EP4004273B1 - Anti-slip underlay - Google Patents

Description

The present invention relates to the technical field of plastic underlays, in particular anti-slip underlays.

In particular, the present invention relates to an anti-slip underlay, preferably intended for use as an anti-slip mat.

In addition, the present invention relates to a method for producing an anti-slip underlay.

In recent years, smooth surfaces, especially smooth floor coverings, have become increasingly popular, as they convey a high-quality and pleasant room look on the one hand and are easy to care for, hygienic and durable on the other. At the same time, carpets, for example, are still a popular decoration for smooth floor coverings, in particular to further enhance the spatial appearance visually. In the carpeted areas, a pleasant feeling underfoot is also created and a certain level of footfall sound absorption is achieved.

Since flat textiles, such as carpets and tablecloths, do not have a good grip on smooth subfloors or subfloors, it is necessary to secure them against slipping on the smooth subfloor. For this purpose, anti-slip underlays have been used successfully for some time.

The anti-slip underlays known in the prior art often have compositions made from vinyl polymers, in particular from polyvinyl chloride (PVC). Polyvinyl chloride is characterized by its good longevity and durability; however, even today, PVC still suffers from a number of disadvantages.

Plasticizers, stabilizers and other additives are usually added to PVC compositions. Even if these additives are generally not very volatile, it has been found that some of them can be released into the air as so-called residential toxins.

However, particularly harmful PVC components are the plasticizers, which are contained in soft PVC in particular. Plasticizers can enter the body via saliva, skin contact or the respiratory tract and can potentially damage the liver or kidneys.

A carcinogenic effect of the absorption of plasticizers in the human body was also found in some cases. In addition, it was found that the emission of harmful substances from PVC occurs all the more, the higher the thermal load on the material, for example due to direct or indirect solar radiation.

In addition, products containing PVC often have an overall poor environmental balance, which is made up of, among other things, energy-intensive production and polluted and complex disposal.

Another major disadvantage of conventional polymer compositions, in particular compositions containing PVC, for the production of non-slip bases is that the stabilizers and plasticizers present migrate from the non-slip base, penetrate the surface of other polymeric materials and damage them. This phenomenon is observed in particular with carpet underlays which are applied to laminate or sealed parquet. Here, especially when the carpet has been used for several months or years, there is a migration of softeners from the carpet underlay into the surface of the floor covering, which at best only leads to a roughening and dulling of the surface, but in the worst case to the underlay sticking - partial blocking - results on the floor covering, which can ultimately make a more complex repair of the floor covering necessary.

Against this background, there has been no lack of attempts in the prior art to develop new and improved compositions for anti-slip underlays.

So describes about the DE 103 25 231 A1 an anti-slip mat made of acrylic rubber as the basic substance, which also contains an activator consisting of a hardener, a catalyst, a bubble-generating agent and a filler. A mat of intersecting threads spanning panels of varying densities is poured into the liquid coating composition immersed, so that sticking material closes densely populated areas of the crossing threads. Finally, the soaked mat is heated, whereby the coating foams and bubble-containing projections form in the area of the densely occupied mesh fields.

Furthermore, the DE 20 2007 007 209 U1 a non-slip mat, in particular for securing cargo against horizontal movement on a substantially horizontal cargo carrier, with an elastic core layer and a top layer made of non-slip material covering at least some areas of the top and bottom of the core layer, which are firmly connected to one another and are characterized in that that the core layer consists of a closed-cell polymer foam. Examples of a closed-cell polymer foam are polyolefinic polymer foams and, alternatively, materials such as polyurethane, PET, latex, PVC, acrylic, cellular rubber or foam rubber. In a preferred embodiment, the anti-slip mat can contain a reinforcement layer made of a fleece or technical textile.

In the examples mentioned, however, the use of PVC is still provided, or at least the use of activators, hardeners and catalysts, which still leave potential for improvement with regard to a mat composition that is to be evaluated positively from the aspects of health and environmental protection.

The CN 105 419 198 B relates to anti-slip materials, in particular a water-based anti-slip adhesive and its production process and application.

The JP S63 146945 A describes a film-like article with anti-slip properties, which are obtained by applying a blend-specific polymer binder and thermally expandable polymer beads to at least one area of the film and then thermally expanding the polymer beads, so that an expanded coating is formed on a carrier film .

The document CN 106 515 143 A relates to a yoga exercise mat. The yoga exercise mat includes a rubber foam layer and one on top of the rubber foam layer applied fabric layer, wherein the fabric layer is a fabric layer formed from natural fibers or synthetic fibers by a tufting technology, or by a weaving process, or by a non-woven process, or a fabric layer formed from synthetic fibers by a flocking technology, or a PU layer, a PU foam layer, a rubber layer or a rubber foam layer.

