DE4116681C2 - Non-slip plastic mat and process for its manufacture - Google Patents

Description

The invention relates to a non-slip plastic mat and a method for their manufacture. In particular, the invention relates to an elastic Plastic mat that is used as an insert for bathtubs, shower basins and the same can be used on their - in the position of use - Top has a grained, textured surface, and on her - In the position of use - bottom is provided with suction cups Slipping of the plastic mat according to the invention on a smooth Prevent surface. The invention also relates to a method for Production of such an elastic, non-slip mat from one or several different plastic materials.

DE 80 29 732 U1 are bathtub or shower trays and associated neck pads made of foamed plastic with scars known textured surface, the be on the bottom suction cups sit. Prevent such an insert from slipping in a tub the suction cups in a satisfactory manner. about the way of befe the suction cups on the underside of the insert is DE-GM 80 29 732 no information except that the attachment in in a manner known per se.

DE 77 21 240 U inserts one in particular in bath tubs bare massage or cleaning mat described, which also on their - in the position of use - bottom is provided with suction cups, which as Adhesive for attaching the mat to a surface such as serve on the bottom of a bathtub. About the attachment of the suction cups No information can be found on the underside of the mat.

DE 30 20 961 A1 discloses a bathtub insert that consists of several there are layers thermally bonded together by welding. To attach the bathtub insert to the bottom of the bathtub are on a base film, for example, suction cups attached by welding intended. The thermal welding of the suction cups with the The base layer of such a bathtub insert requires a separate one Step in making such an insert. This is  very expensive and expensive such a deposit in undesirable way.

It is also a bathtub insert made of soft plastic, moisture-repellent Materials have been described for fastening to a smooth tub floor also has suction cups on its underside. These are fixed with the insert or detachably connected and can in a preferred embodiment in the insert be buttoned up. However, this solution has the disadvantage that the openings of the Mat into which the suction cups are buttoned due to frequent mechanical stress or pull out due to a currently occurring strong mechanical load and thus do not allow a stable fixation of the bathtub insert on the surface. In addition, the process for producing the bathtub insert described very expensive to manufacture.

An insert for shower and bath facilities in the form of a mat-like structure that DE 24 14 also has detachable suction cups for fixing to the substrate 294 B1. The mat consists of a perforated net-like, flat carrier, which is coated with plastic and on which the suction cups are releasably attached. This bath mat - like the one described above - has that Disadvantage that the suction cups of the sudden mechanical stress on the mat Carrier and / or the underside of the mat can be partially or completely detached and thus a secure connection between mat and surface is not guaranteed.

From DE 33 03 993 A1 is an elastic insert for bathtubs, shower basins and known from a foamed plastic with suction cups on the underside, in which the suction cups are integrally connected to the foamed layer of the insert and consist of at least slightly foamed plastic. The foamed layer the insert and the suction cups integrally connected to it are with; an airtight one Skin made of a non-foamed plastic that the foamed Plastic material corresponds. A night  part of this solution is that in the step of foaming the A location and the suction cups integrally connected to it in the form of the Foaming is not sufficient. This makes the part too heavy and too stiff to still meet the usage requirements. Moreover the production of such a part is so expensive that the product too cannot be sold at a price that is still marketable. About it in addition, the sketched manufacturing process leaves too little scope for one Appealing design of the surface, for example through coloring and / or printing.

The present invention has set itself the task Eliminate disadvantages of the prior art. With the invention easy and inexpensive to produce non-slip plastic mats be put. In particular, plastic mats are to be provided the suction cups securely attached to their underside for fixing the Have a plastic mat on a smooth surface.

The process suitable for the production of these mats should make it possible chen, with simple procedural steps a secure fixation of the Suction cups on the underside of the mats - in the direction of use guarantee. It should be possible to use the mat raw material from to be pulled off a wound web and closed by a molding tool lead, in which the suction cups are formed, at the same time on the mat fixed on the underside and the mat contour can be cut.

This is combined with a non-slip mat made of one or more other compatible, flexible, thermoplastic high polymer plant fabric (s) with non-slip top and suction cups on the bottom reached, which is characterized in that the suction cups to the Un are molded onto the underside of the prefabricated mat.

