COMPOSITION, KIT, AND METHOD FOR THE PRODUCTION OF LATEX FOAM TECHNICAL FIELD The present invention concerns a composition, kit, and method for the production of latex foam. The invention concerns a composition for the production of a latex foam, wherein the composition contains the following components: a latex, a cross- linker, and optionally, a gelling agent or latent gelling agent. PRIOR ART

Latex foam is a soft form of latex having a light weight. Its most desirable properties are considered to be (i) that of gripping a substrate, or its anti-slip property with respect to two surfaces between which a latex foam is placed, and (ii) its cushioning properties. The most important application of latex foam is as an underlay for carpets in order to minimize slipping thereof. Other known applications of latex foam are gloves for goalkeepers in football or the use of latex foam in masks or facial prostheses. Latex foam is produced from a liquid latex base containing a variety of additives that is foamed and then poured or injected into a mould. Finally, the liquid latex foam is dried and/or cured in an oven.

A variety of treatments and/or additives are used in order to produce different kinds of latex foam having different properties such as grip or durability.

The most important components of latex foam are the latex base, a foaming agent, a gelling agent, and a curing agent or cross-linker. A number of other additives may be added, depending on the desired application of the foam.

A number of compositions and methods for the production of latex foam are already known.

EP 245,021 describes a curable composition for the production of a latex suitable for forming films and foams comprising a carboxylated latex containing a copolymer composed of 0 to 75% by wt. of a vinyl aromatic monomer, 0-85% by wt. of a diene monomer, and 0.5 to 25% parts by weight of an ethylene-based unsaturated carboxylic acid monomer, an epoxy resin emulsion with a catalyst that is soluble or miscible in organic media, and a water-soluble catalytic curing agent. The latex is obtained by emulsion polymerization of one or more monomers in an aqueous medium. The various components of the curable latex composition are handled separately until immediately prior to use because of their tendency to induce curing at ambient temperature. In some cases, two or more components that do not react with one another may be premixed. This curable latex composition provides improved shelf life and better curing at relatively lower temperatures, and imparts to plastic films or foam improved moisture resistance and other physical properties. This composition is suitable for use as a latex foam textile carrier, a textile and laminate adhesive, or a coating for artificial turf.

WO 02/26873 describes a composition that is suitable for preparing latex foam. The composition contains a latex and a polynitrile oxide such as 2,4,6-triethyl-l,3- dintrile oxide or a latex and an epoxy silane, or a latex and a mixture of two of said curing agents. The composition may also contain extra components such as fillers, surfactants, foam stabilizers, foam boosters, components for reducing viscosity and improving resilience, and antioxidants. The composition is particularly well-suited for use in the production of floors, wall coverings, shoe soles, and non-woven materials. Nevertheless, new, improved compositions for the production of latex foam are needed. In particular, latex compositions that can be stored for periods of several days to several months offer new technological possibilities as well as economically beneficial prospects. One of the accompanying problems, however, is that compositions frequently undergo premature or undesired curing. Another problem is that the compositions are often insufficiently stable for industrial use in certain applications. The insufficient gelling capacity of certain compositions constitutes a limitation of prior art.

Another problem with known gelling agents is that they cause coagulation as soon as they are mixed into the latex composition. Prior art does not provide adequate gelling agents or methods that allow sufficiently homogeneous dispersion or spreading of the gelling agent in the composition before the onset of the gelling action of the gelling agent. In the field of latex foam, and particularly in the field of carboxylated styrene- butadiene rubber latex foam (XSBR) and compositions and methods for the production of such latex foam, there is therefore a need for gelling agents that allow the latex to be homogenously gelled before it is dried, and in a subsequent step, cured. There is also a need for new methods of using such gelling agents.

SUMMARY

The present invention provides a solution to at least one of the aforementioned problems by providing a composition, kit, and method for the production of latex foam as described in claims 1 to 19.

In a first embodiment, the present invention provides a composition for the production of a latex foam, comprising :

- a latex;

- a cross-linker; and

- a latent gelling agent,

wherein said latent gelling agent is convertible to a gelling agent.

The use of a gelling agent that can be dispersed in the latex composition in a sufficiently homogeneous manner leads to a better and more homogeneous gelling process of the latex composition and therefore to more homogeneous quality of the latex foam thus obtained. This leads to a better quality of the final product.

In a second embodiment, the present invention provides a kit for the production of a latex foam, comprising a composition (A) according to the first embodiment of the invention; and a composition (B) comprising at least an acid or acid precursor for converting said latent gelling agent to a gelling agent.

In a third embodiment, the present invention provides a kit for the production of a latex foam, comprising :

(A) a first component A comprising a latex and a cross-linker; and

(B) a second component B comprising a latent gelling agent.

In a fourth embodiment, the present invention provides a method for the production of a latex foam using a kit according to the third embodiment of the invention, comprising the following steps:

- mixing of said component A and component B, thus obtaining an aqueous latex foam; and

- drying and subsequent curing of said aqueous latex foam, thus obtaining a latex foam. In a fifth embodiment, the present invention provides a method for the production of a latex foam, comprising the steps of:

- mixing of a latex, a cross-linker, a latent gelling agent, and optionally, a foam booster and a foam stabilizer, thus obtaining an aqueous latex foam.

- optionally, spreading of said aqueous latex foam onto a substrate; and

- drying of said aqueous latex foam, thus obtaining a latex foam,

wherein said latent gelling agent is converted in solution to a gelling agent. In a sixth embodiment, the present invention provides a method for the production of a latex foam, comprising the steps of:

- mixing of a composition (A) according to the first embodiment of the invention; and a composition (B) comprising at least an acid or acid precursor for converting said latent gelling agent to a gelling agent, thus obtaining an aqueous latex foam;

- optionally, spreading of said aqueous latex foam onto a substrate; and

- drying of said aqueous latex foam, thus obtaining a latex foam,

wherein said latent gelling agent is converted to a gelling agent during mixing. In a seventh embodiment, the present invention provides a latex foam that can be obtained by means of a method according to the fourth embodiment of the invention.

In an eighth embodiment, the present invention provides a latex foam that can be obtained by means of a method according to the fifth embodiment of the invention.

In a ninth embodiment, the present invention provides a product comprising a latex foam according to the seventh embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres, or shoe soles, and in medical or sanitary applications such as surgical gloves. In a tenth embodiment, the present invention provides a product comprising a latex foam according to the eighth embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres, or shoe soles, and in medical or sanitary applications such as surgical gloves. In an eleventh embodiment, the present invention provides an application of a composition according to the first embodiment of the invention for the production of a latex foam.

