpet comprise an additional pressure sensing characteristic, allowing to solely light the areas that are stepped on by the user. When applied to a carpet, as presently disclosed, it is possible to have one sole product where by means of the integration of lighting systems (Electroluminescent and LEDs) it is possible, together with the application of located and personalized filaments (light conductors) to transmit specific patterns and designs, according to the client's requests. This solution is distinct from the ones that are currently available, inasmuch as the optical transmission means is a textile fiber (does not affect the comfort of the carpet), capable of being directly integrated in the textile structure by tufting, while all the electronics and lighting systems are coupled at the rear of the carpet, in a manner that is imperceptible to the user. Thereby, it is possible to obtain a carpet with personalized lighting, without jeopardizing the appearance and comfort of a conventional carpet.

SUMMARY

The present application describes a smart carpet characterized by comprising the following elements: i. Textile fabric (2); ii. Textile carpet yarns (1) placed throughout the textile fabric; iii. Light conductive filaments (1.1) placed throughout the textile fabric together with the textile carpet yarns (1); iv. Lighting system (4) that comprises a luminous source capable of emitting light to the light conductive filaments (1.1); v. Sensing system (5) configured to detect mechanical actions on the surface of the smart carpet; vi. Electronic system (6) configured to receive information from the sensing system (5) and to activate the lighting system (4); vii. And an adhesive layer (3) located between the textile fabric and the lighting system (4), allowing the assembly of the elements that comprise the smart carpet.

In a particular embodiment of the smart carpet, the light conductive filaments (1.1) transmit the light generated by the lighting system (4) to the surface of the carpet.

In another particular embodiment of the smart carpet, the lighting system (4) comprises the use of LED technology or electroluminescence .

In another particular embodiment of the smart carpet, the lighting system (4) comprises a distribution of LEDs in the matrices having less than 1 mm spacing, less than 2.5 mm height, less than 5 mm width and a viewing angle above 120°.

In another particular embodiment of the smart carpet, the sensing system (5) comprises capacitive-type sensors with a structure based on planar electrodes.

In another particular embodiment of the smart carpet the sensing system (5) comprises temperature and humidity integrated sensors.

In another particular embodiment of the smart carpet,the electronic system (6) comprises an energy supply and conversion system. In another particular embodiment of the smart carpet the electronic system (6) comprises communication protocols that are compatible with the sensing and lighting modules integrated in said carpet.

In another particular embodiment of the smart carpet the electronic system (6) comprises communication protocols that are compatible with the use of remote equipment of the user.

In another particular embodiment of the smart carpet, the textile fabric (2) comprisesSmyrna.

The present application further describes a manufacturing method of the smart carpet wherein the following steps are carried out:

- inserting light conductive filaments (1.1) and the textile yarns (1) in the same textile fabric (2);

- applying a layer of transparent coating (3) between the textile fabric (2) and the lighting system (4); -integrating the sensing system (5) immediately behind the lighting system (4); integrating the electronic control system (6) immediately behind the sensing system (5);

- applying a levelling layer (7), immediately behind the electronic control system (6), which will contain all the lighting (4), sensing (5) and electronic (6) systems;

- final coating that includes the sealing of said carpet with the final application of the coating layer (9) and textile fabric (8).

In yet another particular embodiment of the manufacturing method of the smart carpet, the light conductive filaments (1.1) are obtained by resorting to the continuous filament extrusion spinning technique presenting a S-twist with 100 twists/m and a double cable Z-retwist with 300 twists/m, 2500 dtex linear density, 0.80 cN/dtex tenacity, 30% elongation and 2060 cN breaking strength, vapor stabilized at 90 °C for 15 minutes.

In yet another particular embodiment of the manufacturing method of the smart carpet, the textile carpet yearns (1) are introduced in the textile fabric structure by means of a robotic tufting process, that resorts to the use of injection nozzles which are altered to increase the capacity for punching the textile fabric, where the stiffness of said nozzles is optimized, as well as the inner injection tube for yarn aspiration by Venturi effect.

In yet another particular embodiment of the manufacturing method of the smart carpet, the manufacture of the electroluminescent lighting system (4) comprises the serigraph printing of four different layers of ink, wherein two electrodes are comprised of conductive materials, wherein one of them shall be transparent, one dielectric material and one semi-conductive material comprised of phosphoric inks, in flexible substrates.