The invention also relates to a method for producing such a gene non-slip plastic mat, which is characterized in that the prefabricated material of the mat, at least on the bottom from a flexible, thermoplastic, high polymer material A be  is supplied in web form to a mold in which the Suction cups made of a compatible material B in thermoplastic stood on the underside of the web segment under plasticizing conditions are injected, and that the supplied web segment at the same time the desired format of the plastic mat is cut.

The non-slip mat according to the invention consists of one or more reren, compatible, flexible, thermoplastic high poly ren material (s). Such materials are from the state mentioned above known in the art and include, for example, polyolefins such as poly ethylene and polypropylene, acrylic polymers such as polyacrylates and poly methacrylates, polyvinyl chloride, polystyrene, polyamides, polyurethanes and thermoplastically processable elastomers (EVA), and copolymers of such Polymers such as rubber-modified polyolefins [PP / EPDM (Polypropylene / ethylene-propylene-diene terpolymers)]. In particular Cases are also for the non-slip plastic mats according to the invention Mixtures of different polymers are suitable. The high poly mentioned Suitable plasticizers and additives can be added to materials be their properties in terms of flexibility, warmth and chemistry Potassium (especially alkali) resistance etc. in the desired manner improve.

For the non-slip mats according to the invention, it is possible to different to laminate or combine the polymers into a layer structure. This can be particularly advantageous if on the surface the mat should have a certain structure applied to it To ensure slip resistance against slipping of the feet. Regarding Such laminates exist - apart from their compatibility with one another other - no restrictions.

The non-slip mat according to the invention usually has on it Top of a strongly structured surface, for example in the form of Scars or embossing. On the bottom are, as in the following Individual is described, suction cups molded onto the mat a suitable surface, for example the surface of a bathing or shower tray, can be attached non-slip.  

In a preferred embodiment, the mat can also be perforated Have holes or holes that run through or drain the Water. These holes are arranged so that they are the stabilizer lity and tear strength of the mat not undesirably affected pregnant.

According to one aspect of the invention, the high polymer materials are made of which have at least the underside of the mat and the suction cups, chosen so that they enter into a common melt. Below that here as in the description below and in the claims stood that under the processing conditions (pressure, temperature) or the polymeric material (ien) in a narrow temperature range melt and mixed together in the form of the common melt will become. A solid forms when the mixed melt cools has equally good, if not better, mechanical properties, compared to the unmixed polymers, and that of the two parts the mats according to the invention (underside and suction cups) are stable other connects.

It is particularly preferred according to the invention that the suction cups non-slip plastic mat made of a non-foamed high polymer Made of material and at least the underside of the mat from the same material as the suction cups, but this material ge is foaming. It is this embodiment in particular that guarantees it good that when connecting the suction cups to the underside of the mat in the process steps described in detail below increased pressure and temperature a common melt ge is formed and this forms a stable connection between the Suction cups and the mat leads. This stable connection comes from The mat is particularly slip-resistant.

Examples of high polymer materials based on the invention their advantageous properties and longevity particularly be preferred are polyolefins such as polyethylene and polypropylene and de ren copolymers and their mixtures. In such a case  that is, the suction cups, for example, from one of the polyolefins mentioned, a copolymer or a mixture thereof, for example a poly olefin like polypropylene in addition to a thermoplastic elastomer like EPDM (ethylene propylene diene terpolymer), while at least the Un underside of the mat, preferably the entire mat, from one web goods made of polyethylene or polypropylene and possibly also EPDM consists of the usual additives, so as to obtain the desired To give properties.

Another polymer which can also be used advantageously according to the invention is polyvinyl chloride. In this case, the web goods consist of a soft PVC foam sheet that can be used with or without a backing can. The suction cups are also made of soft PVC and are made in the procedure described in detail below on the bottom the web goods sprayed on.

For at least the top of the mat, provided a foamed one Polymer uses the usual solid blowing agents used with the polymers mixed and then in conventional procedures for blowing up or foaming the polymer at an elevated temperature get abandoned. The process steps for the formation of such foams ter polymers are known as such from the prior art and therefore need no further explanation here.

According to a further aspect of the invention, the high polymer material from which at least the underside of the mat, if not the entire mat, and the high polymer material from which the suction cups are made are connected by means of an adhesive or primer 48 . This is particularly advantageous if the polymers used have a chemically different composition and / or their physical properties differ greatly. Suitable adhesives depending on the polymers used are known from the prior art and include polyurethanes and acrylate polymers such as, for example, polymers of acrylic acid and methacrylic acid and their esters and their copolymers. In a further preferred embodiment, a primer is used in such a way that it is already applied to the web material which is fed to the molding tool or is applied to the web product immediately before the web material enters the molding tool.