DETAILED DESCRIPTION OF THE INVENTION

The invention concerns a composition, kit, and method for the production of latex foam.

Unless otherwise specified, all of the terms used in the description of the invention, including technical and scientific terms, have the meaning generally understood by a person skilled in the art in the technical field of the invention. In order to allow better assessment of the description of the invention, the following terms are expressly defined below. "A" and "the" refer in this document both to the singular and plural unless the context clearly indicates otherwise. For example, "a segment" means one or more than one segment.

In cases where the words "approximately" or "around" are used in this document to refer to a measurable quantity, a parameter, a duration or moment in time, and so forth, this indicates variations of ± 20% or less, preferably ± 10% or less, more preferably ± 5% or less, even more preferably ± 1% or less, and most preferably ± 0.1% or less with respect to the cited value, provided that such variations are applicable to the described invention. However, it is to be understood in this case that the value or quantity with respect to which the term "approximately" or "around" is used is itself specific.

The terms "include," "comprising," "consist of," "composed of," "provision of," "contain," "containing," "have," "having," "have in," and "having in" are synonyms inclusive of open terms that indicate the presence of what follows and do not exclude or rule out the presence of other components, characteristics, elements, members, or steps known from or described in prior art. Any citation of numerical intervals by means of the endpoints thereof includes all whole numbers, fractions, and/or real numbers between the endpoints, including said endpoints. In a first embodiment, the present invention provides a composition for the production of a latex foam, comprising :

- a latex;

- a cross-linker; and

- a latent gelling agent,

wherein said latent gelling agent is convertible to a gelling agent.

The term 'latex' refers to a dispersion of one or more polymers in water. The aforementioned polymers or copolymers are generally prepared by means of emulsion polymerization technology. Stabilizing of the dispersion of polymers and/or copolymers is ordinarily carried out using surfactants. The aforementioned surfactants include a polar or hydrophilic group and an apolar or hydrophobic group. As understood within the teaching of the present invention, the term "polymer" also refers to a copolymer or a block copolymer. Latex as understood within the meaning of the present invention preferably refers to a latex wherein said polymer is carboxylated. This means that the chains of the polymer contain monomer groups with carboxylic acid substituents. This type of latex is referred to by the term "carboxylated latex." A wide variety of latexes may be used in implementing this invention. Representative monomers for use in preparing said latex that are suitable for application in the invention and methods for preparing the individual separate latex particles are known in the art and are described in documents such as US Patent 3,404,116 and US Patent 3,399,080, which are incorporated herein by reference. Examples of suitable monomers for imparting carboxylate properties include acrylic acid, methacrylic acid, itaconic acid, and fumaric acid. Examples of monomers that are suitable for preparing the latex for application of this invention are olefins, such as - but not limited to - ethene, propene, vinyl acetate, alkyl acrylates, hydroxyalkyl acrylates, methyl alkyl acrylates, hydroxyalkyl methacrylates, acrylamide, n-methyl thyloylacrylamides, and monomers such as vinyl chloride and vinylidene chloride. Preferably, said latex comprises a modified styrene/butadiene unit such as, but not limited to, styrene/butadiene/acrylic acid, styrene/butadiene/acrylic acid/itaconic acid, styrene/butadiene/vinylidene chloride, styrene/butadiene/beta-hydroxyethyl acrylate, styrene/butadiene/beta-hydroxyethyl acrylate/acrylic acid, styrene/n-butyl acrylate/acrylic acid, methyl methacrylate/n-butyl acrylate/acrylic acid, vinyl acetate/acrylic acid, vinyl acetate/n-butyl acrylate/acrylic acid and/or styrene/n- butyl acrylate and butadiene/acrylic acid. Mixtures of carboxylic acids can be used in the aforementioned latex. In implementation of this invention, a carboxylated latex obtained from a copolymer of a vinyl aromatic monomer and an unsaturated carboxylic acid monomer may be used. The copolymer may also include a diene monomer.

Said vinyl aromatic monomer may be selected from the group comprising styrene, alpha-methyl styrene, ethyl styrene, dimethyl styrene, t-butyl styrene, vinyl naphthalene, methoxy styrene, cyanostyrene, acetyl styrene, monochlorostyrene, dichlorostyrene and other halostyrenes or mixtures thereof. The vinyl aromatic monomer may be contained in any effective amount. The vinyl aromatic monomer may be contained in an amount of approximately 0 to 75% by wt. based on the total weight of the polymer. Preferably, said vinyl aromatic monomer is contained in an amount of approximately 25 to 60% by wt. based on the total weight of the polymer.

Said unsaturated carboxylic acid monomer may contain a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid such as, but not limited to, acrylic acid, methacrylic acid, fumaric acid, maleic acid, itaconic acid, and derivatives of the aforementioned acids and mixtures thereof. The aforementioned unsaturated carboxylic acid monomer may be contained in an amount of 0.5 to 25.0% by wt. based on the total weight of the polymer. More preferably, said unsaturated carboxylic acid monomer is contained in an amount of approximately 1 to 5% by wt., and most preferably in an amount of 2 to 4% by wt. based on the total weight of the polymer.

If included, said diene monomer may be selected for example from the group comprising, but not limited to butadiene, isoprene, divinyl benzene, derivatives thereof, and mixtures thereof. Most preferably, said diene monomer is 1,3- butadiene. The aforementioned diene monomer may be present in an amount of 0 to 85% by wt., and more preferably 40 to 75% by wt. based on the total weight of the polymer.

A latex may also contain an extra ethene-unsaturated monomer component or components. Specific examples of such ethylene-unsaturated compounds include methyl methacrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, lauryl methacrylate, phenyl acrylate, acrylonitrile, methacrylonitrile, ethyl- chloroacrylate, diethyl maleate, polyglycol maleate, vinyl chloride, vinyl bromide, vinylidene chloride, vinyl bromide, vinylmethyl ketone, methyl isopropenyl ketone, and vinyl ethyl ester. In addition, derivatives of the aforementioned compounds and/or mixtures thereof may be included.

The aforementioned monomers are preferably polymerized in an aqueous emulsion with surfactants and regulators under specific conditions of time, temperature, pressure, and agitation in accordance with the known principles of emulsion polymerization.

A latex as referred to in the present invention may also be a multimodal latex, characterized by comprising two or more latexes differing in mean particle size and/or particle size distribution, solid material content, and/or rheological parameters.

The term 'cross-linker' is to be understood as a synonym for terms such as 'curing means,' 'curing agent,' 'hardening means,' 'hardening agent,' 'hardener', 'cross- linking additive,' 'cross-linking means,' or 'cross-linking agent' and includes substances or mixtures of substances that are added to a polymer composition in order to promote or control the curing reaction. The term 'cross-linker' preferably refers to a reactive hardening agent or curing agent that is provided with at least two functional groups that can react with a carboxylic acid group or form an ionic, coordinate, or covalent chemical bond and are therefore suitable for curing a polymer.