Finally, in another particular embodiment of the manufacturing method of the smart carpet, the sensing system (5) comprises serigraph printing, on flexible and laminated substrates with an adhesive consisting of glycol-modified

PET. GENERAL DESCRIPTION

The technology presented herein belongs to the field of industrially manufactured carpets and particularly the field of illuminated and sensorized carpets.

In this sense, the product presented is an answer to the opportunity and the need for the market to develop innovative carpets, integrated with lighting/sensing systems capable of generating luminous effects on the surface of the carpet. The luminous effects generated can be used for several purposes, such as the creation of relaxation spaces, safety, and people orientation, waiting rooms, decoration, or publicity environment, promoting trademarks or places. Associated with the luminous effects, the integration of sensors in the carpet is correlated, which will allow the detection of the presence of the user, increasing the dynamism and interaction with the carpet and with the surrounding ambience in which it is integrated. By having the lighting and sensing systems related, it is possible by means of touch/presence of a person on the carpet, to create luminous dynamics and, consequently, interactivity. In this manner, in continuity with the interactivity with the user a mobile application was developed which allows to control and monitor the carpet, stimulating, and capacitating, in terms of dynamism.

The lighting and sensing systems developed comprise several components, where the following can be observed: i. Lighting system - lighting technologies based on LEDs and/or Electroluminescence; ii. Optical transmission means - light conductive filaments; iii. Insulator, silicon based on organic polymers

(dimethylpolysiloxane or polydimethylsiloxane), for lighting and sensing systems - allows the protection of the different systems, without jeopardizing the efficient passage of light from the lighting systems to the surface of the carpet through the optical transmission means; iv. Sensing system - capacitive sensing technology that will allow the user to interact with the carpet; v. Electronic and electric systems (monitoring/local control hardware); vi. Application for remote control and monitoring.

The integration of the lighting, sensing and hardware systems used in the textile structure is characterized by being one of the innovations in carpet making, since there is the direct application of these components in the carpet, whereby they are subject to mechanical actions (pressures), and chemical (washing, liquid spillage, among others). On the other hand, it must be emphasized that the use of an insulator must simultaneously increase the mechanical and chemical resistance of both the elements that comprise the carpet as well as not interfering in the process of transmission of light from the lighting system to the carpet surface.

DESCRIPTION OF THE FIGURES

For an easier understanding of the present application there are figures attached which represent embodiments that, however, do not intend to limit the technology herein disclosed.

Figure 1 is representative of the inclusion of the components of the carpet now presented, being illustrated the following elements: 1. Textile carpet yarns and light conductive filaments;

2. Textile fabric;

3. Coating layer / backing;

4. Lighting system (LEDs or Electroluminescent);

5. Sensing system;

6.Electronic and electric system;

7. Textile underlayer;

8. Textile fabric;

9. Coating layer / backing.

In Figure 2 the following elements are represented in detail: 1.Textile carpet yarns;

1.1 Light conductive filaments;

DESCRIPTION OF EMBODIMENTS

Referring to the figures, some embodiments are now described in a more detailed manner, which do not intend, however, to limit the scope of the present application.

Throughout the present application a carpet is described, called a smart illuminated carpet controlled remotely and/or by means of presence sensors and the manufacturing method thereof, which comprises several components, among which the following may be observed: i. Lighting system - lighting technologies based on LEDs and/or Electroluminescence; ii. Optical transmission means - light conductive filaments; iii. Insulator, silicon based on organic polymers

(dimethylpolysiloxane or polydimethylsiloxane), for lighting and sensing systems - allows the protection of the different systems, without jeopardizing the efficient passage of light from the lighting systems to the surface of the carpet through the optical transmission means; iv. Sensing system - capacitive sensing technology that will allow the user to interact with the carpet, detecting mechanical actions on the surface thereof; v. Electronic and electric systems (monitoring/local control hardware); vi. Application for remote control and monitoring.

