Electroluminescent coating part and its formation method, light-emitting system and EMB unit

Abstract

In its most general aspect, the present invention relates to a product and a method of manufacturing the same, particularly a caliper for a disc brake, the product comprising an electrically activated light-emitting coating, i.e., an electroluminescent coating. Specifically, the present invention relates to an electroluminescent coating on the surface of a side portion of a vehicle, preferably part of a braking system, the electroluminescent coating comprising multiple layers of electroluminescent coating, each layer including two electrically conductive layers connected to a voltage generator. Furthermore, the present invention also relates to a method of forming an electroluminescent coating on the surface of an article, a light-emitting system including the electroluminescent coating, and an EMB unit including the light-emitting system.

Description

Technical Field

[0001] In its most general sense, the present invention relates to an article and a method of manufacturing the same, the article being particularly for a caliper of a disc brake, the article comprising an electrically activated light-emitting coating, i.e., an electroluminescent coating. Background Technology

[0002] A crucial aspect of any vehicle on the road (whether it's a car, motorcycle, or bicycle) is its nighttime visibility. Numerous accidents occur due to vehicles failing to provide adequate illumination in the dark.

[0003] While a vehicle's front and rear lights are typically achieved effectively using headlights, position lights, or brake lights, good visibility of the vehicle from the side is much more difficult. This can lead to serious accidents when crossing intersections.

[0004] To overcome this problem, installing sidelights has proven to be not very energy-efficient. Therefore, systems have been proposed that involve using luminescent materials or coatings to form some of the side-visible components of a vehicle, such as wheels and their parts. However, these systems also suffer from poor brightness in the dark and short duration of illumination, because the luminescent materials must be charged by sunlight.

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the above-mentioned disadvantages, thereby providing a side-emitting light system for vehicles that is energy-efficient, clearly visible in the dark, and has an almost unlimited duration at night. Summary of the Invention

[0006] The above-mentioned problem is solved by means of an electroluminescent coating on the side portion of the vehicle, preferably a part of the braking system, as described in the appended claims.

[0007] Another object of the present invention is a brake caliper for a disc brake and a method for manufacturing the same, the brake caliper including a coating portion as described below.

[0008] For purposes of full description, the subject matter of the claims forms an integral part of this disclosure.

[0009] Specifically, the object of the present invention is:

[0010] 1) An electroluminescent coating on the surface of a side portion of a vehicle, preferably part of a braking system, the electroluminescent coating comprising a multilayer electroluminescent coating comprising two electrically conductive layers connected to a voltage generator.

[0011] 2) According to point 1, the coating portion comprises, in sequence:

[0012] a) Base layer, i.e., the first conductive layer, the side-facing portion of the base layer to be covered;

[0013] b) Dielectric layer;

[0014] c) Light-emitting layer;

[0015] d) External conductive layer or second conductive layer;

[0016] 3) The coating portion according to point 2, wherein the base layer comprises or is composed of the following resin: the resin contains metal powder, preferably including silver-coated copper powder.

[0017] 4) According to the coating section described in point 3, wherein the percentage of metal powder, particularly copper powder, in the resin of the base layer is in the range of 40% to 60% (w / w);

[0018] 5) The coating portion according to any one of 2 to 4, wherein the dielectric layer comprises or is composed of a resin comprising barium titanate.

[0019] 6) The coating portion as described in point 5, wherein the percentage of barium titanate in the resin of the dielectric layer is between 70% and 90% (w / w);

[0020] 7) The coating portion according to any one of 2 to 6, wherein the light-emitting layer comprises or is composed of the following resin: the resin includes zinc sulfide;

[0021] 8) According to the coating part described in point 7, wherein the percentage of zinc sulfide in the resin of the light-emitting layer is between 60% and 80% (w / w);

[0022] 9) The coating portion according to any one of points 2 to 8, wherein the outer conductive layer or the second conductive layer comprises or is composed of a hydrated polythiophene polymer in water and suitable additives;

[0023] 10) The coating portion according to point 9, wherein the composition for forming the external conductive layer comprises: 80% to 95% (w / w) of a polythiophene polymer, 4% to 15% (w / w) of water, and 1% to 5% (w / w / p) of additives;

[0024] 11) The coating portion according to any one of points 1 to 10, wherein a primer layer is placed between the base layer, i.e. the first conductive layer and the surface to be coated of the side portion, wherein the primer layer preferably comprises or is composed of epoxy resin.

