Anti-slip underlay

Abstract

The present invention relates to the technical field of synthetic underlays, in particular to an anti-slip underlay, preferably provided for use as anti-slip matting for a plurality of applications, and to a method for producing same.

Description

[0001] The present invention relates to the technical field of plastic underlays, in particular anti-slip underlays.

[0002] In particular, the present invention relates to a non-slip surface, preferably intended for use as a non-slip mat.

[0003] Furthermore, the present invention relates to a method for producing a non-slip surface.

[0004] In recent years, smooth surfaces, especially smooth floor coverings, have become increasingly popular, as they convey a high-quality and pleasant room aesthetic while also being easy to clean, hygienic, and durable. Similarly, carpets, for example, remain a popular decorative element for smooth floor coverings, particularly for visually enhancing the room's appearance. Carpeted areas also provide a comfortable feel underfoot and offer some sound insulation.

[0005] Since flat textiles, such as carpets and tablecloths, do not grip well on smooth surfaces, it is necessary to secure them against slipping. Anti-slip mats have been successfully used for this purpose for some time now.

[0006] The anti-slip mats known in the prior art often consist of vinyl polymers, particularly polyvinyl chloride (PVC). While polyvinyl chloride is characterized by its good durability and longevity, PVC still suffers from a number of disadvantages today.

[0007] PVC compounds typically contain plasticizers, stabilizers, and other additives. Although these additives are generally not very volatile, it has been found that some of them can be released into indoor air as so-called indoor pollutants.

[0008] However, the most harmful components of PVC are the plasticizers, which are particularly prevalent in flexible PVC. Plasticizers can enter the body through saliva, skin contact, or the respiratory tract, where they can potentially damage the liver or kidneys.

[0009] In some cases, carcinogenic effects have been observed from the absorption of plasticizers into the human body. Furthermore, it has been found that the emission of harmful substances from PVC increases with the thermal stress placed on the material, for example, by direct or indirect sunlight.

[0010] Furthermore, PVC-containing products often have an overall poor environmental record, which is due, among other things, to energy-intensive production and pollutant-laden and costly disposal.

[0011] Another major disadvantage of common polymer compositions, especially those containing PVC, used to manufacture anti-slip underlays is that the stabilizers and plasticizers migrate from the underlay, penetrate the surface of other polymeric materials, and damage them. This phenomenon is particularly noticeable with carpet underlays applied to laminate or sealed parquet flooring. Especially after several months or years of use, plasticizers migrate from the carpet underlay into the surface of the flooring. At best, this only results in a roughening and matting of the surface; at worst, it leads to the underlay adhering to the flooring—a partial blocking—which can ultimately necessitate more extensive floor repairs.

[0012] Against this background, there has been no shortage of prior art attempts to develop new and improved compositions for anti-slip surfaces.

[0013] For example, DE 103 25 231 A1 describes an anti-slip mat made of acrylic rubber as the base material, which also contains an activator consisting of a hardener, a catalyst, a bubble-inducing agent, and a filler. A mat made of intersecting threads, which span fields with varying densities, is immersed in the liquid coating composition so that the adhering material closes the more densely packed fields of the intersecting threads. Finally, the impregnated mat is heated, causing the coating to foam up and bubble-containing protrusions to form in the area of ​​the densely packed mesh fields.

[0014] Furthermore, DE 20 2007 007 209 U1 describes an anti-slip mat, particularly for securing cargo against horizontal movement on a substantially horizontal load carrier, comprising an elastic core layer and a surface layer made of anti-slip material that covers at least part of the top and bottom of the core layer. These layers are firmly bonded together and are characterized in that the core layer consists of a closed-cell polymer foam. Examples of closed-cell polymer foams include polyolefinic polymer foams and, alternatively, materials such as polyurethane, PET, latex, PVC, acrylic, cellular rubber, or sponge rubber. In a preferred embodiment, the anti-slip mat can include a reinforcing layer made of a nonwoven fabric or technical textile.

[0015] However, the examples mentioned still include the use of PVC, or at least the use of activators, hardeners and catalysts, which leave potential for improvement with regard to a mat composition that can be positively assessed from the perspectives of health and environmental protection.

[0016] CN 105 419 198 B concerns anti-slip materials, in particular a water-based anti-slip adhesive, as well as its manufacturing process and application.