In a more complete manner, the technology presented in Figure 1, covers the integration by robotic process of insertion of light conductive filaments in the carpet's traditional structure (tufting). In this manner, in order to fix the light conductive filaments and traditional textile yarns in the same textile fabric, preferably Smyrna, without compromising the transmission of light from the lighting systems inserted immediately behind the layer 3, a transparent coating is applied (layer 3). Right after the zone of the lighting systems (layer 4), the sensing system (layer 5) will also be integrated, touch/proximity sensors in flexible substrates, in strategic zones to improve the sensitivity. In continuity, an insulator will also be applied, silicon based on organic polymer

(dimethylpolysiloxane or polydimethylsiloxane), to the zone that contains all the lighting, sensing, and electronic systems to protect all the components involved. The manufacture of this type of carpet further includes one more step of final coating with the purpose of finishing off and sealing the resulting smart carpet.

Parallelly to the development of the carpet with said properties, an electronic control system will be developed, which will allow to monitor and receive information from the sensing system in real time, acting and activating the lighting system. This system will also receive data from a mobile application for the remote control of the carpet, thus allowing to turn on or off the system, alter patterns, control the intensity of the lighting system, among others.

LIGHT CONDUCTIVE FILAMENTS

Considering one of the purposes of the technology developed that comprises the lighting for decorative purposes, relaxation, signposting or others that require light points, there exist several approaches that allow the transfer of light from the source thereof to the intended illumination point.

The light guides are the preferred technology, and they are used in the process of transport between the source and the carpet surface, being subsequently integrated in the textile structure of the product. They present in their construction materials with optical properties, most of which comprised of acrylic resins, polycarbonate, epoxies, and glass.

The above cited materials used overall in conventional light guides are rigid, and present inadequate flexibility and comfort properties, both in the integrating processes (insertion or robotic tufting) as in their final utilization. With the purpose of rectifying the inherent difficulties with the insertion in carpets with conventional optical fibers, flexible polymeric filaments were developed that are capable of transmitting light by means of the adjustment of the process parameters (elongation, relaxation, twist and stabilization) so as to maximize the suitability thereof to the robotic tufting process used for the insertion of the yarns in carpets.

The correct coupling between the lighting system and the transmission means, that is, between the LED and the light guide, is essential. This process aims to optimize the process of optical losses in the effective transmission of light in all the structure, allowing the exit of the light from the guide with the minimum losses. To guarantee the referred points and minimize the flow losses, there exists the possibility of being used in the mounting thereof lenses and/or light reflectors.

For the light conductive filaments, the use of polymeric transparent materials is proposed with the possibility of being extruded or co-extruded, granting to the carpet the same characteristics of comfort and durability as that of the traditional materials used, being the most frequently used the acrylics and the polycarbonates.

Alternatively, the cyclic olefin co-polymers (COC) are a relatively new class of materials that present optical properties that are comparable with those of glass which, when compared with the acrylics or the polycarbonates, present a low content of humidity absorption, which in connection with the processing and integration with the carpet may be an advantage. Other characteristics, such as rigidity and glass transition temperature, may vary according to the percentage of the co-monomer.

With the intent of offering a larger number of alternatives to the implementation, namely of the COC, which may present some disadvantages as regards abrasion or comfort, other materials are also considered that, in detriment of a lesser transparency, might be compatible with the desired specifications, without neglecting the desired performance as regards the intended lighting to the surface of the carpet. In this alternative, plastomer materials are further considered, based on olefins that present low modules of elasticity, but which by means of the co-extrusion allow to reach the extrusion simultaneously with several materials, enabling the combination of materials with different physical and rheological properties. The filament manufacturing trials were carried out by resorting to the technique of extrusion spinning, using a system of continuous filament extrusion (BCF - Bulked Continuous Filament), provided by Hills Inc. The filaments produced have cylindrical section structures comprised solely by a cyclic olefin co-polymer. Parameters such as the temperature profile, loss and spinning speed were adjusted to assure a stable process maintaining the mechanical and optical characteristics within the adequate and specified ranges for the tufting process.

Taking as an example the production of a continuous filament with a specified linear density of 1250dtex (g/lOOOOm), the conditions that were most suitable for the processing of the material are described in Tables 1 and 2.

Table 1 . Temperature and loss profiles used in the fiber extrusion process with light conductive capacity.

Table 2 . Processing conditions for spinning of light conductive filaments.

The produced filaments were submitted to twisting, retwisting and vapor stabilization processes according to Table 3.

Table 3. Twisting, retwisting and stabilization conditions of the light conductive filaments.

Based on the described conditions, a plurality of light conductive filaments was developed with 2500 dtex linear density, 8 cN/tex tenacity, 30% and 2060cN elongation and breaking strength, respectively.