[0025] 12) According to the coating section described in point 11, the thickness of the coating layer is as follows:

[0026] - Bottom material layer 20 to 40 micrometers

[0027] -Base layer 20 micrometers to 40 micrometers

[0028] - Dielectric layer 20 micrometers to 40 micrometers

[0029] -Emitting layer 20 to 40 micrometers

[0030] - External conductive layer 10 micrometers to 40 micrometers.

[0031] 13) A method for manufacturing an electroluminescent coating on the surface of an article according to any one of points 1 to 12, the method comprising the following steps in sequence:

[0032] a) Clean the surface, deposit the bottom material layer, and dry the bottom material layer.

[0033] b) Fabricating the circuit, depositing the base layer, and drying the base layer.

[0034] c) Fabricating interconnects, depositing dielectric layers, and drying dielectric layers.

[0035] d) Depositing the luminescent layer and drying the luminescent layer.

[0036] e) Fabricating the interconnects, depositing the outer conductive layer, and drying the outer conductive layer.

[0037] f) Optionally, a transparent protective varnish may be used.

[0038] 14) The method described in point 13, wherein the deposition of the layer is performed by spraying;

[0039] 15) The method described in point 13 or 14, wherein the drying of the layer is preferably carried out using hot air at a temperature above 65°C;

[0040] 16) A light-emitting system including an electroluminescent coating portion according to any one of points 1 to 12, the light-emitting system including a power supply device and an electronic control unit (independent ECU) of the vehicle, the electronic control unit being capable of controlling the electroluminescent coating portion and receiving commands and power supply from the outside.

[0041] 17) The lighting system as described in point 16, wherein the electronic control unit is a vehicle unit (independent ECU) or a separate braking ECU;

[0042] A vehicle EMB (electromechanical brake) unit including the light-emitting system described in point 16 or 17, the vehicle EMB unit comprising:

[0043] i) An EMB brake caliper having at least one portion including an electroluminescent coating;

[0044] ii) An EMB control unit, which is electrically connected to the EMB caliper to provide power to the electroluminescent coating part, thereby controlling the luminous color and luminous brightness of the electroluminescent coating part; wherein, the control unit supplies power to the electroluminescent coating part according to different operating states of the EMB braking system to achieve a luminous effect in a specific operating state;

[0045] iii) A vehicle power supply device for providing power to the EMB control unit;

[0046] iv) Body Control Module (BCM);

[0047] v) In-vehicle infotainment system, which provides user input to the EMB control unit regarding on / off mode, brightness, and frequency;

[0048] 19) According to the EMB unit described in point 18, wherein the operating states include:

[0049] -Glows when unlocking the car

[0050] - Lights up when braking occurs

[0051] - Illuminates when ABS or other functions are activated.

[0052] - Illuminates when a risk to the braking system is detected.

[0053] - Glows when regeneration is performed

[0054] - Lights up when the car is in an emergency.

[0055] - It emits light when the user changes the brightness and frequency in the IVI (In-vehicle Infotainment System).

[0056] It can be seen that using the coating part according to the invention allows for high nighttime brightness, as well as an unlimited duration due to connection with an electrical energy source. Attached Figure Description

[0057] Figure 1 An illustration shows a light-emitting system including the electroluminescent coating of the present invention;

[0058] Figure 2 A schematic enlarged cross-sectional view of the electroluminescent coating portion of the present invention is shown;

[0059] Figure 3 A schematic diagram of a control system for an electroluminescent coating incorporated in a vehicle is shown. Detailed Implementation

[0060] The present invention relates to an electroluminescent coating portion of a side portion P of a vehicle, preferably part of a braking system, the electroluminescent coating portion comprising a multilayer electroluminescent coating portion including two conductive layers electrically connected to a voltage generator.