[0017] 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 spheres to at least one area of ​​the film and subsequently thermally expanding the polymer spheres to form an expanded coating on a carrier film.

[0018] Document CN 106 515 143 A concerns a yoga exercise mat. The yoga exercise mat comprises a rubber foam layer and a fabric layer applied to the rubber foam layer, wherein the fabric layer is a fabric layer formed from natural or synthetic fibers by a tufting technology, a weaving process, or a nonwoven 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.

[0019] Document EP 0 520 151 A1 relates to a process for manufacturing latex-, PVC-, and plasticizer-free textile or plastic floor or wall coverings, which, inter alia, contain a foamed layer. In this process, a powder mixture consisting of 100 parts of a thermoplastic polymer, 0 to 100 parts fillers, 0.5 to 7 parts blowing agents, and 0 to 30 parts additives is sprinkled onto the base layer beneath the subsequent foam layer in an amount corresponding to the desired thickness. The mixture is then fused at temperatures of 70 to 110°C, smoothed between rollers, and foamed at temperatures of 120 to 200°C. The document further relates to the new agents and the coverings produced with them.

[0020] There is still a lack of non-slip mats in the state of the art that can be used in a variety of ways, are compatible with a wide range of substrates, and at the same time have a composition that can be positively assessed from an environmental and health protection perspective.

[0021] In particular, the state of the art lacks anti-slip mats that can prevent the migration of plasticizers and stabilizers from the substrate into surface coverings, even during long periods of use lasting several months or years.

[0022] One object of the present invention is therefore to avoid, or at least mitigate, the aforementioned disadvantages and problems associated with the prior art.

[0023] Another object of the present invention is to provide a non-slip mat which, compared to the prior art, is characterized by a balanced non-slip performance on different materials, such as floor coverings, textile substrates or furniture surfaces, so that the mat can be used in a variety of applications.

[0024] Furthermore, another objective of the present invention is to ensure that the non-slip surface has a composition that is positively assessed from an environmental and health protection perspective.

[0025] A further object of the present invention is to provide a non-slip surface that does not alter or even attack the surface of the material on which it is placed, so that no changes occur in the material that could adversely affect its appearance or functionality.

[0026] The subject matter of the present invention according to a first aspect of the present invention is a non-slip surface according to claim 1; further advantageous embodiments of this aspect of the invention are the subject matter of the related dependent claims.

[0027] The subject matter of the present invention according to a second to fifth aspect of the present invention is the use of a non-slip mat according to claims 9 to 12.

[0028] The subject matter of the present invention according to a sixth aspect of the present invention is a method for producing a non-slip surface according to claim 13; further advantageous embodiments of this aspect of the invention are the subject matter of the related dependent claims.

[0029] It goes without saying that special features, characteristics, designs and embodiments, as well as advantages or the like, which are subsequently described – for the purpose of avoiding unnecessary repetition – only for one purpose of the invention, naturally apply accordingly to the other aspects of the invention without the need for express mention.

[0030] Furthermore, it should be noted that all values ​​or parameters mentioned below, or the like, can in principle be determined or ascertained using standardized or explicitly specified determination procedures, or using determination methods that are generally familiar to those skilled in the field.

[0031] Furthermore, it goes without saying that all percentages relating to weight or quantity are selected by a specialist in such a way that the total results in 100% or 100 wt%; this, however, is self-evident.

[0032] Having said that, the present invention will now be described in more detail.

[0033] The subject matter of the present invention is therefore - according to a first Aspect of the present invention - a non-slip mat having the features of claim 1.

[0034] For, as the applicant surprisingly discovered, anti-slip mats can be obtained using self-crosslinking acrylate-based polymer foams on a suitable substrate material. These mats are characterized by reliable and definably adjustable slip resistance and can be applied in a variety of ways to different subfloors or substrates. Based on the inventive composition of the self-crosslinking acrylate-based polymer foam, the anti-slip effect of the mat can be specifically adjusted by adding additives, ensuring that neither an overly sticky mat nor one with insufficient anti-slip properties is obtained.

[0035] Furthermore, the anti-slip underlay according to the present invention is characterized by the fact that the anti-slip, acrylate-based polymer foam largely does not interact with the underlying substrate. This means, in particular, that no components of the acrylate-based polymer foam migrate into the subfloor or substrate and cause a chemical change to its surface. Therefore, the anti-slip underlay according to the invention can be used safely and without problems on a wide variety of floors.