This process allows to improve the capacity of transmission of light in the filament structure, the compliance with the mechanical properties and suitability to the integration process in the structure of carpet making by robotic tufting.

LIGHTING SYSTEMS

Referring to the lighting systems, these may be integrated in the carpet by two distinct manners, illumination with LEDs and illumination by means of electroluminescence. The placing of the light source is a critical point for the success of the proposed developments, since it must be capable of emitting light to the light conductive filaments, being perfectly aligned and with the most possible proximity to same.

The LED-based lighting system consists in utilizing LED matrices or rows that are available commercially, built on flexible substrates, such as for example PET (polyethylene terephthalate) . Subsequently to the construction on flexible substrates it is necessary to insulate the LEDs, since it is necessary to protect these from external factors that may contribute to damaging same. Subsequently, they are laminated with an adhesive consisting of glycol-modified PET, on the inner part of the carpet, it being necessary to take into account that in this stage it is crucial to ensure the alignment of the LEDs with the filaments, as well as the maximum proximity between them. For this kind of approach where commercial components are used, matrices or LED strips, monochromatic LED devices may be used (one color) or polychromatic (multiple colors) which when controlled trigger several colors and with variable intensity. When LED matrices are used it is possible to initiate luminous patterns/effects with several colors by means of the electronic control, according to the user's intention. As regards the technical characteristics of the matrices or strips, these cover a segment of LED devices from a simple color to multicolor depending on the aesthetic objective desired. In this multicolor aspect the RGB LED device (Red Green Blue) has a particular advantage when used since with the conjugation of these 3 primary colors it is possible to trigger a vast range of colors and variable intensity, due to the fact that in the construction thereof there is an integrated controller, being solely necessary to execute the communication to control and feed with a power source. As regards the LED dimensions, these must present height less than 2.5 mm, width less than 5 mm and further, a viewing angle of the color that is equal to or higher than 120°. The distribution of the LED devices in the matrices or strips must present a spacing of less than 1 mm thus contributing to the uniform distribution of light visualized on the surface of the carpet. These must be assembled on a flexible surface or flexible substrates due to the maneuverability of the overall structure. As an example of RGB LED matrix integration, the solution by Adafruit¹ of a flexible matrix with 8 lines by 32 columns with an integrated LED controller is a practical solution to the application in the structure of the carpet presented.

In order to provide this structure with mechanical and chemical resistance an insulator is applied, consisting essentially of a silicon based on organic polymers (dimethyl polysiloxane or polydimethylsiloxane ). The electric connection points for operating the matrices and/or LED strip are connected to the respective PCBs (Printed Circuit Boards) for control and adaptation of the energy levels.

As regards the electroluminescent lighting system, this is based on serigraph printing with four different layers of ink (two electrodes comprised of conductive materials, wherein one of them shall be transparent, a dielectric material and a semi-conductive material comprised of phosphoric inks), on flexible substrates. In this type of technology of serigraph printing, the pattern is printed and engraved on a porous screen, where the ink/paste is deposited for subsequent printing. During the process, a spatula presses the ink against the screen, transferring it to the substrate .

In a more detailed manner, this typology of monochromatic devices consists in depositing a layer of transparent conductive ink to obtain the light (1^st electrode), a layer of electroluminescent ink, responsible for the luminance of the resulting lamp, a layer of dielectric ink to avoid contact between the two electrodes preventing the occurrence of short-circuits, and a final layer of conductive ink (2^nd

'Flexible 8x32 NeoPixel RGB LED Matrix - btips://¾w .adafii;it.com/product/229 ; electrode) . In the present case a transparent conductive substrate of indium tin oxide (ITO), is used, where this is a substrate that presents conductivity on its surface, it only being necessary to print a layer of electroluminescent ink, DuPont 8152 B cured at 110 °C for 15 minutes, two layers of dielectric ink, DuPont 8153 cured at 110 °C for 15 minutes and finally a layer of silver conductive ink DuPont 5025 cured at 120 °C for 20 minutes.