Of course, the polymers of both the mat material and also that of the material for the suction cups further, their properties mo containing different additives. These are also in the relevant status the technology described in detail and include coloring substances, Stabilizers and agents for increasing chemical resistance, especially the alkali resistance. On a detailed one Enumeration is also omitted here.

The method according to the invention is described below with reference to the figures explained in detail. Show it:

Figure 1 is a non-slip mat according to the invention, with the reference numeral 1 of the mat body and 2, the suction cups are designated. the mat shown in Figure 1 lies with the suction cups 2 upwards and thus shows exactly the opposite position compared to the non-slip plastic mat according to the invention when in use;

Fig. 2 shows - in a use-oriented arrangement - a section through the non-slip plastic mat according to the invention, the actual mat body 1 pointing upwards and the suction cups 2 pointing downwards;

Fig. 3 shows a device with which the non-slip plastic mat according to the invention can be produced; and

Fig. 4 shows a section of the device of FIG. 3, namely the actual molding tool with a feed roller for the web material, extruder for the supply of the polymer granules and molding tool.

According to the invention, the method is characterized in that the pre-made material of the mat, which consists at least on the underside of a flexible, thermoplastic, high-polymer material A, is supplied in web form to a molding tool 4 , 33 , in which the suction cups 2 are made of a compatible material B in the thermoplastic state on the underside of the web segment 43 be injected under plasticizing conditions, and that the supplied web segment 43 is cut simultaneously to the desired format of the plastic mat.

The method preferably runs in several steps. In the first step of the method according to the invention for producing a non-slip plastic mat, as described above, the pre-made material of the mat in sheet form is fed to a molding tool 4 , 33 of the device 3 . For this purpose, the prefabricated mat material is wound up on a roll 31 , 41 , for example as a web material, and consists of one or more of the polymers already described in more detail above.

According to an aspect of the invention already described above at least the side of the mat that later becomes the bottom of the invent product according to the invention is made from a flexible, thermoplastic, high polymer material A. It is possible according to the invention that the ge Entire mat made of this material A. However, it is the same Way possible that one or more layers of mats from one other polymer material as described above and only the bottom of the mat made of flexible, thermoplastic, high poly meren material A.

This material ("web goods") is fed by the roller 31 , 41 via preferably driven take-off rollers 32 , 42 to the molding tool 4 , 33 . Usually, as much material is drawn into the mold 4 , 33 as machined in one processing step, ie shaped, provided with suction cups 2 , cut and, if appropriate, also profi lized and compacted at the resulting edges.

In a process step running parallel to the step of feeding the prefabricated Bahnma material, the molding tool 4 , 33 is fed in a manner known per se, a likewise preferably thermoplastic high-polymer material B. According to one aspect of the invention, this is selected such that it can form a common melt with the high-polymer material A. This has been described in detail above.

The high-polymer material B is introduced, for example, via a plasticizing unit 35 , 44 provided with a filling funnel 34 . The high polymer material B, usually in the form of pellets, granules or the like, is conveyed into the filling funnel 34 and flows from it via the gravity of the preferably heatable plasticizing unit 35 , 44 , in which a screw 45 kneads the material under the influence of heat and directs it in the direction on the mold dies 46 , 47 of the mold 4 , 33 promotes. The processing of the polymeric material B in the plasticizing unit 35 , 44 takes place in a manner known per se from the prior art. If desired, additives such as plasticizers, coloring substances or the like can be added to the high-polymer material B in this processing step, which are intimately mixed with the polymer when the polymer is kneaded and whose properties - depending on the additive - influence in the desired manner.

At the end of the screw flight of the plasticizing unit 35 , 44 there is a molding die 46 which has the corresponding suction cups 2 corresponding for men 461 . The molten polymer is injected into these molds. The molds 461 corresponding to the suction cups are located in the die 46 of the molding tool 33 spatially opposite the underside of the web segment 43 which was fed in in the first method step described above.