The document EP 0 520 151 A1 finally relates to a process for the production of latex, PVC and plasticizer-free textile or plastic floor or wall coverings, which contain, among other things, a foamed layer, with a powder mixture consisting of 100 parts of a thermoplastic polymer, 0 up to 100 parts of fillers, 0.5 to 7 parts of blowing agents, 0 to 30 parts of auxiliaries, sprinkled on in an amount corresponding to the desired thickness and melted at temperatures of 70 to 110°C, smoothed between smoothing rollers and at temperatures of 120 to 200°C is foamed. The document also relates to the new agents and the coverings made with them.

The prior art therefore still lacks anti-slip underlays that can be used in a variety of ways, are compatible with a large number of substrates and at the same time have a composition that is positive in terms of environmental and health protection aspects.

In particular, the prior art lacks anti-slip underlays that can prevent migration of plasticizers and stabilizers from the underlay into surface coverings, even after long periods of use of several months or years.

One object of the present invention is therefore to be seen in avoiding the aforementioned disadvantages and problems associated with the prior art, but at least reducing them.

A further object of the present invention is to provide an anti-slip underlay which, compared to the prior art, is characterized by balanced anti-slip properties on different materials, such as floor coverings, textile surfaces or furniture surfaces, so that the underlay can be used in a variety of ways given is.

In addition, a further object of the present invention is that the anti-slip base has a composition that is to be rated positively from the environmental and health protection aspects.

Yet another object of the present invention is to provide an anti-slip base that does not change or even attack the surface of the material on which it is placed, so that there are no changes in the material that could adversely affect its appearance or functionality .

The subject of the present invention according to a first aspect of the present invention is an anti-slip pad according to claim 1; further advantageous refinements of this aspect of the invention are the subject matter of the relevant dependent claims.

The subject matter of the present invention according to a second to fifth aspect of the present invention is the use of an anti-slip underlay according to claims 9 to 12.

The subject of the present invention according to a sixth aspect of the present invention is a method for producing an anti-slip base according to claim 13; further advantageous refinements of this aspect of the invention are the subject matter of the relevant dependent claims.

It goes without saying that special features, features, configurations and embodiments as well as advantages or the like, which are listed below - for the purpose of avoiding unnecessary repetitions - only for one purpose of the invention, of course apply correspondingly in relation to the other aspects of the invention, without it being requires an explicit mention.

In addition, all values or parameter information or the like mentioned below can be determined or determined using standardized or explicitly specified determination methods or using determination methods familiar to the person skilled in the art in this field.

In addition, it goes without saying that all percentages based on weight or quantity are selected by the person skilled in the art in such a way that the sum total is 100% or 100% by weight; however, this goes without saying.

Having said this, the present invention is described in more detail below.

The subject of the present invention is thus - according to a first aspect of the present invention - an anti-slip base, preferably intended for use as an anti-slip mat, wherein a layer of a self-crosslinking polymer foam based on acrylate is arranged on a carrier material, the polymer foam layer in the form of a the carrier material encasing coating is formed, and the self-crosslinking polymer foam based on acrylate is closed-cell, and is obtainable from an aqueous acrylate dispersion, wherein the aqueous acrylate dispersion has a solids content in amounts of 35 to 75% by weight, based on the total composition, and wherein the aqueous Acrylate dispersion contains at least one additive, the additive being selected from at least one filler and/or at least one blowing agent and/or mixtures thereof, the at least one blowing agent being selected from expandable polymer particles.

Because, as the applicant has surprisingly found out, with self-crosslinking polymer foams based on acrylate on a corresponding carrier material, slip-resistant underlays can be obtained, which are characterized by reliable and definably adjustable slip resistance and can be used in particular in a variety of ways on different subfloors or underlays. Based on the inventive composition of the self-crosslinking polymer foam based on acrylate, the anti-slip effect of the underlay according to the invention can be specifically adjusted by adding additives, so that neither an overly sticky underlay is obtained nor an underlay whose anti-slip effect is insufficient.

In addition, the anti-slip underlay according to the present invention is characterized in that the anti-slip, acrylate-based polymer foam largely does not interact with the underlying subsoil. This means in particular that no ingredients of the acrylate-based Polymer foam migrate into the subfloor or substrate and lead to a chemical change in the surface of the substrate there. Thus, the use of the anti-slip underlay according to the invention is possible safely and without problems on a large number of floors.

Yet another advantage of the present invention can be seen in the fact that polymer foam compositions are used which are essentially free of PVC, latex or synthetic and/or natural rubbers, plasticizers, stabilizers, catalysts and other negative environmental and health aspects additives. This means that the anti-slip underlay according to the invention can also be produced in an environmentally friendly manner and, moreover, does not entail any potential health hazards when used, for example in closed rooms.