Examples of functional groups that can react with said carboxylic acid groups include, but are not limited to, aliphatic and aromatic alcohols, aliphatic and aromatic thiols, aliphatic and aromatic amines, aliphatic and aromatic anhydrides, aliphatic and aromatic epoxides, aliphatic and aromatic peroxides, and aliphatic and aromatic nitrile oxides. In addition, a cross-linker may contain additives in order to promote the stability of said cross-linker and/or catalysts in order to promote the curing reaction.

Preferably, said catalyst is soluble or miscible in an organic medium. Suitable catalysts include phosphonium salts such as ethyltriphenyl phosphonium salts with an inorganic or organic anion such as, but not limited to, fluoride, chloride, bromide, iodide, acetate, sulphate, phosphate and quaternary ammonium salts such as, but not limited to, alkylbenzyl dimethyl ammonium chloride, benzyl chloride, methyltrioctyl ammonium chloride, tetraethyl ammonium bromide, IM- dodecyl pyridinium chloride and/or iodide, and tetraethyl ammonium iodide. More preferably, said catalyst is selected from the group including ethyltriphenyl phosphonium acetate, ethyltriphenyl phosphonium bromide, and methyltrioctyl ammonium chloride, most preferably ethyltriphenyl phosphonium bromide. The aforementioned catalyst may be present in an amount of approximately 0.1 to approximately 10.0% by wt., preferably 0.3 to 2.0% by wt. based on the total weight of the cross-linker composition.

The term 'latent gelling agent' refers to a precursor for a gelling agent that can be converted to a gelling agent after chemical and/or thermal activation .

The advantage of using a latent gelling agent is that the composition can be stored under normal storage conditions such as room temperature and normal air pressure without causing premature gelling due to the latex composition . The gelling takes place only after said latent gelling agent is activated. Moreover, a latent gelling agent makes it possible to achieve favourable mixing of the latex composition and therefore ensure a homogenous composition . After activation, said latent gelling agent is converted to a gelling agent, wherein the gelling of the latex leads to high- quality and uniform properties of the latex foam thus obtained.

Depending on the storage conditions, said composition for the production of latex foam may be stored without visible gelling for a period of at least 5 days. Preferably, said composition may be stored without visible gelling for a period of between 50 days and 5000 days, more preferably between 100 days and 1000 days, most preferably 150, 200, 300, 400, 500, 600, 700, 800 or 900 days, or any value in between.

The term 'gelling agent' is a synonym for the term 'thickening agent' and refers to a substance that is added to a liquid composition in order to reduce its flowing properties and thus convert the composition into a gel.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, comprising 70.0 to 98.9% by wt. of latex with optional additives, 1.0 to 25.0% by wt. of a cross-linker with optional additives, and 0.1 to 5.0% by wt. of a latent gelling agent, relative to the total weight of said composition. In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, comprising 80.0 to 94.9% by wt. of latex with optional additives, 5.0 to 15.0% by wt. of a cross-linker, and 0.1 to 5.0% by wt. of a latent gelling agent, relative to the total weight of said composition. In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is at least 50% converted to a gelling agent after 1 hour at a temperature of 100°C.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is at least 50% converted to a gelling agent after 1 hour at a temperature of 50°C.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is at least 50% converted to a gelling agent after 1 hour at a temperature of 25°C.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is converted to a gelling agent after reacting with an acid.

As described in the above paragraph, said latent gelling agent should be understood as a base that is converted to a gelling agent after reacting with an acid . In this case, the aforementioned latent gelling agent may be either a neutral base B, such as in reaction ( 1), or a negatively charged base B ^" , such as in reaction (2) :

B + H ⁺ - BH +

reaction (1) B ^" + H ⁺ ^ BH reaction (2) BH ⁺ and BH represent a positively charged gelling agent and a neutral gelling agent respectively. It should be noted in this connection that said gelling agent may be a mono-, di-, tri-, tetra-, penta-, hexa-, hepta-, octa-, nona-, or decavalent acid, or a polyvalent acid or polyacid.

Some examples of bases that give rise to a gelling agent after reaction with a proton H ⁺ include, but are not limited to, amine oxide and suiphoxide and/or phosphoxide compounds. Preferably, said base is an amine oxide, suiphoxide, and/or phosphoxide compound with one or more alkyl groups.

The aforementioned proton H ⁺ from reaction (1) and reaction (2) may be derived from a compound having the general formula H ⁺ X ^" , wherein X ^" may be an organic and/or an inorganic molecule. Preferably, said proton H ⁺ is derived from an inorganic acid.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention wherein said acid is hydrogen halide. Preferably, said acid is hydrogen fluoride, hydrogen chloride, hydrogen bromide, or hydrogen iodide. Most preferably, said acid is hydrogen fluoride or hydrogen chloride.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said acid is formed from an acid precursor.

The term 'acid precursor' refers to a molecule that under the effect of temperature T, such as shown in reaction (3), or by a chemical reaction such as that with water shown in reaction (4), releases an acid HX.

AHX (ΔΤ) -> A + HX reaction (3)

AX _n + n H ₂ 0 - A(OH) _n + n HX reaction (4)

A first example of suitable acid precursors are ammonium salts such as, but not limited to, NH ₄ ⁺ c , which at high temperature split into NH ₃ and HCI. This reaction is well known in the art. Analogous ammonium salts release an acid in a similar manner. A second example of suitable acid precursors are main group metal and transition metal salts, preferably halides that, on reaction with water in an aqueous medium, hydrolyze to a metal hydroxide or a metal oxide, releasing an acid in the process, preferably a hydrogen halide.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said acid precursor is an alkali- or alkaline earth metal silicon fluoride, preferably sodium silicon fluoride. As a non-limiting example, the above paragraph is further clarified by means of hydrolysis of sodium silicon fluoride. The aforementioned silicon fluoride undergoes hydrolysis in an aqueous medium accompanied by the release of hydrogen fluoride.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is an amine oxide, preferably a trialkyl amine oxide, and more preferably an alkyl dimethyl amine oxide.