[0036] A further advantage of the present invention lies in the fact that polymer foam compositions are used which are free of PVC, latex, synthetic and / or natural rubbers, plasticizers, stabilizers, catalysts, and other additives that are negatively assessed from an environmental and health protection perspective. This means that the anti-slip mat according to the invention can be manufactured in an environmentally friendly manner and, moreover, poses no health hazard potential when used, for example, in enclosed spaces.

[0037] In general, the anti-slip mat according to the invention is compatible with a wide variety of substrates and subfloors, as previously explained. Accordingly, it can be advantageously used in a variety of applications, for example as an anti-slip carpet underlay and tablecloth underlay, but also as a non-slip sports mat and, for example, as an anti-slip liner for drawers and similar movable compartments in which household items, such as hand tools, are placed. Thus, the anti-slip mat according to the present invention opens up a very broad range of applications.

[0038] The particular advantages of the anti-slip underlay according to the invention become especially apparent in the form of carpet or tablecloth underlays, which generally remain permanently in one place, as it does not require plasticizers or stabilizers in its polymer composition, i.e., the acrylate-based polymer foam. This prevents the migration of plasticizers and stabilizers from the anti-slip underlay into the underlying surface, such as a painted surface, particularly parquet or tables, or even laminate flooring. 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 after extended periods of inactivity. The anti-slip underlay according to the invention can therefore remain in the same location without any problems, even for months.

[0039] In the context of the present invention, slip resistance is understood in particular to mean an increase in the sliding friction for the sliding of two bodies against each other, wherein the corresponding coefficient of sliding friction is determined in accordance with DIN EN 14882:2005-11.

[0040] Within the scope of the present invention, it is usually provided that the substrate as a whole is at least substantially planar, in particular flat.

[0041] In the context of the present invention, a flat substrate is understood to mean that the substrate as a whole forms a flat surface, particularly when it is used together with a flat textile placed on top, such as a carpet or a tablecloth.

[0042] Furthermore, it is preferred if the substrate has a structure that is at least substantially full-surface, in particular a full-surface structure.

[0043] In the context of the invention, a full-surface structure is understood to mean, in particular, that the substrate has a continuous, uninterrupted surface, especially a coating made of the polymer foam based on acrylate.

[0044] Anti-slip mats designed in this way provide ideal slip resistance when used, for example, as carpet or tablecloth underlays, as well as sports mats, protecting the textile placed on top of them, and also the skin and clothing of the user. Furthermore, the anti-slip mat provides pleasant sound insulation when used as a carpet underlay or comfortable cushioning of a table surface when used under tablecloths.

[0045] Furthermore, the anti-slip surface can be structured. Particularly good results are obtained if the anti-slip surface has a microstructure, especially a three-dimensional microstructure, preferably a three-dimensional, nub-like microstructure.

[0046] In the context of the present invention, microstructuring preferably means structuring of the surface which is applied essentially regularly over the entire surface of the substrate, without, however, negating the overall impression of a flat and evenly formed substrate.

[0047] For such structured, non-slip mats, it has been observed that the non-slip effect is further enhanced by the three-dimensional microstructuring, thus preventing the object placed on them from slipping even more effectively. This is particularly true when the non-slip mat is used as a sports mat.

[0048] Furthermore, it may be provided that the substrate has at least an essentially grid-like structure, in particular the structure of a grid.

[0049] Likewise, within the scope of the present invention, a structure that is at least substantially grid-like can also be understood as a net-like structure, and the structure of a grid also includes the structure of a net.

[0050] Such a structured, non-slip underlay is particularly suitable for use under carpets, as it allows for better ventilation between the carpet and the floor, preventing, for example, the build-up of any moisture between the floor, underlay and / or carpet.

[0051] With regard to the backing material used in the anti-slip underlay, this can be a common backing material that is known to those skilled in the art. In a preferred embodiment of the present invention, the backing material is a woven fabric, knitted fabric, or non-woven fabric, in particular a woven fabric, preferably a knitted fabric.

[0052] If a previously described carrier material is used, it is preferably provided that the carrier material has regularly shaped meshes.