[0061] More specifically, according to certain embodiments of the present invention, the multilayer electroluminescent coating portion, generally indicated by reference numeral 1 in the drawings, comprises, in sequence:

[0062] a) Base layer 2, i.e., the first conductive layer, which faces the side portion P of the vehicle to be coated;

[0063] b) Dielectric layer 3;

[0064] c) Light-emitting layer 4;

[0065] d) External conductive layer 5, i.e., the second conductive layer.

[0066] In a preferred embodiment, the base layer 2 comprises or is composed of a resin that includes metal powder, more preferably silver-coated copper powder.

[0067] Silver-coated copper powder is a composite material in which a thin layer of silver is coated on the surface of copper powder particles.

[0068] The resin must possess: sufficient mechanical resistance, meaning it must be strong enough to support the entire structure; high heat resistance, as the resin may have to withstand high temperatures during manufacturing; and sufficient chemical stability, specifically, the resin must not decompose under the influence of an electric field.

[0069] Preferably, the percentage of metal powder, particularly copper powder, in the resin of the base layer 2 is in the range of 40% to 60% (w / w).

[0070] In some embodiments, the dielectric layer 3 comprises or is composed of a resin including barium titanate. This layer forms an insulating layer between the conductive layers and provides protection for the coated portion.

[0071] The resin of the dielectric layer must have: a high dielectric constant to increase the electric field strength; high transparency to avoid affecting the light emission of the light-emitting layer; and high voltage resistance to avoid damage.

[0072] Preferably, the percentage of barium titanate in the resin of dielectric layer 3 is between 70% and 90% (w / w).

[0073] In some embodiments, the light-emitting layer 4 comprises or is composed of a resin containing zinc sulfide. This layer determines the luminescence of the coated portion and can be made in various colors.

[0074] The resin of the light-emitting layer 4 must have high luminous efficiency; the resin of the light-emitting layer 4 must have considerable chemical stability so that it remains stable and does not decompose under the action of an electric field; the resin of the light-emitting layer 4 must have high heat resistance during production and use.

[0075] Preferably, the percentage of zinc sulfide in the resin of the light-emitting layer 4 is between 60% and 80% (w / w).

[0076] In some embodiments, the outer conductive layer 5 or the second conductive layer comprises or is composed of a hydrated polythiophene polymer and suitable additives.

[0077] Essentially a conductive polythiophene polymer, it must have good conductivity to allow for uniform current distribution; the polythiophene polymer must also be transparent so as not to affect light emission; and as the outermost layer, the polythiophene polymer must have good abrasion resistance.

[0078] Preferably, the composition for forming the outer conductive layer 5 comprises: 80% to 95% (w / w) of polythiophene, 4% to 15% (w / w) of water, and 1% to 5% (w / w) of additives.

[0079] The coating portion of this invention creates a potential difference between the base layer 2 and the outer layer 5, generating an electric field effect that causes the light-emitting layer 4 to emit light. The brightness and frequency of the light can be adjusted by controlling the AC current.

[0080] In a preferred embodiment, a bottom material layer 6 is provided between the base layer 2 and the surface S to be coated on the side portion P. The main function of this bottom material layer is to isolate the electroluminescent coating portion 1 from the surface S to be coated. The bottom material layer 6 preferably comprises epoxy resin or is composed of epoxy resin.

[0081] In some embodiments, the thickness of each layer of the coating section 1 is as follows:

[0082] - Bottom material layer 6 20 micrometers to 40 micrometers

[0083] -Base layer 2 20 micrometers to 40 micrometers

[0084] -Dielectric layer 3 20 micrometers to 40 micrometers

[0085] -Emitting layer 4 20 micrometers to 40 micrometers

[0086] - External conductive layer 5 10 micrometers to 40 micrometers.