Amine oxides are known surface-active substances having cationic characteristics at low and neutral pH and non-ionic characteristics at alkaline pH. Amine oxides preferred for use in the present invention are in accordance with the following formula :

R ₂ - N - O

wherein Rl, R2 and R3, independently of one another, may be an alkyl group or a functionalized or substituted alkyl group, preferably selected from the group comprising a CI, C2, C3, C4, C5, C6, C7, C8, C9, CIO, Cl l, C12, C13, C14, C15, C16, C17, C18, C19, or C20 group. In a preferred embodiment, a composition for the production of latex foam is provided comprising a carboxylated latex and a cross-linker or an alkyl dimethyl amine oxide as a latent gelling agent. The composition is thoroughly stirred in order to obtain a homogeneous mixture. This composition causes little or no gelling of the latex composition. By adding Na ₂ SiF ₆ (NSF) to the composition, hydrogen fluoride is released after hydrolysis of Na ₂ SiF ₆ in the water present in the latex composition. The aforementioned hydrogen fluoride then reacts with said alkyl dimethyl amine oxide to form a gelling agent. The hydrolysis reaction causes protonation of the amine oxide to occur relatively slowly compared to use of other acids such as HCI, resulting in a smaller pH shock and better distribution of the acid in the latex. This relatively slow reaction causes coagulation to occur. In this process, the pH drops from 7-8 to approximately 5. In a subsequent heating step, if applicable, the pH may decrease to approximately 4 due to the release of volatile bases (such as NH ₃ ). The advantage of this is that the gelling agent is generated homogeneously, simultaneously, and to an identical degree throughout the liquid, aqueous latex composition, which results in homogeneous gelling properties. This is reflected in the homogeneous physical properties of the latex foam obtained as a final product.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is a salt comprising a metal and an alkyl carboxylate. The term 'alkyl carboxylate' refers to a chemical compound comprising an alkyl group and a carboxylate group. The term 'alkyl' refers to both linear and branched alkyl groups, and by extension to unsaturated hydrocarbons such as alkenyl- and alkynyl groups as well as alkyl groups having functional groups such as, but not limited to, halogens, aldehydes, ketones, ethers, esters, and amides.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said metal is selected from groups IA, IIA or IIIA, preferably from the group comprising magnesium, calcium and aluminium or any combination of one or more of the aforementioned metals.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said alkyl carboxylate is selected from the group comprising lactate, citrate, and acetyl acetonate, or any combination of one or more of the aforementioned carboxylates.

In addition to the use of a latent gelling agent formed by means of an acid, the invention also provides improved gelling by using a metal cross-linker such as Al ³⁺ , Mg ²⁺ , or Ca ²⁺ . Preferably, a lactate salt such as calcium lactate is used rather than a chloride salt such as calcium chloride, because the former gradually releases the Ca ²⁺ ions in solution, thus preventing coagulation of the latex. The Ca ²⁺ ions bring about gelling of the latex and simultaneously give rise to cross-linking of the carboxylated polymer in the latex by means of ionic interaction.

As an alternative to lactates, one may also use other organic anions such as, but not limited to, citrate, acetyl acetonate and propionate.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latex contains 35 to 60% by wt. of water.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said latex contains 45 to 50% by wt. of water.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, wherein said cross-linker is selected from the group comprising : metal oxides, alkyl carboxylate metals, epoxide compounds such as epoxide resins, organic epoxy compounds of epoxy silane compounds, or a combination of one or more of said cross-linkers.

The choice of the cross-linker may also be determined based on the reaction rate. Specifically, substituents may affect the hydrolysis rate of e.g. silane groups and/or the reactivity of the epoxide compound.

Suitable epoxy silanes that may be used in implementing this invention can generally be described as epoxy-terminated silanes. These compounds are generally known in the literature and are commercially available. These compounds have reactive, preferably terminal, epoxy groups and terminal, reactive silane groups. The epoxy- and silane groups may be compounds derived from non- hydrolyzable aliphatic, aromatic or aliphatic and aromatic carbon-based compounds that may possibly include nitrogen and/or oxygen atoms, such as ether bonds. These carbon-based compounds may generally be substituted as known in the art so that they will not exert any major effect on the reactivity of the epoxy- terminated silanes. Suitable epoxy resins are all compounds containing more than one 1,2-epoxy group. Generally speaking, said epoxy resin is a saturated or unsaturated aliphatic, cyclo-aliphatic, aromatic or heterocyclic compound and may be substituted or unsubstituted. Preferably, said epoxy resins are selected from the group comprising polyglycidyl ethers of bisphenol compounds, polyglycidyl ethers of novolac resins, and polyglycidyl ethers of polyglycol, or mixtures of two or more epoxy resins.

The composition for the production of latex foam may also contain surfactants or tensioactive or surface-active substances. A surfactant normally contains a hydrophobic and hydrophilic portion. In this case, the hydrophobic portion has a chain length of 4 to 20 carbon atoms, preferably 6 to 19 carbon atoms, and even more preferably 8 to 18 carbon atoms. Preferably, the surfactant used is selected from the group of anionic, cationic or non-ionic surface-active substances. Anionic surface-active substances include saponified fatty acids and derivatives of fatty acids with carboxyl groups such as sodium dodecyl sulphate (SDS), sodium dodecyl benzene sulphonate, sulphates and sulphonates, and abietinic acid. Examples of anionic surfactants also include carboxylates, sulphonates, sulphofatty acid methyl esters, sulphates, and phosphates. The anionic surfactants are preferably added as salts. Examples of salts include alkali metal salts such as sodium, potassium, lithium, ammonium, hydroxyethyl ammonium, di(hydroxyethyl) ammonium, and tri(hydroxyethyl) ammonium salts or alkanolamine salts.

Cationic surface-active substances include dialkyl benzene alkyl ammonium chloride, alkylbenzyl methyl ammonium chloride, alkyl benzyl dimethyl ammonium bromide, benzalkonium chloride, cetyl pyridinium bromide, C ₁₂ , C ₁₅ , or C ₁₇ trimethyl ammonium bromides, halide salts, or quaternized polyoxyethyl alkylamines, dodecyl benzyl triethyl ammonium chloride, and benzalkonium chloride. Examples of cationic surfactants also include quaternary ammonium compounds. A quaternary ammonium compound is a compound that contains at least one R ₄ N ⁺ - group in its molecule.

A betaine surfactant is a compound that under application conditions contains at least one positive charge and at least one negative charge. An alkyl betaine is a betaine surfactant that contains at least one alkyl unit per molecule.

Non-ionic surfactants include polyvinyl alcohol, polyacrylic acid, methalose, methyl cellulose, ethyl cellulose, propyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, natural rubbers, polyoxyethylene cetyl ether, polyoxyethylene lauryl ether, polyoxyethylene octyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene oleyl ether, polyoxyethylene sorbitan monolaurate, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether, and dialkylphenoxy poly(ethyleneoxy) ethanol.