[0053] In the event that a substrate with a full-surface structure is to be obtained, it may be provided that the carrier material preferably has regularly shaped meshes with a mean 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.

[0054] 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 support material preferably has regularly shaped meshes with a mean 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.

[0055] Furthermore, the substrate material is preferably characterized by having a basis weight of 80 to 2500 g / m2 , in particular 120 to 2000 g / m2 , preferably 150 to 1500 g / m2 .

[0056] Furthermore, it may be provided that the carrier material consists of a fiber-reinforced plastic.

[0057] In a further preferred embodiment of the present invention, it can then be provided that the carrier material, in particular the fiber composite plastic, contains inorganic fibers, in particular silicate fibers, preferably glass fibers, preferably glass yarn.

[0058] Furthermore, for this embodiment of the present invention, it is preferred if the carrier material, in particular the fiber-reinforced plastic, contains a plastic matrix of polyurethane, polyamide, polyester or mixtures thereof, preferably polyester.

[0059] In another preferred embodiment of the present invention, the carrier material consists of a plastic fiber and / or inorganic fiber or a mixture thereof.

[0060] In this context, it can be provided that the carrier material, in particular the inorganic fiber, contains glass fibers, preferably glass yarn. Likewise, it has proven advantageous if the carrier material, in particular the plastic fiber, consists of polyurethane, polyamide, polyester, and mixtures thereof, preferably polyester. In this context, it can be provided, for example, that the warp threads of the carrier material are formed from glass fibers, while the weft threads consist of plastic fibers, in particular polyester fibers.

[0061] Anti-slip mats, which have a carrier material made of the aforementioned fibers, are characterized by their special resistance and durability, especially against mechanical stress, and are designed in such a way that weight-optimized anti-slip mats can be obtained.

[0062] With regard to the polymer foam layer, it is provided within the scope of the present invention that the polymer foam layer is formed on the substrate material in the form of a coating encasing the substrate material.

[0063] In the context of the present invention, a coating encasing the substrate material is understood to be a coating that completely surrounds the substrate material, but which nevertheless can have a certain thickness in all spatial directions, in particular coating thicknesses of several millimeters. Thus, an encasing coating is not necessarily a thin layer; the layer thickness can vary, even within the substrate. It is also possible that, in the plane preferably defined by the anti-slip substrate, individual strands or threads of the substrate material are interconnected via the surrounding polymer foam.

[0064] According to a further preferred embodiment, it can be provided that the coating is applied at least substantially over the entire surface, in particular over the entire surface.

[0065] Alternatively, in a preferred embodiment of the present invention, it may be desirable for the coating to surround the carrier material in such a way that spaces are formed in the meshes of the carrier material.

[0066] In this way, a grid-like structure is achieved across the entire surface of the anti-slip underlay. This allows, for example, the unimpeded evaporation of any moisture that may form between the anti-slip underlay and the surface to which it is applied. The anti-slip underlay is therefore vapor-permeable.

[0067] Regarding the polymer foam used in the invention, this can be a polymer foam generally known to those skilled in the art, which has self-crosslinking properties and is acrylate-based. In the present invention, it is further provided that the self-crosslinking, acrylate-based polymer foam is closed-cell.

[0068] The use of closed-cell polymer foams positively impacts aspects such as improved hygiene and reduced absorption of liquids, sweat, and / or similar substances. Furthermore, it achieves better overall contact between the mat and the substrate, as well as with the object placed upon it, ensuring a continuous surface free of interruptions from bubble-like openings.

[0069] Furthermore, within the scope of the present invention, it is provided that the self-crosslinking polymer foam based on acrylate is available from an aqueous acrylate dispersion, in particular a pure acrylate dispersion, preferably a pure acrylate dispersion with ethyl acrylate as the main component.

[0070] Furthermore, it is provided within the scope of the present invention that the aqueous acrylate dispersion contains a solid content in amounts of 35 to 75 wt.%, preferably 45 to 70 wt.%, based on the composition.

[0071] Furthermore, it is provided within the scope of the present invention that the aqueous acrylate dispersion contains at least one additive.

[0072] In a further preferred embodiment of the present invention, it has proven advantageous if the aqueous acrylate dispersion contains the additive in amounts of 10 to 55 wt.%, in particular 15 to 45 wt.%, preferably 20 to 40 wt.%, based on the total composition.