The existence of intermediary layers, electroluminescent and dielectric, between the two electrodes is essential for forming a condenser. It must be observed that there exists a limitation as regards the color of the light emitted by electroluminescence, since it may only present two colors: blue and pink. Whereby, for the intended purpose, the color blue is most noticeable on the carpet surface. In this manner, when applied to an AC low voltage electric current there occurs the emission of photons by the phosphorus layer (electroluminescent) and consequently light is obtained. Finally, in order to guarantee the correct working of the electroluminescent device and the non-occurrence of short- circuits, it is extremely important that the deposition of the layers follow the order mentioned. Similarly, to the other approach to lighting systems, LEDS, these are also laminated with an adhesive consisting of glycol-modified PET, on the inner part of the carpet.

INTEGRATED SENSORS SYSTEM

As regards the sensing component integrated in the carpet, the use of integrated touch/proximity sensors is proposed. The objective of this system involves the detection of presence of the user in zones of the carpet, creating interactive effects. For this purpose, preferably capacitive sensors are used, for detecting presence since they present higher precision and higher immunity to the electric noise compared with resistive technology or piezoelectric for the same purpose. Additionally, the capacitive technology presents high resolution and sensitivity, even when reduced magnitudes of force are applied. In the context of comfort and integration these sensors are printed, by serigraphy, on flexible substrates laminated with an adhesive consisting of glycol- modified PET, on the carpet, in strategic zones for higher sensitivity of the sensor. The printing process used is previously described as a component of the lighting systems based on electroluminescence. The ink used for the printing of the capacitive sensors must comprise conductive properties that are compatible with the printing process and the printing process used and the substrate used must present flexibility to be capable of integrating in the carpet. In this sense, the ink used is a silver conductive ink, Du Pont 5025, the cure process is thermal, 120 °C for 20 minutes. The structure of the capacitive sensors is based on planar electrodes, thereby allowing the detection on multiple points when placed on strategic zones in the interior of the carpet.

ELECTRONIC SYSTEMS

As regards the electronic control hardware, this aims at the integration of different interface and functionality modules associated to acting components over the lighting, sensing, and control, without underestimating the protection and safety systems of all the integrated electronic developments. These systems are integrated in the inner layer of the carpets developed, according to the prerequisites and the specifications for the development of the electric and electronic circuits, summarized below: i. Electric energy supply and conversion system; ii. Integration of low energy consumption components; iii. Protection against electric phenomena; iv. Heat dissipation, in general; v. Systems for receival and filtration of signs; vi. Versatility and adaptability of modules; vii. Modularity of integrated systems and with reduced dimensions; viii. Communication protocols compatible between peripheral modules and user.

In this sense, the electronic and electric systems are comprised of several modules developed in PCBs (each module is a PCB), which are connected electrically between themselves (by wiring) and communicate within control units (micro-controllers) by communication protocol I²C (Inter-

Integrated Circuit). Thus, the architecture of the electronic and electric modules comprises a general control module (master) that coordinates, monitors and communicates with all the peripheral modules, but also with the user (mobile device) via Bluetooth technology. Each control/module interface will be electrically connected by wiring to the general control module and energy module (two electric power conductors and two for communication). Therefore: i. General control module (master) - this module is responsible for coordinating, monitoring, and communicating with all peripheral modules and with the App user on smartphone. At the construction level tis module is comprised of a Bluetooth device with privileged connection to the micro-controller, this contains the task processing algorithms triggered by each sensing or lighting action or for the communication, parallelly to the actions there exists a data logger of events and actions. To expand the memory capacity of this module it contains a memory outside the micro-controller, circuits for storing and insulating the communication signals, interface system with wiring for peripherals, integrated sensor for temperature and humidity, touch/presence sensor (for minimalist solution) and power converters, ii. LED interface module - this is responsible for controlling the energy, the intensity and the colors for all the patterns presented in the structures on matrix or in strips with the LED lighting technology, by means of the orders issued by the general control module. This module is comprised of a micro controller, circuits for sign interface for control for LED matrix, it further contains electric power converters, and monitoring thereof and circuits for connection interface for electric power and communication; iii. Electroluminescence interface module - this is responsible for adapting the tension levels and controlling the working of the electroluminescent lighting technology. This module is comprised of a micro-controller, circuits for interface for electric control of the electroluminescent, it further contains electric power converters and monitoring thereof and circuits for connection interface for electric power and communication; iv. Sensing module - this is comprised of a unit for control and monitoring of the values registered by the capacitive sensors applied to detect the presence (in the form of pressure). This module contains an integrated temperature and humidity sensor, instantly reporting the parameters to the general control; circuits for connection interface for capacitive sensors, circuits for connection interface for power and communication, a micro controller reporting instantly the parameters to the general control; v. Power and protection module - this is responsible for conversion of the power levels of 5 and 12 volts, and for protection and electric safety circuits of all the electronic devices against electric phenomena. This is comprised of transformers and electric power converters for all levels of the complete system, by protection and safety circuits by means of fuses, of voltage transient suppressors, polarity inversion and equipotential protection (earth conductor), this module contains circuits for connection interface for electric power and distribution of energy stored for the system. In this manner, the architecture of the electronic systems is fed by means of the power grid 120V to 240V AC which by means of the energy converters adjusts the tension levels to those defined in the system.