In general, the anti-slip underlay according to the invention is compatible with a large number of underlays or subfloors, as already explained above. Accordingly, it can advantageously be used in a variety of ways, for example as a non-slip carpet underlay and tablecloth underlay, but also as a non-slip sports mat and, for example, as a non-slip insert for drawers and comparable, movable compartments in which common household items, such as hand tools, are placed. The anti-slip underlay according to the present invention thus opens up a very wide range of applications.

Especially in the form of carpet underlays or tablecloth underlays, which usually remain permanently in one place, the special advantages of the anti-slip underlay according to the invention are evident, since this does not require plasticizers and stabilizers in the polymer composition, ie the acrylate-based polymer foam. In this way, the migration of plasticizers and stabilizers from the anti-slip base into the underlying surface, such as a painted surface, in particular of parquet or tables, or a floor laminate can be prevented. Consequently, when using the anti-slip mat according to the invention, no chemical interactions with the surface to which the anti-slip underlay is applied are observed, even if the anti-slip underlay is left lying for a long time. The anti-slip underlay according to the invention can thus remain in one and the same place for months without any problems.

In the context of the present invention, anti-slip means in particular an increase in the sliding friction for the sliding of two bodies on one another, with the relevant coefficient of sliding friction being determined in accordance with DIN EN 14882:2005-11.

Within the scope of the present invention, it is usually provided that the base is at least essentially planar, in particular planar, in its entirety.

In the context of the present invention, a planar underlay is understood to mean that the underlay forms a flat surface in its entirety, particularly when it is used together with a flat textile placed thereon, such as a carpet or a tablecloth.

In addition, it is preferred if the base has an at least essentially full-surface structure, in particular a full-surface structure.

Within the scope of the invention, a full-surface structure is understood in relation to the base in particular to mean that the base has a continuous, uninterrupted surface, in particular a coating of the acrylate-based polymer foam.

Such non-slip underlays, when used as, for example, carpet or tablecloth underlays and sports mats, have an ideal anti-slip effect on the textile laid on or the skin and clothing of the user of the sports mat. In addition, the non-slip underlay creates a pleasant impact sound absorption when used as a carpet underlay or a pleasant padding of a table surface when the underlay is used under tablecloths.

In addition, provision can be made for the anti-slip base to be structured. Particularly good results are obtained if the anti-slip base has a microstructure, in particular a three-dimensional microstructure, preferably a three-dimensional, nub-like microstructure.

A microstructuring in the context of the present invention preferably means a structuring of the surface, which is applied essentially regularly over the entire surface of the base, but without destroying the overall impression of a flat and evenly formed base.

For anti-slip underlays structured in this way, it was observed that the anti-slip effect is further enhanced by the three-dimensional microstructuring, so that the object placed on top can be prevented from slipping even more efficiently. This is especially true when the non-slip underlay is used as a sports mat.

Furthermore, it can be provided that the base has an at least essentially lattice-like structure, in particular the structure of a lattice.

At the same time, within the scope of the present invention, an at least essentially lattice-like structure is also to be understood as meaning a network-like structure, and the structure of a lattice also includes the structure of a network.

A non-slip underlay structured in this way is particularly suitable for use under carpets, since better ventilation is achieved here between the carpet and the floor, so that, for example, there is no accumulation of any moisture between the floor, underlay and/or carpet.

With regard to the carrier material that is used in the anti-slip base, this can be a common carrier material that is known per se to a person skilled in the art. Within the scope of a preferred embodiment of the present invention, it is provided that the carrier material is a woven fabric, knitted fabric, crocheted fabric, scrim, in particular a woven fabric, preferably a mesh fabric.

If a carrier material as described above is used, it is preferably provided that the carrier material has regularly shaped meshes.

In the event that an underlay with a full-surface structure is to be obtained, it can be provided that the carrier material preferably has regularly shaped meshes with an average width of 0.5 x 1 mm to 7.5 x 9 mm, in particular 1×1.5 mm to 5×6.5 mm, preferably 1.5×2 mm to 3×4.5 mm.

In the event that a substrate with a grid-like or net-like structure is to be obtained, it can alternatively be provided that the carrier material preferably has regularly shaped meshes with an average width of 1 × 1 mm to 3 × 3 cm, preferably 3 × 3 mm to 2×2 cm, preferably 4×4 mm to 1.5×1.5 cm.

In addition, the carrier material is preferably characterized in that the carrier material has a basis weight of 80 to 2500 g/m ² , in particular 120 to 2000 g/m ² , preferably 150 to 1500 g/m ² .

Furthermore, it can be provided that the carrier material consists of a fiber-reinforced plastic.

Within the scope of a further preferred embodiment of the present invention, it can then be provided that the carrier material, in particular the fiber-reinforced plastic, contains inorganic fibers, in particular silicate fibers, preferably glass fibers, preferably glass yarn.