[0073] Furthermore, within the scope of the present invention, it is provided that the additive is at least a filler and at least one propellant.

[0074] The invention provides that the acrylate dispersion contains only blowing agents and fillers as additives. It has been found that by using acrylate dispersions containing only fillers and blowing agents as additives, a high-performance, non-slip surface can be provided that is completely free of plasticizers or stabilizers.

[0075] With regard to the filler, it is preferable if the aqueous acrylate dispersion contains the filler in amounts of 10 to 45 wt.%, in particular 15 to 35 wt.%, preferably 17 to 30 wt.%, based on the total composition.

[0076] Furthermore, it has proven advantageous if the aqueous acrylate dispersion contains the blowing agent in amounts of 1 to 10 wt.%, in particular 2 to 9 wt.%, preferably 3 to 8 wt.%, based on the total composition.

[0077] With regard to the filler, it may 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 silicate, carbonate, sulfate and / or oxide fillers, and mixtures thereof.

[0078] In a particularly preferred embodiment of the present invention, it has proven advantageous if the filler is selected from silicates, in particular clay, talc, mica, kaolin, silica, preferably talc, and / or sulfates, in particular barite, sodium sulfate, preferably barite, and / or hydroxides, in particular aluminum hydroxide, magnesium hydroxide, and mixtures thereof.

[0079] It is particularly preferred if the filler is selected from silicates and / or sulfates, especially talc and barite, and mixtures thereof.

[0080] For the aforementioned fillers, it has been observed that, within the scope of the invention, the anti-slip effect of the anti-slip underlay can be advantageously adjusted by the targeted addition of these fillers. In particular, an optimized addition of at least one of the aforementioned fillers prevents an excessively sticky composition for the anti-slip underlay, which could then interact adversely, especially with the underlay or subfloor. The use of fillers in the area covered by the invention avoids this, thus resulting in an anti-slip underlay that exhibits balanced anti-slip properties and does not alter the surface of the underlying subfloor or substrate.

[0081] As regards 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.

[0082] Expandable polymer particles, particularly Expancel, are spherical hollow particles with a thermoplastic shell. This thermoplastic shell is designed to begin expanding within a defined temperature range. The expansion process is further influenced by gases or liquids trapped within the hollow particle, such as CO2 or lower alkanes. During expansion, a typical expandable polymer hollow particle increases in size by approximately four times its diameter or 60 times its volume. On average, these polymer hollow particles have a particle size of around 10 µm in their unexpanded state.

[0083] A particular advantage of using expandable polymer particles is that they provide a defined and uniform particle size distribution, which allows for the planned and controllable foaming of polymers. Furthermore, the use of expandable polymer particles has a particularly positive effect on the generation of uniform, closed-cell pores in the polymer foam according to the invention.

[0084] With regard to the polymer foam produced from the aqueous acrylate dispersion, it is preferably provided within the scope of the present invention if the filler is present in amounts of 35 to 75 wt.%, in particular 35 to 60 wt.%, preferably 40 to 55 wt.%, based on the polymer foam composition.

[0085] Furthermore, within the scope of the present invention, it is preferred if the anti-slip surface is at least substantially free of vinyl polymers, in particular polyvinyl chloride, and / or rubber and / or stabilizers and / or plasticizers.

[0086] Anti-slip mats of this type are considered extremely beneficial, particularly from an environmental and health perspective, as they are essentially free of, among other things, harmful plasticizers, which have been shown to be damaging to the liver and kidneys and may also have carcinogenic effects. Furthermore, polyvinyl chlorides are known to emit so-called indoor pollutants, i.e., potentially harmful volatile compounds. Accordingly, a particular advantage of the present invention is that the anti-slip mat is preferably completely free of the aforementioned substances.

[0087] A particular advantage also arises from the absence of stabilizers and plasticizers, which not only offers benefits from a health and environmental protection perspective, but also prevents the stabilizers and plasticizers from migrating out of the substrate and thus affecting or damaging the surfaces of adjacent objects or floors.

[0088] Furthermore, within the scope of the present invention, it may be provided that the non-slip surface is flocked, in particular with plastic flakes, preferably with polyamide flakes.

