Multi-layer Decoupling Mat with Deep-drawn Film
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Solution Overview
Problem
Existing decoupling mats in construction lack a balance between high decoupling capability, load-bearing capacity, and impact sound insulation, often requiring additional on-site mortar filling and leading to instability and increased costs.
Innovation Solution
A multi-layer decoupling mat comprising a fabric or fleece layer, a first plastic film layer, a second plastic film layer with deep-drawn forms filled with a binder and quartz sand mixture, and a second fabric or fleece layer, which is prefabricated to ensure stability and prevent mortar loss, providing both decoupling and sealing while allowing vapor pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a structured plastic film with cavities is used for decoupling, then flexibility and stress absorption in the XY plane are improved, but load-bearing capacity deteriorates due to low material thickness and narrow bridges
Solution Approach 1:
The patent combines a plastic film with a reinforcing layer made of glass fibers or metal meshes to create a composite material structure. This composite structure maintains the flexibility and stress absorption capabilities of the plastic film while the reinforcing layer provides the necessary load-bearing capacity and dimensional stability, resolving the contradiction between flexibility and strength.
2Reliability
If the cavities are kept small and narrow for full functionality, then decoupling performance is improved, but mortar filling becomes insufficient and stability deteriorates
Solution Approach 1:
The reinforcing layer of glass fibers or metal meshes provides structural stability and dimensional support to the plastic film structure. This composite approach allows the cavities to maintain their small and narrow dimensions for effective decoupling performance while the reinforcing layer ensures overall structural stability and prevents deformation under load.
3Strength
If a relatively thick polyethylene sheet with large webs is used, then load-bearing capacity and stability are improved, but flexibility deteriorates making handling and cutting difficult
Solution Approach 1:
The patent divides the structure into two functional segments: a thin plastic film layer that provides flexibility and adaptability, and a separate reinforcing layer that provides load-bearing capacity. This segmentation allows each layer to optimize its specific function without compromising the other, enabling easy handling and cutting while maintaining structural strength.
Solution Approach 2:
By combining a thin plastic film with a reinforcing layer of glass fibers or metal meshes, the patent creates a composite material that exhibits both flexibility from the film and strength from the reinforcement. This composite structure resolves the contradiction between load-bearing capacity and flexibility, making the material easy to handle and cut while maintaining high strength.
4Reliability
If additional sealing measures are provided, then sealing performance is improved, but device complexity and construction costs increase
Solution Approach 1:
The plastic film with cavities serves multiple functions simultaneously: it provides decoupling between layers, acts as a sealing barrier against moisture ingress, and offers stress absorption capabilities. By integrating these multiple functions into a single component, the patent eliminates the need for separate sealing measures, thereby reducing structural complexity and construction costs while maintaining high sealing performance.
Data Source
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Figure 3
AI summary
The invention relates to a decoupling mat for sealing, decoupling, and impact sound insulation, comprising several layers in the following order: α) woven or nonwoven layer (1), β) plastic film layer (2), γ) plastic film layer (3) with a flat, continuous base (4) and one-sided deep-drawn features (5), wherein the continuous base is connected to the plastic film layer β) and wherein the features (5) are filled with a filler (6), δ) woven or nonwoven layer (7), wherein the decoupling mat is waterproof. Furthermore, a structure comprising this decoupling mat and the use of the decoupling mat for decoupling, sealing, and impact sound insulation are disclosed.