Angled Channel Decoupling Mat for Floor Covering
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Solution Overview
Problem
Decoupling mats used in floor covering structures often deform under mechanical load, leading to weakening lines that can cause hairline cracks or damage to the adhesive mortar layer, especially when these lines coincide with joints between adjacent floor covering elements.
Innovation Solution
The decoupling mat features non-convex surface-shaped formations with channel sections aligned at angles, preventing the formation of long, straight weakening lines by ensuring that channel sections intersect with protrusions, thereby distributing mechanical stress and reducing the likelihood of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If channels run in parallel rows across the entire decoupling mat, then mechanical stresses can be absorbed, but straight weakening lines are formed that promote deformation and cracking
Solution Approach 1:
The patent applies curvature by designing channels that follow curved or angled paths instead of straight lines. The channels are configured to change direction at various points, creating a non-linear pattern that distributes stress more evenly across the decoupling mat surface, thereby preventing the formation of straight weakening lines that would lead to deformation and cracking.
Solution Approach 2:
The patent segments the continuous channel structure into multiple sections with varying orientations. Instead of having channels extend continuously in parallel rows, the channels are divided into segments that change direction, creating a more complex pattern that interrupts potential weakening lines while maintaining stress absorption capability.
2Stability of the object's composition
If channels extend across the entire decoupling mat, then stress compensation is achieved, but weak lines coincide with floor covering joints causing hairline cracks
Solution Approach 1:
The curved or angled configuration of channels ensures they do not align with the regular grid pattern of floor covering joints. By curving the channels, the patent prevents coincidence between channel locations and joint locations, thereby avoiding the concentration of stress at joint areas that leads to hairline cracks and damage.
Solution Approach 2:
The patent introduces asymmetry in the channel arrangement by using channels with varying directions and curves rather than uniform parallel rows. This asymmetric pattern disrupts the alignment between channels and the symmetric grid of floor covering joints, preventing harmful stress concentration at joint interfaces.
3Ease of manufacture
If regular row arrangements of features are used, then manufacturing is simplified, but straight channel sections create lines of weakening
Solution Approach 1:
The patent maintains ease of manufacture by using standardized features arranged in a systematic pattern, but introduces curvature and angular variations in the channel paths between features. This allows the manufacturing process to remain relatively simple while the curved channel configurations prevent straight weakening lines from forming.
Solution Approach 2:
The patent applies local quality by having features arranged regularly in some areas while introducing angular variations and curved channel sections in specific locations. This allows the overall structure to maintain manufacturing simplicity while specific local modifications prevent the formation of continuous straight weakening lines.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The mat has a web or plate-like compensating element (1) that includes multiple protrusions (2) regularly spaced-apart on a support plane. Multiple open channels (3) extend along the protrusions from one side edge to other side edge of the compensating element. Each open channel is composed of several merging channel sections (4,5), such that the respective end portions are connected to the section line. The section lines are aligned at an angle to each other, such that the open channels are not formed over the channel course extending straight lines of weakness.