Decoupling mat
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Solution Overview
Problem
Existing decoupling mats face limitations in decoupling capability and air inclusion issues when filled with thin-bed mortar, leading to uncontrolled cavities and inadequate stress absorption.
Innovation Solution
The decoupling mat features additional weak zones, such as grooves with semicircular, semielliptical, or triangular cross-sections, which provide enhanced freedom of movement transverse to the rectilinear direction, combined with a grid-like cavity arrangement and fleece or fabric with specific passage openings to prevent mortar clogging and air inclusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional weak zones are added to improve decoupling capacity, then stress absorption improves, but device complexity increases
Solution Approach 1:
The plastic layer is segmented into multiple weak zones that extend through it, dividing the structure into functional regions. These weak zones create controlled planes of separation that allow independent movement of substrate and slab covering, improving decoupling capacity while maintaining a manageable structural complexity through systematic segmentation.
Solution Approach 2:
The weak zones introduce localized variations in the plastic layer's mechanical properties. By creating specific regions with reduced thickness or altered material characteristics at predetermined locations, the structure achieves enhanced decoupling capacity only where needed, rather than requiring complete structural redesign.
2Strength
If depressions are filled with thin-bed mortar to improve bonding, then adhesion improves, but air inclusions form causing uncontrolled cavities
Solution Approach 1:
The depressions are pre-formed with specific geometric characteristics, including undercuts and air channel connections, before mortar application. This preliminary structuring of the depressions ensures that air can escape during the filling process, allowing complete mortar penetration without forming uncontrolled cavities, while still achieving strong bonding.
Solution Approach 2:
The air channels act as intermediary pathways that facilitate air escape during mortar filling. These channels provide a controlled route for air to leave the depressions, preventing air entrapment and ensuring complete mortar penetration, thereby improving filling quality without compromising bonding strength.
3Strength
If fleece or fabric is used to cover cavities to improve anchoring, then adhesion improves, but passage openings may clog with mortar
Solution Approach 1:
The fleece or fabric is equipped with passage openings of specifically designed size and distribution. These openings are locally optimized to be large enough to prevent clogging by thin-bed mortar while small enough to allow the fabric to effectively anchor and decouple stresses. The selective placement and sizing of openings create local quality variations that balance anchoring and flow requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly improves decoupling capacity and load-bearing capability while ensuring even filling and preventing air pockets, effectively absorbing stresses and preventing crack formation in the slab covering.
Implementation Method 1
Existing stresses in the substrate, which are caused, for example, by the remaining drying or drying time. The hardening process of the subsoil, caused by the so-called settlement of a building, temperature changes due to different thermal expansion coefficients of the materials used or the like, are then absorbed and compensated for in the composite by corresponding deformation of the decoupling mats
Implementation Method 2
In a further step, the slab covering is then laid on the plastic layer of the decoupling mat using thin-bed mortar again, with the thin-bed mortar being anchored in the depressions provided with undercuts, forming thin-bed mortar stilts. In this way, a firm bond between the subsurface and the paving is achieved overall
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Decoupling mat (1) comprising a flexible plastic layer (2) made of film-like plastic with a structure that has depressions (6) provided with undercuts (5) on the first side (4) and on the opposite second side (7) between the depressions (6 ) arranged cavities (8) are defined, and a fleece or fabric (3) which is firmly connected to the second side (7) and covers the cavities (8), characterized in that the plastic layer (2) is provided with a large number of weakened zones (12) is provided, which extend continuously between opposite side edges of the plastic layer (2).