Non-ionic surfactants have neutral, polar, and hydrophilic heads that make non- ionic surfactants water-soluble. Such surfactants are adsorbed onto surfaces and aggregate into micelle above a critical micelle concentration. Depending on the type of head, various types of surfactants may be distinguished, such as (oligo)oxyalkylene groups, and in particular (oligo)oxyethylene groups, (polyethylene)glycol groups, and carbohydrate groups such as alkyl polyglycosides and fatty acid-N-methylglucamides. Alcohol phenol alkoxylates are surfactants that can be produced by the addition of alkylene oxide, and preferably ethylene oxide, to alkyl phenols. Non-limiting examples include Norfox® OP-102, Surfonic® OP-120, and T-Det® 0-12.

Fatty acid ethoxylates are fatty acid ester surface-active substances that are treated with various amounts of ethylene oxide. Triglycerides are esters of glycerols (glycerides) in which all three of the hydroxyl groups are esterified with fatty acids. These may be modified with alkylene oxides. Fatty acid alcohol amides include at least one amide group with an alkyl group and one or two alkoxyl groups. Alkyl polyglycosides are mixtures of alkylmonoglycosides (alkyl-a-D- and -β-D- glucopyranoside with a small amount of -glucofuranoside), alkyl diglycosides (-isomaltosides, -maltosides, etc.) and alkyl oligoglycosides (-maltotriosides, -tetraosides, etc.). Alkyl polyglycosides may be synthesized in a non-limiting manner by means of an acid-catalyzed reaction (Fisher reaction) of glucose (or starch) or n-butyl glycosides with fatty acid alcohols. In addition, alkyl polyglycosides may also be used as non-ionic surfactants. A non-limiting example is Lutensol® GD70. In addition, non-ionic N-alkylated, and preferably N-methylated fatty acid amides may be used as surfactants.

Alcohol alkoxylates contain a hydrophobic portion with a chain length of 4 to 20 C atoms, preferably 6 to 19 C atoms and more preferably 8 to 18 C atoms, wherein the alcohol may be in linear or branched form, and a hydrophilic portion that may contain alkoxylate units, such as ethylene oxide, propylene oxide and/or butylene oxide, with 2 to 30 repeating units. Non-limiting examples include Lutensol® XP, Lutensol® XL, Lutensol® ON, Lutensol® AT, Lutensol® A, Lutensol® AO, and Lutensol® TO.

The aforementioned surfactant or surface-active substance may be present in amounts of approximately 0.5 to 5% by wt., and preferably 1 to 3% by wt., based on the dry weight of the copolymer. It has been found that inclusion of a surfactant can improve the shelf life of the curable composition according to the present invention.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, comprising a foam booster and/or a foam stabilizer.

The foams of the composition for the production of a latex foam may be produced by any suitable or commonly-used method of prior art. A foam can be produced by methods known in the art, for example by releasing a non-coagulating gas such as nitrogen, or by causing decomposition of a gas-releasing chemical compound after a chemical reaction with an ingredient of the mixture, resulting in the release of a non-coagulable gas as a reaction product. The mixture of the reactive latex and the co-reactive material is also foamed by means of whipping, if applicable by means of a device that is commercially available and suitable for this purpose according to the art. Foaming auxiliaries such as sodium lauryl sulphate or foam stabilizers such as potassium oleate, or sulphosuccinimate soaps such as - but not limited to - disodium tallow sulphosuccinimate soap, may be added as desired. Preferably, such additives should be fairly non-reactive with the reactive group in the latex polymer of the co-reactive material, the composition of the mixture in the preferred composition may therefore be varied as necessary. As an alternative to disodium tallow sulphosuccinimate, one may also use betaine soap, sodium silicate, or ethyl vinyl acetate (EVA) latex. However, other soaps, emulsifiers, moisturizing agents and/or surface-active substances may also be used, even though they may be reactive to a certain degree.

In a preferred embodiment, the present invention provides a composition according to the first embodiment of the invention, comprising one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more of such additives. A composition according to the present invention for the production of a latex foam may also include components such as, but not limited to, fillers, thickeners, antioxidants, dispersing agents, colorants, acidity regulators and flame retarding agents.

Adjustment of the pH or composition comprising a latex, and optionally, co-reactive material, may be carried out if desired by adding commonly-used acidifying or alkalizing agents such as, but not limited to, acetic acid, citric acid, dilute inorganic acids, ammonium hydroxide, and dilute aqueous solutions of alkali metal hydroxides.

As a supplement to an epoxy compound as a cross-linker for the curing of the latex composition, accelerators such as, but not limited to, zinc (II) oxide (ZnO) may also be preferred. In cases where ammonium salts are present in the aqueous latex composition, on dissolving in water, ZnO will form Zn ²⁺ ions, which in turn may form complexes with ammonia derived from the reaction of ammonium salts with ZnO. The zinc-amine complexes formed in this manner then act as a gelling agent for the polymer particles. Other additives and fillers, if applicable, may be selected from metals in powder form or filament form and non-metals such as carbon, silicates, titanium dioxide, zinc oxide, chalk or calcium carbonate, zinc sulphide, potassium titanate and titanate fibres, carbon fibres, clay, kaolins, and glass fibres. The fillers may be present in amounts of approximately 0 to 80% by wt. or more with respect to the total weight of the composition.

A water softener, antioxidants, bactericides, and/or ammonia may also be added.

A flame retardant may also be added to the composition. The term "flame retardant" refers to any substances that can cause one or more of the following effects:

- removal of H- and OH-radicals;

- a delay in the occurrence of pyrolysis;

- formation of a protective layer on the material;

- release of nitrogen or other non-flammable gases that shield oxygen from the air from the burning or flammable material;

- release of water, causing the burning or flammable material to be cooled and thus discharging heat (energy). A suitable flame retarding agent may preferably be selected from the group comprising nitrogen- and phosphorus-based flame retardants.

In a second embodiment, the present invention provides a kit for the production of a latex foam, comprising a composition (A) according to the first embodiment of the invention; and a composition (B) comprising at least an acid or acid precursor for converting said latent gelling agent to a gelling agent.