Furthermore, it is preferred for this embodiment of the present invention if the carrier material, in particular the fiber composite plastic, contains a plastic matrix made of polyurethane, polyamide, polyester or mixtures thereof, preferably polyester.

Another preferred embodiment of the present invention provides for the carrier material to consist of a plastic fiber and/or inorganic fiber or a mixture thereof.

It can then be provided that the carrier material, in particular the inorganic fiber, in particular glass fibers, preferably glass yarn, contains. It has also proven useful if the carrier material, in particular the plastic fiber, consists in particular of polyurethane, polyamide, polyester and mixtures thereof, preferably polyester. In this context, it can be provided that, for example, the warp threads of the carrier material are made of glass fibers are formed, while the weft threads are made of plastic fibers, in particular polyester fibers.

Anti-slip mats that have a carrier material made of the aforementioned fibers are distinguished by their particular resilience and durability in relation to mechanical stress in particular, and at the same time are designed in such a way that weight-optimized non-slip mats can be obtained.

With regard to the polymer foam layer, it is provided within the scope of the present invention that the polymer foam layer is formed in the form of a coating encasing the carrier material on the carrier material.

In the context of the present invention, a coating encasing the carrier material is understood to mean a coating that completely surrounds the carrier material, but can nevertheless have a certain thickness in all spatial directions, in particular coating thicknesses of a few millimeters. Thus, an enveloping coating is not necessarily a thin layer; the thickness of the layer can vary, even within the substrate. It is also possible for individual strands or threads of the carrier material to be connected to one another via the surrounding polymer foam in the plane which is preferably defined by the anti-slip base.

According to a further preferred embodiment, it can be provided that the coating is applied at least essentially over the entire surface, in particular over the entire surface.

Alternatively, within the scope of another preferred embodiment of the present invention, it may be desirable for the coating to surround the carrier material in such a way that free spaces are formed in the meshes of the carrier material.

In this way, a lattice-like structure or a lattice-like structure is achieved for the anti-slip underlay over the entire surface of the anti-slip underlay. This allows, for example, an unproblematic volatilization of moisture, which is between the non-slip Support and the surface to which it is applied can form. The non-slip underlay is therefore open to diffusion.

As far as the polymer foam used in the context of the invention is concerned, this can be a polymer foam that is generally familiar to the person skilled in the art, which has self-crosslinking properties and is based on acrylate. In the context of the present invention, it is provided that the self-crosslinking polymer foam based on acrylate has a closed-cell design.

Aspects such as improved hygiene, reduced absorption of, for example, liquids, perspiration and/or similar compositions are positively influenced by the use of closed-cell polymer foams. In addition, an overall better contact of the base with the subsurface and with the object placed on it is achieved, since the surface of the mat itself is continuous and is not interrupted by bubble-shaped openings.

Furthermore, it is provided within the scope of the present invention that the self-crosslinking polymer foam based on acrylate can be obtained from an aqueous acrylate dispersion, in particular a pure acrylate dispersion, preferably a pure acrylate dispersion with ethyl acrylate as the main component.

In addition, it is provided within the scope of the present invention that the aqueous acrylate dispersion contains a solids content in amounts of 35 to 75% by weight, preferably 45 to 70% by weight, based on the composition.

In addition, the present invention provides for the aqueous acrylate dispersion to contain at least one additive.

It has proven itself within the scope of a further preferred embodiment of the present invention if the aqueous acrylate dispersion contains the additive in amounts of 10 to 55% by weight, in particular 15 to 45% by weight, preferably 20 to 40% by weight, based on the total composition , contains.

Furthermore, it is provided within the scope of this preferred embodiment of the present invention that the additive is selected from at least one filler and/or at least one blowing agent and/or mixtures thereof, in particular a mixture of at least one filler and at least one blowing agent.

In the context of the invention, it is preferred if the acrylate dispersion contains only blowing agents and fillers as additives. As has been found, the use of acrylate dispersions, which only have fillers and blowing agents as additives, can provide a high-performance anti-slip underlay that does not require any plasticizers or stabilizers.

With regard to the filler, it is preferable if the aqueous acrylate dispersion contains the filler in amounts of 10 to 45% by weight, in particular 15 to 35% by weight, preferably 17 to 30% by weight, based on the total composition.

In addition, it has proven advantageous if the aqueous acrylate dispersion contains the blowing agent in amounts of 1 to 10% by weight, in particular 2 to 9% by weight, preferably 3 to 8% by weight, based on the total composition.

With regard to the filler, it can be provided within the scope of the present invention that the filler is a mineral filler, in particular a neutral to acidic mineral filler, preferably selected from siliceous, carbonate, sulphate and/or oxidic fillers, preferably selected from siliceous, sulphate and/or oxidic fillers, and mixtures thereof.