[0087] Preferably, the outer layer 5 is further provided with an additional transparent coating layer, which has a protective function.

[0088] In a preferred embodiment, the method for producing the electroluminescent coating 1 on the surface S of the article comprises the following steps in sequence:

[0089] a) Clean the surface S, deposit the bottom material layer 6, and dry the bottom material layer 6;

[0090] b) Fabricate the circuit by depositing the base layer 2 and drying the base layer 2;

[0091] c) Prepare connecting wires, deposit dielectric layer 3, and dry dielectric layer 3;

[0092] d) Deposit the light-emitting layer 4 and dry the light-emitting layer 4;

[0093] e) Prepare connecting wires, deposit the outer conductive layer 5, and dry the outer conductive layer 5;

[0094] f) Apply a transparent protective varnish.

[0095] In the above method, the composition of each layer is preferably as defined above.

[0096] In some implementations, in step a), cleaning of surface S is performed using alcohol. Deposition of the bottom material layer 6 is performed by spraying. Two consecutive coats may be necessary to obtain a sufficiently thick bottom material layer 6 to ensure electrical insulation, which can be verified by appropriately measuring the resistance.

[0097] The bottom material layer 6 is dried, for example, at 80°C for 20 minutes, or at 70°C for one and a half hours, or at 60°C for about 6 hours. After drying, the surface must be cooled to room temperature.

[0098] In stage b), the circuit is configured such that the positive electrode (light-emitting area) is located in the center of the material, while the negative electrode is located at the edge.

[0099] The base coating 2 is applied by spraying from a diluted suspension (base coating / diluent composition of 1:0.5). Subsequent drying can be carried out, for example, at 65°C for about 15 minutes.

[0100] The resistance measured at the maximum distance between the negative (outer ring) and positive (middle) terminals must be within 10Ω.

[0101] In step c), in the negative electrode area, masking tape is used to properly adhere the negative electrode, and the masking tape is used to adhere the negative electrode to the center of the electrical tape.

[0102] At the same time, fold the extension line of the positive electrode (bright area) in half and attach it, making sure to leave a certain distance, which must be reserved for the wiring terminal (a wiring terminal must be reserved in the positive electrode area).

[0103] At this point, the edges of the central positive electrode (bright area) should be sanded with sandpaper, and the central part should be lightly polished with sandpaper 1 to 2 times, and then wiped with a lint-free cloth.

[0104] The dielectric coating cannot be diluted, so it must be shaken well before direct spraying. The entire positive electrode (bright area) must be sprayed with the dielectric coating.

[0105] The drying of dielectric layer 3 can be carried out using hot air at a temperature higher than 65°C.

[0106] In step d), the luminescent coating is deposited by spraying, thereby uniformly covering the entire luminescent area. Drying is carried out by heating, for example, using hot air at a temperature above 65°C.

[0107] In step e), the connection between the positive and negative electrodes is achieved by attaching a conductive copper film, which must be pressed firmly and then carried to the rear end.

[0108] The external conductive layer 5 is obtained by spraying a diluted suspension (conductive composition / alcohol with a volume ratio of 1:4 or a weight ratio of 1:3) after preheating the surface to be coated, for example, with hot air.

[0109] The drying of the outer conductive layer 5 is carried out, for example, with hot air at a temperature greater than 65°C for about 5 minutes.

[0110] In step f), after the transparent protective coating is sprayed, preferably, the surface S having the electroluminescent coating 1 is kept at about 80°C for about 1 hour.

[0111] When forming each layer, it can be sprayed 2-3 times to obtain the desired thickness.

[0112] Figure 1 A possible power supply scheme for a light-emitting system including an electroluminescent coating 1 is shown. A voltage of 12V and a power of 12W to 30W are applied to a vehicle electronic control unit (an independent ECU), which is associated with, for example, the braking system. This ECU provides an AC voltage of 80V to 130V (frequency 600Hz to 1800Hz) to the electroluminescent coating 1 to illuminate the side portion of the vehicle, for example, during braking or at other times upon instruction.