As described in the above paragraph, said latent gelling agent should be understood as a base that is converted to a gelling agent after reacting with an acid. In this case, the aforementioned latent gelling agent may be either a neutral base B, such as in reaction (1), or a negatively charged base B ^" , such as in reaction (2) :

B + H ⁺ - BH ⁴ + reaction (1) B ^" + H ⁺ -> BH reaction (2) BH ⁺ and BH represent a positively charged gelling agent and a neutral gelling agent respectively. It should be noted in this connection that said gelling agent may be a mono-, di-, tri-, tetra-, penta-, hexa-, hepta-, octa-, nona-, or decavalent acid, or a polyvalent acid or polyacid. Some examples of bases that give rise to a gelling agent after reacting with a proton H ⁺ include, but are not limited to, amine oxide, sulphoxide and/or phosphoxide compounds. Preferably, said base is an amine oxide, sulphoxide, and/or phosphoxide compound with one or more alkyl groups. The aforementioned proton H ⁺ from reaction (1) and reaction (2) may be derived from a compound having the general formula H ⁺ X ^" , wherein X ^" may be an organic and/or an inorganic molecule or anion. Preferably, said proton H ⁺ is derived from an inorganic acid. In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein said salt is a hydrogen halide, preferably hydrogen fluoride, hydrogen chloride, hydrogen bromide and/or hydrogen iodide. Most preferably, said salt is hydrogen fluoride or hydrogen chloride. In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein said acid is formed from an acid precursor. The term 'acid precursor' refers to a molecule that under the effect of temperature T, such as shown in reaction (3), or by a chemical reaction such as that with water shown in reaction (4), releases an acid HX.

AHX (ΔΤ) - A + HX reaction (3)

AX _n + n H ₂ 0 ^ A(OH) _n + n HX reaction (4) A first example of suitable acid precursors are ammonium salts such as, but not limited to, l\IH ⁺ CI ^" , which at high temperature split into NH ₃ and HCI. This reaction is well known in the art. Analogous ammonium salts release an acid in a similar manner. A second example of suitable acid precursors are main group metal and transition metal salts, preferably halides that, on reaction with water in an aqueous medium, hydrolyze to a metal hydroxide or a metal oxide, releasing an acid in the process, preferably a hydrogen halide. In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein said acid precursor is an alkali- or alkaline earth metal silicon fluoride, preferably sodium silicon fluoride.

As a non-limiting example, the above paragraph is further clarified by means of the hydrolysis reaction of sodium silicon fluoride. The aforementioned silicon fluoride undergoes hydrolysis in an aqueous medium accompanied by the release of hydrogen fluoride.

In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein said latent gelling agent is an amine oxide, preferably a trialkyl amine oxide, and more preferably an alkyl dimethyl amine oxide.

Amine oxides are known surface-active substances having cationic characteristics at low and neutral pH and non-ionic characteristics at alkaline pH. Amine oxides preferred for use in the present invention are in accordance with the following formula :

R ₂ - N - O

wherein Rl, R2 and R3, independently of one another, may be an alkyl group or a functionalized or substituted alkyl group, preferably selected from the group comprising a CI, C2, C3, C4, C5, C6, C7, C8, C9, CIO, Cll, C12, C13, C14, C15, C16, C17, C18, C19, or C20 group.

In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) contains an alkyl dimethyl amine oxide as a latent gelling agent. The composition is thoroughly stirred in order to obtain a homogeneous mixture. This composition causes little or no gelling of the latex composition. By adding Na ₂ SiF ₆ (NSF) to the composition, hydrogen fluoride is released after hydrolysis of Na ₂ SiF ₆ in the water present in the latex composition. The aforementioned hydrogen fluoride then reacts with said alkyl dimethyl amine oxide to form a gelling agent.

The hydrolysis reaction causes protonation of the amine oxide to occur relatively slowly compared to use of other acids such as HCI, resulting in a smaller pH shock and better distribution of the acid in the latex. This relatively slow reaction causes coagulation to occur. In this process, the pH drops from 7-8 to approximately 5. In a subsequent heating step, if applicable, the pH may decrease to approximately 4 due to the release of volatile bases (such as NH ₃ ). The advantage of this is that the gelling agent is generated homogeneously, simultaneously, and to an identical degree throughout the liquid, aqueous latex composition, which results in homogeneous gelling properties. This is reflected in the homogeneous physical properties of the latex foam obtained as a final product.

The aforementioned surfactant or surface-active substance may be present in amounts of approximately 0.5 to 5% by wt., preferably 1 to 3% by wt., based on the dry weight of the copolymer. It has been found that the inclusion of a surfactant can improve the shelf life of the curable composition according to the present invention. In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) and/or composition (B) also contain a foam booster and/or a foam stabilizer. In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) and/or composition (B) also contain one or more additives selected from the group of fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.

In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) and/or composition (B) also include components such as, but not limited to, fillers, thickeners, antioxidants, dispersing agents, colorants, acidity regulators and flame retarding agents.

In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) and/or composition (B) also contain acidifying or acidifying or alkalizing agents such as, but not limited to, acetic acid, citric acid, dilute inorganic acids, ammonium hydroxide, and dilute aqueous solutions of alkali metal hydroxides.

In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) and/or composition (B) also contain accelerators such as, but not limited to, zinc (II) oxide (ZnO). In cases where ammonium salts are present in the aqueous latex composition, on dissolving in water, ZnO will form Zn ²⁺ ions, which in turn may form complexes with ammonia derived from the reaction of ammonium salts with ZnO. The zinc- amine complexes formed in this manner then act as a gelling agent for the polymer particles.

In a preferred embodiment, the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) and/or composition (B) also include other additives and fillers selected from metals in powder form or filament form and non-metals such as carbon, silicates, titanium dioxide, zinc oxide, chalk or calcium carbonate, zinc sulphide, potassium titanate and titanate fibres, carbon fibres, clay, kaolins, and glass fibres. The fillers may be present in amounts of approximately 0 to 80% by wt. or more with respect to the total weight of the composition. A water softener, antioxidants, bactericides, and/or ammonia may also be added. A flame retardant may also be added to the composition. A suitable flame retarding agent may preferably be selected from the group comprising nitrogen- and phosphorus-based flame retardants.

In a third embodiment, the present invention provides a kit for the production of a latex foam, comprising :

(A) a first component A comprising a latex and a cross-linker; and

(B) a second component B comprising a latent gelling agent.

This is advantageous in that the kit provides an application-friendly packaging form for the user of latex foam, thus ensuring a constant composition for the production of latex foam. This in turn leads to an improved and more uniform composition of the latex foam obtained as a final product and thus to better product properties.

In a preferred embodiment, the present invention provides a kit according to the third embodiment of the invention, wherein both compositions are further provided with one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.

This makes it possible to adjust the product properties as required for the intended application of the latex foam. In a fourth embodiment, the present invention provides a method for the production of a latex foam using a kit according to the third embodiment of the invention, comprising the steps of:

- mixing of said component A and component B, thus obtaining an aqueous latex foam; and

- drying and subsequent curing of said aqueous latex foam, thus obtaining a latex foam.