Within the scope of a particularly preferred embodiment of the present invention, it has proven useful if the filler is selected from silicates, in particular clay, talc, mica, kaolin, silica, preferably talc, and/or sulphates, in particular barite, sodium sulphate, preferably barite, and/or hydroxides, in particular aluminum hydroxide, magnesium hydroxide, and mixtures thereof.

It is very particularly preferred if the filler is selected from silicates and/or sulfates, in particular talc and barite, and mixtures thereof.

For the fillers mentioned, it was observed that, within the scope of the invention, an advantageous adjustment of the anti-slip effect of the anti-slip underlay is possible through the targeted addition of the fillers mentioned. In particular, an optimized addition of at least one of the aforementioned fillers allows the avoidance of an overly sticky composition for the anti-slip underlay, which could then interact in a disadvantageous manner, in particular with the underlay or the underbody. This is avoided by the use of fillers in the range according to the invention and a non-slip underlay is thus obtained which has balanced non-slip properties and does not change the surface of the subfloor or the subfloor located underneath.

With regard to the blowing agent, it is generally provided within the scope of the present invention that the at least one blowing agent is selected from expandable polymer particles, in particular Expancel.

Expandable polymer particles, in particular Expancel, are to be understood as meaning spherical hollow particles having a shell made of a thermoplastic material. The thermoplastic plastic shell is designed in such a way that it begins to expand within a defined temperature range. The expansion process is further influenced by gases or liquid gases enclosed in the hollow particle, such as CO ₂ or lower alkanes. In the course of the expansion, an example of an expandable hollow polymer particle increases by approximately 4 times its diameter or approximately 60 times its volume. On average, the hollow polymer particles described have a particle size in the range of around 10 μm in the non-expanded state.

A particular advantage of using expandable polymer particles is that there is a defined and uniform particle size distribution, which allows planned and controllable foaming of polymers. In addition, the use of expandable polymer particles has a particularly positive effect on the production of uniform closed-cell pores in the polymer foam according to the invention.

With regard to the polymer foam produced from the aqueous acrylate dispersion, it is preferably provided in the context of the present invention if the filler is present in amounts of 35 to 75% by weight, in particular 35 to 60% by weight, preferably 40 to 55% by weight based on the polymeric foam composition.

Furthermore, it is preferred within the scope of the present invention if the anti-slip base is at least essentially free of vinyl polymers, in particular polyvinyl chloride, and/or rubber and/or stabilizers and/or plasticizers, in particular free of vinyl polymers, in particular polyvinyl chloride, and/or rubber and/or stabilizers and/or plasticizers.

Slip-resistant underlays designed in this way can be classified as extremely positive, especially from an environmental and health protection perspective, since they are essentially free of, for example, plasticizers that are harmful to health, for which it has been shown that these can be liver and kidney-damaging and may also have carcinogenic effects. In addition, it is also known for polyvinyl chlorides that they can emit so-called residential toxins, i. H. potentially harmful volatile compounds. Accordingly, it is a particular advantage of the present invention that the anti-slip base is preferably completely free of the aforementioned substances.

A particular advantage also results from the absence of stabilizers and plasticizers, which not only has advantages from the point of view of health and environmental protection, but also means that the stabilizers and plasticizers do not migrate out of the substrate and thus damage the surfaces of adjacent objects or can affect or damage floors.

Furthermore, it can be provided within the scope of the present invention that the anti-slip base is flocked, in particular is flocked with plastic flakes, preferably with polyamide flakes.

Provision is also preferably made for the anti-slip base to have a coefficient of sliding friction of less than μ3 , in particular less than μ2.5 , preferably less than μ2 . Within the scope of the present invention, the coefficient of sliding friction is determined according to the guideline DIN EN 14882:2005-11.

Furthermore, an anti-slip base, in particular if it is intended for use as a base to secure an object placed on it, can preferably be designed within the scope of the present invention such that the base has a total thickness of up to 5 mm, in particular 3.5 mm, preferably 2.5mm.

Alternatively, an anti-slip base, especially if it is intended for use as a sports base, can preferably be designed within the scope of the present invention such that the base has a total thickness of up to 15 mm, in particular 11 mm, preferably 7 mm.

The anti-slip underlay according to the present invention, in particular with the aforementioned features, is particularly suitable for use in securing an object, in particular a flat, textile object, preferably a carpet, a tablecloth, against horizontal movement on a substantially smooth surface, in particular on a wooden floor, stone floor, carpet floor, plastic floor, preferably a wooden floor, stone floor.

In addition, the anti-slip underlay according to the invention is preferably suitable for use as a sports underlay, in particular as a sports mat, fitness mat, gymnastics mat, yoga mat, preferably a fitness mat or yoga mat.