[0113] Figure 3 A light-emitting system including an electroluminescent coating 1 is shown, which is integrated into the vehicle's EMB (electromechanical brake) unit.

[0114] The system includes:

[0115] i) An EMB brake caliper having at least one portion including an electroluminescent coating 1;

[0116] ii) An EMB control unit, which is electrically connected to the EMB clamping member, is used to provide power to the electroluminescent coating part, thereby controlling the luminescent color and luminescent brightness of the electroluminescent coating part; wherein, the control unit supplies power to the electroluminescent material part according to different operating states of the EMB braking system, so as to realize the display of luminescent effect under specific operating states;

[0117] iii) A vehicle power supply device for providing power to the EMB control unit;

[0118] iv) Body Control Module (BCM);

[0119] v) In-vehicle infotainment system, which provides user input to the EMB control unit regarding on / off mode, brightness, and frequency.

[0120] The lock / unlock signal is received from the vehicle network by the ECU, such as the BCM, which is responsible for managing the lock / unlock signal.

[0121] The light emission modes of the above system include, but are not limited to:

[0122] -Glows when unlocking the car

[0123] - Lights up when braking occurs

[0124] - Illuminates when ABS or other functions are activated.

[0125] - Illuminates when a risk to the braking system is detected.

[0126] -Glows when updating

[0127] - Lights up when the car is in an emergency.

[0128] - It emits light when the user changes the brightness and frequency in the IVI (In-vehicle Infotainment System).

[0129] The advantages of the above technical solution are obvious, and mainly include high brightness and long duration of light emission, which can be obtained by command or in automatic mode according to the needs of use.

[0130] With respect to the above preferred embodiments, those skilled in the art will be able to make various modifications, adjustments, and replace each element with other functionally equivalent elements to meet specific needs, without departing from the scope of the appended claims.

Claims

1. An electroluminescent coating on the surface (S) of a side portion (P) of a vehicle, preferably the side portion (P) being part of a braking system, the coating comprising a multilayer electroluminescent coating (1) including two electrically conductive layers (2, 5) connected to a voltage generator.

2. The electroluminescent coating portion according to claim 1, wherein, The multilayer electroluminescent coating (1) includes, in sequence: a) A base layer (2) or a first conductive layer, the base layer (2) facing the surface (S) to be coated of the side portion (P); b) Dielectric layer (3); c) Emissive layer (4); d) External conductive layer (5) or second conductive layer.

3. The electroluminescent coating portion according to claim 2, wherein, The base layer (2) comprises or is composed of the following resins: the resin includes metal powder, preferably silver-coated copper powder.

4. The electroluminescent coating portion according to claim 3, wherein, The percentage of metal powder in the resin of the base layer (2) is included in the range of 40% to 60% (w / w), and in particular, the percentage of copper powder in the resin of the base layer (2) is included in the range of 40% to 60% (w / w).

5. The electroluminescent coating according to any one of claims 2 to 4, wherein, The dielectric layer (3) comprises or is composed of the following resin: barium titanate is included in the resin.

6. The electroluminescent coating portion according to claim 5, wherein, The percentage of barium titanate in the resin of the dielectric layer (3) is between 70% and 90% (w / w).

7. The electroluminescent coating according to any one of claims 2 to 6, wherein, The light-emitting layer (4) comprises or is composed of the following resin: zinc sulfide is included in the resin.

8. The electroluminescent coating portion according to claim 7, wherein, The percentage of zinc sulfide in the resin of the light-emitting layer (4) is between 60% and 80% (w / w).

9. The electroluminescent coating according to any one of claims 2 to 8, wherein, The external conductive layer (5) or the second conductive layer comprises a hydrated polythiophene polymer and suitable additives, or the external conductive layer (5) or the second conductive layer is composed of a hydrated polythiophene polymer and suitable additives.