In this sense, the electronic and electric system provides the integrated technologies in the carpet with the functionalities mentioned above, emphasizing the energetic efficiency, the modularity and versatility of the system to expand the integrated modules in the system and the interactivity between them. Therefore, the carpet is provided with a larger interactivity area, being capable of demonstrating different forms of signposting, presence alerts or fall detection. CARPET MANUFACTURING PROCESS

The robotic tufting process is used to introduce the yarns in carpets. In this sense, the textile yarns that comprise the carpet as well as the light conductive filaments are introduced in a structure, usually of fabric, using a robot. In one preferred embodiment, the carpet yarns to be used may be 100% Visrayon Ne 16/2, or 100% Wool Nm 5.5/3, or 100% Wool Nm 16/2, or 100% Botanical Silk Ne 20/4/2, or 100% Botanical Silk Nm 7/3, or 100% Linen Nm 6/2. For the development of this robotic tufting technology, the injection nozzles were altered in order to increase the punching capacity of the textile fabric, the hardness of said nozzles having been optimized, as well as the inner injection tube for yarn aspiration by Venturi effect. Further, there were developed air reservoirs for stabilizing the yarn injection and a new piston with Venturi interior incorporated and improved. This robot has a nozzle that introduces one or several filaments through the fabric. The filaments are subsequently cut and reinserted in another point of the fabric forming a U type insertion, the filaments remaining perpendicular to the base fabric. The properties of the light conductive filaments were optimized to enable the incorporation thereof in the carpet by means of a tufting device used in the traditional yarn insertion. This process is carried out resorting to a specific yarn injection software, which enables the adjustment of specific parameters of the light conductive yarns and their respective characteristics, such as for example, their flexibility, surface friction or cut. In order to reduce the conditions for carpets with large dimensions, which originally required multiple part production, making it necessary to roll up with a reduced radius for the next step of production, it was necessary to use robots with larger dimensions. Subsequently to the insertion of the filaments, with the purpose of guaranteeing the fixation of the filaments in the textile fabric a layer of coating is applied after the insertion thereof. This coating was especially developed for this type of product and can be called backing. The insulator used for this coating, comprised of synthetic resins preferably copolymers based on vinyl acetate and ethylene, has properties that allow it to present a translucid aspect after drying, which enables the passage of light through the same being thus essential to maximize the intended luminous effect and provide better adherence of the yarns to the structure.

Subsequently to the carpet manufacturing process, where the textile yarns and light conductive filaments are inserted throughout the textile fabric (preferably Smyrna fabric) it is necessary to integrate the lighting and sensing systems to obtain a smart carpet. In this manner, after applying said backing layer, the lighting and sensing systems are integrated, being observed that both mentioned systems are in the same plane as well as all the electronics necessary to control same. However, the mentioned systems present different thicknesses, not only due to the insulation thereof, but also due to the different geometries they present, it being therefore necessary to uniformize the plane so that the different systems are not perceivable on the surface of the carpet. In this manner, in said plane, a layer of textile levelling is used, with the purpose of compensating the different thicknesses of the systems used, thus providing increase in comfort as well as acting to reduce the wear of the carpet, and to provide insulation from humidity and/or heat. It must be observed that subsequently to the integration of these systems, a Smyrna textile fabric is added and finally, a second coating/insulation layer for all the components that make up the carpet.

INTERFACE WITH THE USER

As regards the application of control/interface by the user, this follows the innovative aspect and the worldwide technological tendency of the "Internet of Things". Therefore, this application commands the acting modes over lighting (luminous patterns with different intensities and colors), and the sensor modes as regards the detection of the presence of the user and/or intruders.