The anti-slip base described above is also suitable according to the invention for use in securing small and medium-sized items of daily use, in particular hand tools, transportable machines and household goods, in particular against horizontal movement in a vehicle.

Last but not least, the non-slip underlay described can be used as an insulating underlay under a floor covering, in particular carpeting, in particular for damping impact noise or thermal insulation.

A particular advantage of the anti-slip underlay according to the invention is that it can generally be obtained in a manufacturing process that is efficient and easy to carry out.

Another object of the present invention - according to a second aspect of the present invention - is the use of the previously described anti-slip base for securing an object, in particular a flat, textile object, preferably a carpet, a tablecloth, against horizontal movement on a substantially smooth surface , in particular on a wooden floor, stone floor, carpet floor, plastic floor, preferably a wooden floor, stone floor.

For further details on this aspect of the invention, reference can be made to the above statements on the anti-slip underlay according to the invention, which apply accordingly in relation to the use according to the invention.

Another subject of the present invention - according to a third aspect of the present invention - is the use of the previously described non-slip base as a sports base, in particular as a sports mat, fitness mat, gymnastics mat, yoga mat, preferably fitness mat or yoga mat.

For further details on this aspect of the invention, reference can be made to the above statements on the further aspects of the invention e, which apply correspondingly in relation to the use according to the invention.

Another subject of the present invention - according to a fourth aspect of the present invention - is the use of the non-slip base described above to secure small and medium-sized items of daily use, in particular hand tools, transportable machines and household loads, in particular against horizontal movement in a vehicle.

For further details on this aspect of the invention, reference can be made to the above statements on the further aspects of the invention e, which apply correspondingly in relation to the use according to the invention.

Another object of the present invention - according to a fifth aspect of the present invention - is the use of the previously described anti-slip underlay as an insulating underlay under a floor covering, in particular carpeting, in particular for footfall sound absorption or thermal insulation.

For further details on this aspect of the invention, reference can be made to the above statements on the further aspects of the invention e, which apply correspondingly in relation to the use according to the invention.

1. (a) in einem Verfahrensschritt (a) ein Trägermaterial mit einer wässrigen Acrylatdispersion beschichtet
   und
2. (b) in einem nachfolgenden Verfahrensschritt (b) das beschichtete Trägermaterial erhitzt wird, sodass die Ausbildung eines selbstvernetzenden Polymerschaums auf Acrylatbasis erfolgt,

wobei die Polymerschaumschicht in Form einer das Trägermaterial ummantelnden Beschichtung ausgebildet ist, und der selbstvernetzende Polymerschaum auf Acrylatbasis geschlossenzellig ausgebildet ist, und wobei die wässrige Acrylatdispersion einen Feststoffanteil in Mengen von 35 bis 75 Gew.%, bezogen auf die Gesamtzusammensetzung, enthält, und wobei die wässrige Acrylatdispersion mindestens ein Additiv enthält, wobei das Additiv ausgewählt ist aus mindestens einem Füllstoff und/oder mindestens einem Treibmittel und/oder deren Mischungen, wobei das mindestens eine Treibmittel ausgewählt ist aus expandierbaren Polymerpartikeln.Another object of the present invention - according to a sixth aspect of the present invention - is a method for producing a non-slip base, in particular a non-slip base described above, wherein

1. (a) in a process step (a), a carrier material is coated with an aqueous acrylate dispersion
   and
2. (b) in a subsequent process step (b), the coated carrier material is heated so that a self-crosslinking polymer foam based on acrylate is formed,

wherein the polymer foam layer is in the form of a coating encasing the carrier material, and the self-crosslinking polymer foam based on acrylate is closed-cell, and wherein the aqueous acrylate dispersion contains a solids content in amounts of 35 to 75% by weight, based on the total composition, and wherein the aqueous acrylate dispersion contains at least one additive, the additive being selected from at least one filler and/or at least one blowing agent and/or mixtures thereof, the at least one blowing agent being selected from expandable polymer particles.

It has proven advantageous here if the carrier material is coated with the aqueous acrylate dispersion in step (a) by dipping, spraying, wetting, spattering, impregnating.

Furthermore, it has proven to be suitable if the carrier material coated with the aqueous acrylate dispersion is predried in step (b) at medium temperatures, in particular at about 40.degree. C., preferably at about 50.degree.

In this context, it can be provided in particular that the carrier material coated with the aqueous acrylate dispersion is predried in step (b) at temperatures in the range from 30 to 60° C., in particular 40 to 60° C., preferably 45 to 55° C.

Furthermore, as part of the production process, it can be provided that the carrier material coated with the aqueous acrylate dispersion is heated in some areas in step (b) to foam the acrylate, in particular heated over the entire area of the substrate.

For this purpose, it has proven preferable if the carrier material coated with the aqueous acrylate dispersion is heated in step (b) to temperatures above 60° C., in particular above 70° C., preferably above 80° C., to foam the acrylate.