[0089] It is also preferably provided that the anti-slip surface has a coefficient of sliding friction of less than µ 3, in particular less than µ 2.5, preferably less than µ 2. The coefficient of sliding friction is determined within the scope of the present invention in accordance with the standard DIN EN 14882:2005-11.

[0090] Furthermore, a non-slip surface, particularly 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 surface has a total thickness of up to 5 mm, in particular 3.5 mm, preferably 2.5 mm.

[0091] Alternatively, a non-slip mat, particularly if it is intended for use as a sports mat, can preferably be designed within the scope of the present invention such that the mat has a total thickness of up to 15 mm, in particular 11 mm, preferably 7 mm.

[0092] The anti-slip mat according to the present invention, in particular with the aforementioned features, is particularly suitable for use to secure 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, carpeted floor, plastic floor, preferably a wooden floor, stone floor.

[0093] Furthermore, the non-slip mat according to the invention is preferably suitable for use as a sports mat, in particular as a sports mat, fitness mat, gymnastics mat, yoga mat, preferably fitness mat or yoga mat.

[0094] The previously described non-slip mat according to the invention is also suitable for use in securing small and medium-sized everyday objects, in particular hand tools, portable machines, and household goods, especially against horizontal movement in a vehicle.

[0095] Last but not least, the described non-slip underlay can be used as an insulating underlay under a floor covering, especially carpet, particularly for impact sound insulation or thermal insulation.

[0096] A particular advantage of the anti-slip mat according to the invention is that it can generally be obtained using an efficient and uncomplicated manufacturing process.

[0097] Further subject matter of the present invention - according to a secondAn aspect of the present invention is the use of the previously described anti-slip mat to secure an object, in particular a flat, textile object, preferably a carpet or tablecloth, against horizontal movement on a substantially smooth surface, in particular on a wooden floor, stone floor, carpeted floor, plastic floor, preferably a wooden floor or stone floor.

[0098] For further details on this aspect of the invention, reference can be made to the above statements on the anti-slip surface according to the invention, which apply accordingly to the use according to the invention.

[0099] Further subject matter of the present invention - according to a thirdAn aspect of the present invention is the use of the previously described non-slip mat as a sports mat, in particular as a sports mat, fitness mat, gymnastics mat, yoga mat, preferably a fitness mat or yoga mat.

[0100] For further details on this aspect of the invention, reference can be made to the above statements on the other aspects of the invention, which apply accordingly to the use according to the invention.

[0101] Further subject matter of the present invention - according to a fourth An aspect of the present invention is the use of the previously described anti-slip mat for securing small and medium-sized everyday objects, in particular hand tools, portable machines, and household goods, especially against horizontal movement in a vehicle.

[0102] For further details on this aspect of the invention, reference can be made to the above statements on the other aspects of the invention, which apply accordingly to the use according to the invention.

[0103] Further subject matter of the present invention - according to a fifth An aspect of the present invention is the use of the previously described anti-slip underlay as an insulating underlay beneath a floor covering, in particular carpet, especially for impact sound insulation or thermal insulation.

[0104] For further details on this aspect of the invention, reference can be made to the above statements on the other aspects of the invention, which apply accordingly to the use according to the invention.

[0105] Further subject matter of the present invention - according to a sixthAn aspect of the present invention is a method for producing a non-slip surface, in particular a non-slip surface as previously described, with the features of claim 13.

[0106] In this process, it has proven advantageous if the carrier material is coated in step (a) by dipping, spraying, wetting, splashing, or impregnation with the aqueous acrylate dispersion.

[0107] Furthermore, it has proven suitable if the carrier material coated with the aqueous acrylate dispersion is pre-dried in step (b) at medium temperatures, in particular at approx. 40 °C, preferably at approx. 50 °C.

[0108] In this context, it may be particularly possible that the carrier material coated with the aqueous acrylate dispersion is pre-dried in step (b) at temperatures in the range of 30 to 60 °C, in particular 40 to 60 °C, preferably 45 to 55 °C.

[0109] Furthermore, as part of the manufacturing process, it may be provided that the carrier material coated with the aqueous acrylate dispersion is heated in step (b) to foam the acrylate in certain areas, in particular over the entire area of ​​the substrate.

[0110] For this purpose, it has proven particularly advantageous 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.