Mixing of the composition may be carried out using agents such as those known in the art. Drying and curing may be carried out at a suitable temperature above ambient temperature.

The residence time varies and depends on factors such as temperature, layer thickness, water content, and the components of the curable composition. The typical residence time is between 1 and 20 minutes, and preferably between 5 and 10 minutes. The person skilled in the art will understand that the residence time for drying and curing in an air circulation oven increases with increasing layer thickness. Thus, the optimum residence time can be determined in a simple manner. Drying and curing may be carried out in an air circulation oven. The internal temperature of the oven should preferably be kept above 120°C.

In a preferred embodiment, the present invention provides a method for the production of a latex foam, wherein said latex foam is a non-gel latex foam, comprising the steps of:

- preparation of a composition comprising a latex and a cross-linker, and optionally, a foam booster and a foam stabilizer, thus obtaining an aqueous latex foam;

- foaming of the aforementioned aqueous latex foam to the desired specific weight;

- optionally, spreading of said aqueous latex foam onto a substrate such as the underside of a carpet;

- treating of the aqueous latex foam using infrared light, thus obtaining a foam film; and

- drying and subsequent curing of said aqueous latex foam, thus obtaining a latex foam.

According to the preferred embodiment of the above paragraph, said cross-linker may also fulfil the function of a latent gelling agent.

In a preferred embodiment, the present invention provides a method for the production of a latex foam wherein said latex foam is a gel latex foam, comprising the steps of:

- preparation of a composition comprising a latex, a cross-linker, and a gelling agent or a latent gelling agent, and optionally, a foam booster and a foam stabilizer, thus obtaining an aqueous latex foam;

- foaming of the aforementioned aqueous latex foam to the desired specific weight;

- optionally, spreading of said aqueous latex foam onto a substrate such as the underside of a carpet;

- treating of the aqueous latex foam using infrared light, thus obtaining a foam film; - compression, printing, or printing of mouldings in the aforementioned foam film; and

- drying and subsequent curing of said aqueous latex foam, thus obtaining a latex foam.

In a fifth embodiment, the present invention provides a method for the production of a latex foam, comprising the steps of:

- mixing of a latex, a cross-linker, a latent gelling agent, and optionally, a foam booster and a foam stabilizer, thus obtaining an aqueous latex foam;

- optionally, spreading of said aqueous latex foam onto a substrate; and

- drying of said aqueous latex foam, thus obtaining a latex foam,

wherein said latent gelling agent is converted in solution to a gelling agent.

Mixing and drying are carried out according to the same method as described above.

In a preferred embodiment, the present invention provides a method for the production of a latex foam comprising the step of mixing a latex, a cross-linker, a latent gelling agent, a foam booster and a foam stabilizer, thus obtaining an aqueous latex foam.

The aqueous latex foam may be poured into moulds, spread onto a flat plate or strip, or coated onto substrates. For the application of this specification, the term "substrate" is defined as any material, such as cloth, leather, skin, glass, or metal or some form of support such as a carpet, shoe soles, or wall covering to which the latex foam is to adhere when it is applied, after which it is cured.

In an embodiment of this invention wherein the foam is used as a textile carrier, the foam can be applied to the textile prior to drying and curing. A typical foam formed from the aqueous latex foam has a density during this process of approximately 100 to 1000 g/L when wet, preferably 200 to 600 g/L, and more preferably 200, 250, 300, 350 of 400 g/L or any value in between. The foam can be applied to the substrate using a scraper. In a preferred embodiment, the present invention provides a method according to the fifth embodiment of the invention, comprising the step of mixing said aqueous latex foam with one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.

In a preferred embodiment, the present invention provides a method according to the fifth embodiment of the invention, wherein said aqueous latex foam is dried by heating to a temperature of between 50°C and 150°C.

Preferably, said aqueous latex foam is dried at a temperature of between 60°C and 100°C, more preferably at a temperature of between 70°C and 90°C, and most preferably at a temperature of 71, 72, 73, 74, 75, 76, 77, 78, 79, 80°C, or any temperature in between.

In a preferred embodiment, the present invention provides a method according to the fifth embodiment of the invention, wherein said aqueous latex foam is treated using an infrared lamp.

In a preferred embodiment, the present invention provides a method according to the fifth embodiment of the invention, wherein said latex foam is subjected to mechanical post-treatment such as compression, printing, or pressing.

In a preferred embodiment, the present invention provides a method according to the fifth embodiment of the invention, wherein said latex foam is thermally post- treated, e.g. by curing at a temperature of between 100°C and 200°C. Preferably, said latex is thermally post-treated in an oven at a temperature of between 125°C and 175°C, more preferably at a temperature of between 140°C and 160°C, and most preferably at a temperature of 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155°C, or any temperature in between. In a sixth embodiment, the present invention provides a method for the production of a latex foam, comprising the steps of:

- mixing of a composition (A) according to the first embodiment of the invention; and a composition (B) comprising at least an acid or acid precursor for converting said latent gelling agent to a gelling agent, thus obtaining an aqueous latex foam;

- optionally, spreading of said aqueous latex foam onto a substrate; and

- the drying of said aqueous latex foam, thus obtaining a latex foam, wherein said latent gelling agent is converted to a gelling agent during mixing. In a preferred embodiment, the present invention provides a method according to the sixth embodiment of the invention, comprising the step of mixing said aqueous latex foam with one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.

In a preferred embodiment, the present invention provides a method according to the sixth embodiment of the invention, wherein said aqueous latex foam is dried by heating to a temperature of between 50°C and 150°C.

Preferably, said aqueous latex foam is dried at a temperature of between 60°C and 100°C, more preferably at a temperature of between 70°C and 90°C, and most preferably at a temperature of 71, 72, 73, 74, 75, 76, 77, 78, 79, 80°C, or any temperature in between.

In a preferred embodiment, the present invention provides a method according to the sixth embodiment of the invention, wherein said aqueous latex foam is treated using an infrared lamp.

In a preferred embodiment, the present invention provides a method according to the sixth embodiment of the invention, wherein said latex foam is subjected to mechanical post-treatment such as compression, printing, or pressing. In a preferred embodiment, the present invention provides a method according to the sixth embodiment of the invention, wherein said latex foam is thermally post- treated, e.g. by curing at a temperature of between 100°C and 200°C.

Preferably, said latex is thermally post-treated in an oven at a temperature of between 125°C and 175°C, more preferably at a temperature of between 140°C and 160°C, and most preferably at a temperature of 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155°C, or any temperature in between.

In a seventh embodiment, the present invention provides a latex foam that can be obtained by means of a method according to the fourth embodiment of the invention. In an eighth embodiment, the present invention provides a latex foam that can be obtained by means of a method according to the fifth embodiment of the invention.