In the matter of controllability and operability, the communication module is responsible for the interaction with the devices that are external to the system, with the purpose of there being communication with a smartphone or other similar device. In this manner, the micro-controller present in the general control module will act over the modules of the electroluminescence and LED components according to the orders/data originating from the sensors and from smartphones .

As regards the firmware present in the micro-controllers, this will be based on the concept of control algorithms over lighting and sensor component, in a functional, adaptive manner, with aesthetic value and personalized as well as the energetic efficiency and comfort for the final user.

The present specification is naturally not restricted in any manner to the embodiments presented in this document and a person of ordinary skill in the art may foresee many possibilities of modifying same without departing from the general idea, such as defined in the claims. The above- described preferred embodiments are obviously interchangeable between each other. The following claims further define preferred embodiments.

Claims

1. Smart carpet comprising the following elements: i. Textile fabric; ii. Textile carpet yarns placed throughout the textile fabric; iii. Light-conductive filaments placed throughout the textile fabric together with the textile carpet yarns; iv. Lighting system comprising a luminous source capable of emitting light to the light conductive filaments; v. Sensing system configured to detect mechanical actions on the surface of the smart carpet and comprising integrated temperature and humidity sensors; vi. Electronic system configured to receive information from the sensing system and to activate the lighting system; vii. and an adhesive layer located between the textile fabric and the lighting system, allowing the assembly of the elements that comprise the smart carpet.

2. Carpet according to claim 1, wherein the light conductive filaments transmit to the surface of the carpet the light generated by the lighting system.

3. Carpet according to claim 1, wherein the lighting system comprise the use of LED or electroluminescence technology.

4. Carpet according to any one of the previous claims, wherein the lighting system comprise a distribution of LEDs in the matrices having less than 1 mm spacing, less than 2.5 mm height, less than 5 mm width and a viewing angle above 120°.

5.Carpet according to claim 1, wherein the sensing system comprises capacitive-type sensors with a structure based on planar electrodes.

6.Carpet according to claim 1, wherein the electronic system comprises an energy supply and conversion system.

7.Carpet according to claim 1, wherein the electronic system comprises communication protocols that are compatible with the sensing and lighting modules integrated in said carpet.

8.Carpet according to claim 1, wherein the electronic system comprises communication protocols that are compatible with the use of remote equipment by the user.

9.Carpet according to claim 1, wherein the textile fabric comprises Smyrna.

10. Method of manufacturing the smart carpet described in any one of the previous claims, comprising the steps of: inserting the light conductive filaments and the textile yarns in the same textile fabric;

- applying a layer of transparent coating between the textile fabric and the lighting system;

-integrating the sensing system immediately behind the lighting system;

- integrating the electronic control system immediately behind the sensing system;

- applying a levelling layer immediately behind the electronic control system, which will contain all the lighting, sensing and electronic systems; - final coating that includes the sealing of said carpet with the final application of the coating layer and textile fabric.

11. Method of manufacturing the smart carpet according to claim 10, wherein the light conductive filaments being obtained by resorting to the continuous filament extrusion spinning technique presenting a S-twist with 100 twists/m and a double cable Z-retwist with 300 twists/m, 2500 dtex linear density, 0.80 cN/dtex tenacity, 30% elongation and 2060 cN breaking strength, vapor stabilized at 90°C for 15 minutes.

12.Method of manufacturing the smart carpet according to claim 10, wherein the textile carpet yarns is introduced in the textile fabric structure by means of a robotic tufting process that resorts to the use of altered injection nozzles to increase the capacity of punching the textile fabric, the hardness of said nozzles having been optimized, as well as the injection inner tube for yarn aspiration by Venturi effect.

13.Method of manufacturing the smart carpet according to claim 10, wherein the manufacturing of the electroluminescent lighting system comprises the serigraph printing of four different layers of ink, wherein two electrodes are comprised of conductive materials, wherein one of them shall be transparent, one dielectric material and one semi-conductive material comprised of phosphoric inks, in flexible substrates.

14.Method of manufacturing the smart carpet according to claim 10, wherein the sensing system comprises the serigraph printing on flexible substrates laminated with an adhesive consisting of glycol-modified PET.