[0111] Particularly good results are obtained in this context if the carrier material coated with the aqueous acrylate dispersion is heated in step (b), in particular for foaming the acrylate, to temperatures in the range of 60 to 130 °C, in particular 70 to 120 °C, preferably 80 to 110 °C.

[0112] Last but not least, it may be provided that in a subsequent process step (c) a flocculant is applied to the polymer foam formed.

[0113] The described method thus represents a straightforward and time-efficient process from which a non-slip surface with the aforementioned characteristics, features and advantageous properties can be reliably obtained.

[0114] For further details on this aspect of the invention, reference can be made to the above statements on the other aspects of the invention, which apply accordingly to the method according to the invention.

[0115] The following drawings will be used to explain the present invention in more detail, without limiting the scope of the explanation, for better understanding.

[0116] Further advantages, properties, aspects and features of the present invention will become apparent from the following description of embodiments preferred according to the invention as shown in the drawing.

[0117] The depictions of figures show: Fig. 1 shows a non-slip mat with a full-surface structure and a microstructured surface according to the invention. Fig. 2 shows a non-slip mat with a grid-like structure. Fig. 3 shows a non-slip mat with a grid-like structure and irregular coating thickness. Fig. 4 shows a schematic structure of a non-slip mat according to the invention.

[0118] In particular, it shows Fig. 1A preferred embodiment of an anti-slip mat 1 according to the invention, which is formed over its 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 mat 1 a special anti-slip property. The polymer foam 2 surrounds the carrier material 5 so completely, in particular, that no carrier material protrudes even at the side edges of the mat 1. The mat designed in this way is further characterized by a pleasant feel underfoot and efficient impact sound insulation.

[0119] Fig. 2Figure 1 shows an alternative embodiment of the present invention, in which the substrate 1 has a grid-like structure. The cavities or spaces 6 of the meshes of the support material remain free of polymer foam, resulting in a weight-optimized substrate 1. This embodiment also allows for good ventilation between the substrate and the object placed upon it, particularly in the case of flat textiles such as carpets.

[0120] In Fig. 3 A further embodiment of the anti-slip substrate 1 with a grid-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 are combined. Fig. 1 and Fig. 2so efficiently combined that the result is both a weight-optimized base and a base that achieves a certain level of ventilation as well as a pleasant foot feel.

[0121] Finally, it shows Fig. 4The schematic cross-sectional structure of an anti-slip mat 1 according to the invention is shown. According to the embodiment of the mat 1 shown in the figures, the carrier material 5 is arranged centrally within the mat 1 and uniformly surrounded or encased by polymer foam 2. Preferably, closed-cell pores 9 are formed in the polymer foam 2, which can be created during the manufacturing process by heating with a blowing agent. The formation of closed-cell pores 9 ensures a continuous surface within the polymer foam 2, resulting in a continuous contact surface. Based on this, the advantageous anti-slip properties of the acrylate-based polymer foam can be largely achieved. Example implementation:

[0122] 1. Preparation of the aqueous acrylate dispersion: 300 kg of a commercially available aqueous dispersion of acrylates are mixed with 15 kg of Expancel (propellant) and a total of 120 kg of baryta (filler) and processed into a homogeneous dispersion. 2. Preparation of the anti-slip backing

[0123] A PES-glass yarn fabric is coated with an aqueous acrylate dispersion. After pre-drying, the acrylate-coated PES-glass yarn fabric is heated to approximately 100 °C, causing the blowing agent to expand and the acrylate to foam up by creating closed pores. Once the foaming process is complete, the substrate cools down and can then be cut and processed further.

[0124] The anti-slip mat produced in this way is characterized by both very good slip-resistant properties and excellent mechanical strength. Furthermore, the anti-slip mat according to the invention is free of stabilizers and plasticizers, as well as polymers that are questionable from a health or environmental protection perspective, and can therefore be used for a wide variety of applications. Reference symbol list:

[0125] 1 Anti-slip backing 2 Polymer foam 3 Microstructure 4 Nub pattern 5 Carrier material 6 Mesh spaces 7 Coated glass yarns (z-direction) 8 Coated glass yarns (x-direction) 9 Closed-cell pores

Claims

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 on 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 acrylic dispersion as additives comprises only at least one filler and / or at least one blowing agent, 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 on 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 acrylic dispersion as additives comprises only at least one filler and / or at least one blowing agent, 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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