10. The electroluminescent coating portion according to claim 9, wherein, The composition used to form the external conductive layer (5) comprises: 80% to 95% (w / w) of a polythiophene polymer, 4% to 15% (w / w) of water, and 1% to 5% (p / p) of additives.

11. The electroluminescent coating according to any one of claims 1 to 10, wherein, A bottom material layer (6) is placed between the base layer (2) and the surface (S) of the side portion (P) to be coated, that is, the bottom material layer (6) is placed between the first conductive layer and the surface (S) of the side portion (P) to be coated, wherein, preferably, the bottom material layer (6) comprises epoxy resin or is composed of epoxy resin.

12. The electroluminescent coating portion according to claim 11, wherein, The thicknesses of each layer of the coating part (1) are as follows: - Bottom material layer (6) 20 micrometers to 40 micrometers -Base layer (2) 20 micrometers to 40 micrometers -Dielectric layer (3) 20 micrometers to 40 micrometers -Emitting layer (4) 20 micrometers to 40 micrometers - External conductive layer (5) 10 micrometers to 40 micrometers.

13. A method for forming an electroluminescent coating (1) according to any one of claims 1 to 12 on the surface (S) of an article, the method comprising the following steps in sequence: a) Clean the surface (S), deposit the bottom material layer (6), and dry the bottom material layer (6); b) Fabricating the circuit, depositing the base layer (2), and drying the base layer (2); c) Prepare connecting wires, deposit dielectric layer (3), and dry dielectric layer (3); d) Deposit the light-emitting layer (4) and dry the light-emitting layer (4); e) Prepare connecting wires, deposit an outer conductive layer (5), and dry the outer conductive layer (5); f) Optionally, a transparent protective varnish may be used.

14. The method according to claim 13, wherein, The base layer (2), the dielectric layer (3), the light-emitting layer (4), the outer conductive layer (5) and the bottom material layer (6) are deposited by spraying.

15. The method according to claim 13 or 14, wherein, The base layer (2), the dielectric layer (3), the light-emitting layer (4), the external conductive layer (5) and the bottom material layer (6) are dried at a temperature above 65°C. Preferably, the base layer (2), the dielectric layer (3), the light-emitting layer (4), the external conductive layer (5) and the bottom material layer (6) are dried by means of hot air at a temperature above 65°C.

16. A light-emitting system comprising an electroluminescent coating portion (1) according to any one of claims 1 to 12, the light-emitting system comprising a power supply device and an electronic control unit, the electronic control unit being capable of controlling the electroluminescent coating portion and receiving commands and power supply from an external source.

17. The light-emitting system according to claim 16, wherein, The electronic control unit (ECU) is either a separate unit of the vehicle or a separate braking ECU.

18. An EMB unit for a vehicle, the EMB unit comprising the light-emitting system according to claim 16 or 17, the EMB unit comprising: i) EMB brake caliper, the EMB brake caliper having at least one portion including an electroluminescent coating (1); ii) An EMB control unit, which is electrically connected to the EMB brake caliper, is used to provide power to the electroluminescent coating part, thereby controlling the luminescent color and luminescent brightness of the electroluminescent coating part; wherein, the control unit supplies power to the electroluminescent material part according to different operating states of the EMB braking system, so as to achieve the display of luminescent effect under specific operating states; iii) A vehicle power supply device, which is used to supply power to the EMB control unit; iv) Body Control Module (BCM); v) An in-vehicle infotainment system, which is used to provide user input to the EMB control unit regarding on / off mode, brightness, and frequency.

19. The EMB unit according to claim 18, wherein, The operational status provides: -Glows when unlocking the car - Lights up when braking occurs - Illuminates when ABS or other functions are enabled. - Illuminates when a risk to the braking system is detected. -Glows when updating - Lights up when the car is in an emergency. - It emits light when the user changes the brightness and frequency in the in-vehicle infotainment system.

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