Particularly good results are obtained in this context if the carrier material coated with the aqueous acrylate dispersion in step (b), in particular for foaming the acrylate, is heated to temperatures in the range from 60 to 130° C., in particular 70 to 120° C., preferably 80 to 110 °C, is heated.

Last but not least, it can be provided that, in a subsequent process step (c), a flocking agent is applied to the polymer foam that is formed.

The method presented thus represents an uncomplicated process that can be carried out in a time-efficient manner, from which an anti-slip underlay with the aforementioned features, special features and advantageous properties can be reliably obtained.

For further details on this aspect of the invention, reference can be made to the above statements on the further aspects of the invention e, which apply correspondingly in relation to the method according to the invention.

On the basis of the following drawings, the present invention is to be explained in more detail in a non-limiting manner for a better understanding.

Further advantages, properties, aspects and features of the present invention result from the following description of preferred embodiments according to the invention illustrated in the drawing.

Fig. 1

eine rutschhemmende Unterlage mit vollflächiger Struktur und einer erfindungsgemäß mikrostrukturierten Oberfläche.

Fig. 2

eine rutschhemmende Unterlage mit gitterartiger Struktur.

Fig. 3

eine rutschhemmende Unterlage mit gitterartiger Struktur mit unregelmäßiger Beschichtungsdicke.

Fig. 4

einen schematischen Aufbau einer erfindungsgemäßen rutschhemmenden Matte.

In the figure representations shows:

1

an anti-slip underlay with an all-over structure and a surface microstructured according to the invention.

2

a non-slip base with a grid-like structure.

3

a non-slip backing with a lattice-like structure with an irregular coating thickness.

4

a schematic structure of an anti-slip mat according to the invention.

In particular shows 1 a preferred embodiment of an anti-slip base 1 according to the invention, which is designed over the entire surface and is microstructured on its surface, which is formed by the polymer foam 2 . The microstructure 3 preferably forms a continuous nub pattern 4 and gives the base 1 a special slip resistance. The polymer foam 2 surrounds the carrier material 5 in particular so completely that no carrier material protrudes at the side edges of the base 1 either. The underlay designed in this way is also characterized by a pleasant feeling underfoot and efficient footfall sound absorption.

2 shows an alternative embodiment of the present invention, in which the base 1 has a lattice-like structure. The cavities or interstices 6 of the meshes of the carrier material remain free of polymer foam here, so that a weight-optimized base 1 is obtained. This embodiment also permits good ventilation between the subsurface and the object placed on it, particularly in the case of flat textiles such as carpets.

In 3 Another embodiment of the anti-slip base 1 with a lattice-like structure and irregular coating thicknesses is shown. In particular, for example, the glass yarn threads 7 running in the z-direction have a thinner polymer foam coating 2 than the glass yarn threads 8 running in the x-direction. In this way, the advantageous effects of the embodiments in 1 and 2 combined so efficiently that both a weight-optimized underlay and an underlay that achieves a certain ventilation as well as a pleasant foot feeling result.

Finally shows 4 the schematic structure of a non-slip pad 1 according to the invention in cross section. According to the embodiment of the base 1 shown in the figure, the carrier material 5 is arranged centrally in the base 1 and is evenly surrounded or encased by polymer foam 2 . In the polymer foam 2, closed-cell pores 9 are preferably formed, which can be produced as part of the production process by heating using a blowing agent. Due to the formation of closed-cell pores 9, a continuous surface is retained in the polymer foam 2, so that there is a continuous contact surface. On the basis of this, the advantageous anti-slip properties of the acrylate-based polymer foam can be significantly achieved.

Example:

1. 1. Preparation of the aqueous acrylate dispersion:
   15 kg of Expancel (blowing agent) and a total of 120 kg of barite (filler) are added to 300 kg of a commercially available aqueous dispersion of acrylates and processed to form a homogeneous dispersion.
2. 2. Making the anti-slip base

A PES glass yarn fabric is coated with the aqueous acrylate dispersion. After pre-drying, the PES glass yarn fabric coated with the acrylate dispersion is heated to temperatures of approx. 100 °C, during which the blowing agent begins to expand so that the acrylate foams by creating closed pores with the blowing agent. After completion of the foaming process, the underlay cools down and can then be further cut and processed.

The anti-slip underlay produced in this way is characterized on the one hand by very good anti-slip properties and on the other hand by excellent mechanical strength. The anti-slip underlay according to the invention is also free of stabilizers and plasticizers as well as polymers that are questionable from the point of view of health or environmental protection and can consequently be used for a large number of applications.