If the two mold halves 46 and 47 of the mold 4 , 33 are pressed together ge, they contain a web segment 43 in the cavity formed in their center, which was fed in the first process step. In the next step of the method, the suction cups 2 formed in the plasticizing step are molded onto the underside of the web segment 43 under plasticizing conditions. Temperatures are used which are in the range of the melting point or the melting points of the polymers used and which also depend on the particular polymers used. It is crucial that temperatures are used which, in accordance with the aspect of the invention described above, are conducive to the formation of a common melt in the case of the high-polymer materials A and B. Under increased pressure, the suction cups 2 formed by the extrusion in the corresponding molds 461 are firmly attached to the underside of the web segment 43 . This creates a firm connection between the suction cups 2 and the underside of the mat material in a process-economical, inexpensive and safe manner, which later offers a high level of slip resistance of the non-slip plastic mat according to the invention.

Simultaneously with the step of molding the suction cups 2 onto the underside of the web segment 43 of the plastic mat, which takes place under plasticizing conditions, the mat is cut to the desired format. It is thus achieved in a simple manner that a further process step for setting the desired mat size can be omitted.

It corresponds to a preferred embodiment of the method according to the invention that for at least the underside of the mat and the suction cups 2 thermoplastic high-polymer materials are selected which are made up of a monomer which corresponds to the same basic type of monomer. By this advantageous embodiment of the method, it is enough according to the described aspect of the invention that highly polymeric materials A and B are used, which can enter into a common melt and which then, due to the similar characteristics of the materials involved, form a firm connection between guide the suction cups 2 and the underside of the mat.

An even more preferred process form is that poly selects other materials that are built from the same monomers are. Polymers whose maxima are particularly suitable for this purpose the molecular weight distribution in the same mass or number range lie.  

Even more preferred is the procedure in which one chooses the same poly mers (A = B), of which the non-foamed high polymer material is used for the suction cups 2 , but the foamed high polymer material is used for the mat body, but at least for its underside becomes. In this context, the usual blowing agents known from the prior art are used.

According to the invention, the procedure has proven to be particularly advantageous proven to be soft PVC or a as a highly polymeric material Polyolefin used. Of the polyolefins, polyethylene is preferred and to name polypropylene. These are particularly preferred for the Suction cups, with advantage also for the web goods, with other polymers Modified materials, such as with EPDM (ethylene propylene Diene terpolymers). These as well as the other usable high poly Other materials can be the usual additives such as Plasticizers, dyes or the like contain their properties to modify in a manner appropriate to the application.

According to the invention, the method according to the invention is particularly preferably used for high-polymer materials in which the mat body or at least its underside consists of a PVC foam film and the suction cups 2 consist of soft PVC. Rubber-modified polyolefin, in particular polypropylene, and for the suction cups, 2 polyolefins such as polyethylene, polypropylene or their copolymers or corresponding rubber-modified polyolefins and / or mixtures thereof according to the specification given above can also be used advantageously for the mat body. For example, PP / EPDM (polypropylene / ethylene-propylene-diene terpolymers) are used for the web goods and for the suction cups.

The one for plasticizing and then gating the suction cups Temperatures applied to the underside of the mat should melt points of the polymers do not exceed or only slightly so as not lead to degradation of the polymer or polymers. Usually - depending on the polymer used - temperatures  used, which - if at all - only slightly above the melting area are rich in the polymer or polymers.

Usually, it is sufficient by the method steps according to the invention that the suction cups 2 adhere securely and firmly to the underside of the mat, since highly polymeric materials are used as materials for the two mat parts, which can enter into a common melt and combine optimally with one another during cooling.

This situation is shown in detail in FIG. 4. After the suction cups have been sprayed onto the underside of the web segment 43 , the second molding die 47 of the molding tool 4 , 33 moves from the first molding die 46 - driven by the opening and closing mechanism 36 of the molding tool 4 , 33 - and the corresponding finished and tailored web segment 43 is released and, if necessary, further processed in the manner described below.

According to a further aspect of the invention, such as, for example, when using certain polymers which are very different in their chemical and / or physical properties or for particularly secure connections between the underside of the mat and suction cups, adhesion promoters, so-called primers, can be used to impart adhesion between the underside of the mat and suction cups. Preferred examples of such primers are polyurethanes and acrylate primers, as have already been described above. These are intended to provide improved adhesion between the underside of the mat and the suction cups, and also to connect polymers with one another, the chemical and / or physical properties of which do not allow a stable melt connection between the polymers, at least the underside of the mat and the suction cups, to occur. In a further, particularly preferred embodiment, one of the primers 48 mentioned is used in such a way that it is already applied to the web material which is fed to the molding tool or is applied to the web material immediately before the web material enters the molding tool.