In a ninth embodiment, the present invention provides a product comprising a latex foam according to the seventh embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres, or shoe soles, and in medical or sanitary applications such as in surgical gloves.

In a tenth embodiment, the present invention provides a product comprising a latex foam according to the eighth embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres, or shoe soles, and in medical or sanitary applications such as in surgical gloves.

In an eleventh embodiment, the present invention provides an application of a composition according to the first embodiment of the invention for the production of a latex foam.

EXAMPLES

The following examples are illustrative of this invention and are not intended to limit the scope of the invention or claims. All percentages are percentages by weight unless otherwise indicated.

EXAMPLES 1-15 The general methods for preparation of a composition for the production of a latex foam and for production of said latex foam are described below, after which the various examples of the compositions obtained are presented in Examples 1 to 15. The compositions may also be obtained by first combining two or more separate compositions that can be stored in the form of a kit and then reactively mixed in order to produce the desired latex.

In a first step, a latex (A) and a cross-linker (B) are mixed to obtain a composition (A+B). A latent gelling agent (C) is also mixed into the aforementioned composition (A+B) at room temperature. A latex composition (A+B+C) is obtained in this manner. In addition, other substances may be mixed into the aforementioned latex composition, such as additives and a foam booster and -stabilizer. Immediately before or during the production of said latex foam, said latent gelling agent is activated and converted to a gelling agent. In a second step, the latex composition is intensively mixed in order to obtain an aqueous latex foam.

When the aqueous latex foam shows favourable foam quality, it is applied to a substrate. For example, the substrate may be the underside of a carpet. Thus favourable contact is provided between the aqueous latex foam and the substrate, for example by applying pressure using a rolling mill.

Next, in a third step, the aqueous latex foam is treated by means of an infrared lamp at a temperature of 70 to 80°C.

In a final step, the at least partially dried latex foam is cured and further dried. In this manner, cross-linking of the latex composition takes place. If applicable, this thermal treatment is followed by a mechanical treatment such as compression, printing, or pressing and thermal post-treatment for curing in an oven at a temperature of approximately 150°C.

The various compositions are given in Tables 1-15.

Table 1 : Composition for the production of a latex foam according to example 1 of the present invention.

parts on a dry matter basis.

* parts on a wet matter basis.

Table 2: Composition for the production of a latex foam according to example 2 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane

Disodium tallow sulphosuccinimate soap 6 17

Sodium lauryl sulphate 1.5 5.4

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.2 0.8

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 3 : Composition for the production of a latex foam according to example 3 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane

Betaine soap 1.5 4.2

Sodium lauryl sulphate 0.5 1.8

EVA latex 2 3.8 Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.2 0.8

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 4: Composition for the production of a latex foam according to example 4 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane

Betaine soap 1.5 4.2

Sodium lauryl sulphate 1 3.6

Sodium silicate 4 9.8

Zinc oxide 0.5 1

Calcium earbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.2 0.8

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 5: Composition for the production of a latex foam according to example 5 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane

Disodium tallow sulphosuccinimate soap 1 2.8

Betaine soap 1.25 3.5

Sodium lauryl sulphate 0.5 1.8

EVA latex 2 3.8

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.2 0.8

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 6: Composition for the production of a latex foam according to example 6 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane

Disodium tallow sulphosuccinimate soap 1 2.8 Betaine soap 0.5 1.4

Sodium lauryl sulphate 1 3.6

Sodium silicate 1 2.5

EVA latex 2 3.8

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.2 0.8

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 7: Composition for the production of a latex foam according to example 7 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 6.86 11.44

Phosphonium salt 0.10 1.58

Disodium tallow sulphosuccinimate soap 4 11

Sodium lauryl sulphate 1 3.6

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.23 0.95

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 8: Composition for the production of a latex foam according to example 8 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 6.86 11.44

Phosphonium salt 0.10 1.58

Disodium tallow sulphosuccinimate soap 2 5.6

Betaine soap 2 3.6

Sodium lauryl sulphate 1 3.6

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.23 0.95

Amine oxide 1 2.5

Sodium silicofluoride 10 20 Table 9: Composition for the production of a latex foam according to example 9 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 6.86 11.44

Phosphonium salt 0.10 1.58

Betaine soap 1.5 4.2

Sodium lauryl sulphate 1 3.6

Sodium silicate 2 4.9

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.23 0.95

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 10: Composition for the production of a latex foam according to example 10 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 6.86 11.44

Phosphonium salt 0.10 1.58

Betaine soap 1.5 4.2

Sodium lauryl sulphate 1 3.6

EVA latex 2 3.8

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.23 0.95

Amine oxide 1 2.5

Sodium silicofluoride 10 20

Table 11 : Composition for the production of a latex foam according to example 11 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 6.86 11.44

Phosphonium salt 0.10 1.58

Betaine soap 1.5 4.2

Sodium lauryl sulphate 1 3.6

Sodium silicate 1 2.5

EVA latex 1 1.9

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5 Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.23 0.95

Amine oxide 1 2.5

Sodium siiicofluoride 10 20

Table 12: Composition for the production of a latex foam according to example 12 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 3.60 6.0

Phosphonium salt 0.05 0.79

Disodium tallow sulphosuccinimate soap 6 17

Sodium lauryl sulphate 1.5 5.4

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.22 0.87

Calcium lactate 1 6,3

Table 13 : Composition for the production of a latex foam according to example 13 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 3.60 6,0

Phosphonium salt 0.05 0.79

Disodium tallow sulphosuccinimate soap 2.5 6.9

Betaine soap 0.5 1,3

Sodium lauryl sulphate 1 3,6

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.22 0.87

Calcium lactate 3 19

Table 14: Composition for the production of a latex foam according to example 14 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 3.6 6.0

Phosphonium salt 0.05 0.79

Disodium tallow sulphosuccinimate soap 2.5 6.9

Betaine soap 0,5 1,3

Zinc oxide 0.5 1 Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.22 0.87

Magnesium oxide 2 10

Table 15: Composition for the production of a latex foam according to example 15 of the present invention.

Composition Pts/dry Pts/wet

Acrylic acid functional latex 100 190

Epoxy emulsion 3.6 6

Phosphonium salt 0.05 0.79

Disodium tallow sulphosuccinimate soap 2.5 6.9

Betaine soap 0,5 1,3

Zinc oxide 0.5 1

Calcium carbonate/chalk 180 180

Calgon 1 5

Bactericide 0.15 1.2

Antioxidant 2 4

Ammonia 0.22 0.87

Calcium lactate 1 6,3

Magnesium oxide 4 20