Reference list:

1

Anti-slip pad

2

polymer foam

3

microstructure

4

nub pattern

5

carrier material

6

mesh spaces

7

coated glass yarn threads (z-direction)

8th

coated glass yarn threads (x-direction)

9

closed cell pores

Claims (16)

1. Anti-slip underlay, preferably intended for use as an anti-slip mat,

   characterised in

   that a layer of a self-crosslinking polymer foam based on acrylate is arranged on a carrier material,

   wherein the polymer foam layer is in the form of a coating sheathing the carrier material, and the self-crosslinking acrylate-based polymer foam is of closed-cell form and is obtainable from an aqueous acrylate dispersion, wherein

   the aqueous acrylic dispersion contains a solids content in amounts of 35 to 75% by weight, based on the total composition, and wherein the aqueous acrylic dispersion contains at least one additive, wherein

   the additive is selected from at least one filler and/or at least one blowing agent and/or mixtures thereof, wherein the at least one blowing agent is selected from expandable polymer particles.
2. Anti-slip underlay according to claim 1, characterised in that the carrier material is a woven, knitting, knitted fabric, laid fabric, in particular a woven fabric, preferably a mesh.
3. Anti-slip underlay according to claim 1 or 2, characterised in that the carrier material consists of a synthetic fibre and/or inorganic fibre or mixture thereof.
4. Anti-slip underlay according to any one of claims 1 to 3, characterized in that the self-crosslinking acrylate-based polymer foam is obtainable from a pure acrylate dispersion, preferably a pure acrylate dispersion with ethyl acrylate as the main component, in particular wherein the aqueous acrylate dispersion contains a solids content in amounts of from 45 to 70 % by weight, based on the total composition.
5. Anti-slip underlay according to one of the preceding claims, characterized in that the aqueous acrylate dispersion contains the additive in amounts of 10 to 55 % by weight, in particular 15 to 45 % by weight, preferably 20 to 40 % by weight, based on the total composition.
6. Anti-slip underlay according to one of the preceding claims, characterised in that the at least one filler is a mineral filler, in particular a neutral to acidic mineral filler, preferably selected from silicate, carbonate, sulphate and/or oxide fillers, preferably selected from silicate, sulphate and/or oxide fillers, and mixtures thereof.
7. Anti-slip underlay according to one of the preceding claims, characterized in that the filler is present in the polymer foam in amounts of 30 to 75% by weight, in particular 35 to 60% by weight, preferably 40 to 55% by weight, based on the polymer foam composition.
8. Anti-slip underlay according to one of the preceding claims, characterised in that the underlay has a coefficient of sliding friction of less than µ 3, in particular less than µ 2.5, preferably less than µ 2.
9. Use of an anti-slip underlay according to any one of claims 1 to 8 for securing an object, in particular a flat textile object, preferably a carpet and/or a tablecloth, against horizontal movement on a substantially smooth substrate, in particular on a wooden floor, stone floor, carpet or plastic floor, preferably a wooden floor or stone floor.
10. Use of an anti-slip underlay according to any one of claims 1 to 8 as a sports underlay, in particular as a sports mat, fitness mat, gymnastics mat and/or yoga mat, preferably fitness mat or yoga mat.
11. Use of an anti-slip underlay according to one of claims 1 to 8 for securing small and medium-sized objects of use, in particular hand tools, transportable machines and household loads, in particular against horizontal movement in a vehicle.
12. Use of an anti-slip underlay according to any one of claims 1 to 8 as an insulating underlay under a floor covering, in particular carpeting, in particular for impact sound damping or thermal insulation.
13. A method of manufacturing an anti-slip underlay, in particular according to any one of claims 1 to 8,

    characterised in that

    (a) in a process step (a) a carrier material is coated with an aqueous acrylate dispersion
    and

    (b) in a subsequent process step (b), the coated carrier material is heated so that the formation of a self-crosslinking acrylate-based polymer foam takes place,

    wherein the polymer foam layer is in the form of a coating sheathing the carrier material, and the self-crosslinking acrylate-based polymer foam is of closed-cell form, and wherein

    the aqueous acrylic dispersion contains a solids content in amounts of 35 to 75% by weight, based on the total composition, and wherein the aqueous acrylic dispersion contains at least one additive, wherein

    the additive is selected from at least one filler and/or at least one blowing agent and/or mixtures thereof, wherein the at least one blowing agent is selected from expandable polymer particles.
14. Process according to claim 13, characterized in that the carrier material is coated in process step (a) by dipping, spraying, wetting, spraying, impregnating with the aqueous acrylate dispersion.
15. Process according to any one of claims 13 or 14, characterized in that the carrier material coated with the aqueous acrylate dispersion is heated to temperatures above 60°C, in particular above 70°C, preferably above 80°C, in process step (b), in particular for foaming the acrylate.
16. Process according to any one of claims 13 to 15, characterized in that in a downstream process step (c) a flocking agent is applied to the polymer foam formed.

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