It corresponds to a further preferred embodiment according to the invention in the form of holes in the non-slip plastic mat Allow water to flow through. These will be before or applied during the step that the suction cups onto the The underside of the mat can be sprayed.

In a final process step, which can also take place in the molding tool 4 , 33 , but can also be performed separately by special equipment, the edges of the mat or the edges of the water holes, which may also be additionally introduced, become through-holes with simultaneous heating compressed and thus compressed with the aim of preventing water from penetrating into the foam structure of the mat body. In addition, this step prevents the edges from fraying and thus quickly wearing out during use.

Claims (19)

1. Non-slip mat made of one or more compatible, flexible, thermoplastic high-polymer material (s) with non-slip top and suction cups on the underside, characterized in that the suction cups are molded onto the underside of the prefabricated mat. 2. Mat according to claim 1, characterized in that the high polymer ren materials, from which at least the underside of the mat and the Suction cups exist, are chosen so that they melt together come in. 3. Mat according to one of the two claims 1 and 2, characterized indicates that the high polymer materials are made from the same monomer Basic type exist. 4. Mat according to one or more of claims 1 to 3, characterized ge indicates that the high polymer materials from the same mono always exist. 5. Mat according to one or more of claims 1 to 4, characterized ge indicates that the suction cups are made from a non-foamed high polymer Material and at least the underside of the mat from the same factory fabric like the suction cups, but is foamed. 6. Mat according to one or more of claims 1 to 5, characterized ge indicates that the high polymer material is polyvinyl chloride or a Is polyolefin.   7. Mat according to claim 6, characterized in that the high polymer Material at least for the suction cups, but preferably also for the Mat, in addition to polyolefins, especially polypropylene, a thermoplastic cal elastomer, in particular EPDM, contains. 8. Mat according to claim 1, characterized in that the high polymer ren materials, from which at least the underside of the mat and the Suction cups exist by means of an adhesive (primer) are bound. 9. A method for producing a non-slip plastic mat according to one of claims 1 to 8, characterized in that the prefabricated material of the mat, which consists at least on the underside of a flexible, thermoplastic, high polymer material A, in sheet form a mold ( 4 , 33 ) is supplied in which the suction cups ( 2 ) are injected from a compatible material B in the thermoplastic state on the underside of the web segment ( 43 ) under plasticizing conditions, and that the supplied web segment ( 43 ) is simultaneously ge to the desired format of the plastic mat will cut. 10. The method according to claim 9, characterized in that the high polymeric materials A and B are selected so that when heated can melt together under the injection conditions nen. 11. The method according to any one of claims 9 and 10, characterized records that for at least the underside of the mat and the Suction cups chooses thermoplastic high polymer materials from the same basic monomer type, preferably from the same monomer, still more preferably from a foamed high polymer material A and an unfoamed high polymer material B, where A and B are the same polymers.   12. The method according to one or more of claims 9 to 11, characterized characterized in that PVC or a poly olefin, the latter preferably polypropylene. 13. The method according to claim 12, characterized in that as high polymer material B soft PVC, as high polymer material A PVC foam sheet used. 14. The method according to claim 12, characterized in that as high polymer material A a polyolefin, especially polypropylene, ge optionally rubber modified, and as a high polymer material B. rubber modified polyolefin, especially polypropylene, especially preferably PP / EPDM used. 15. The method according to claim 9, characterized in that one for Promotion of adhesion between the polymers at least on the underside of the mat A and the suction cup B uses an adhesion promoter (primer). 16. The method according to claim 15, characterized in that as Adhesion promoter (primer) polyurethane or acrylate primer used. 17. The method according to one or more of claims 9, 15 and 16, characterized in that the primer is already applied to the web material which is fed to the molding tool ( 4 , 33 ) or immediately before the web material enters the molding tool ( 4 , 33 ) is applied to the web goods. 18. The method according to one or more of claims 9 to 17, characterized characterized in that the water flow or drain in the mat Provides holes. 19. The method according to one or more of claims 9 to 18, characterized characterized in that one additionally the mat edges under pressure and Warming condensed.