Decoupling Mat Rib Formations for Uneven Surface Adaptation
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Solution Overview
Problem
Existing decoupling mats for ceramic coverings do not effectively adapt to uneven support surfaces and are not easily handled during installation, lacking a design that optimally supports the surface while allowing for vapor pressure equalization.
Innovation Solution
A decoupling mat with elongated rib-like formations, where the longitudinal extent is three times or more than the width, and formations or recesses are offset, providing a constant material thickness and allowing for improved adaptation to support surfaces through a continuous channel system for vapor pressure equalization, facilitating easier handling and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional decoupling mat designs are used, then the mat can be manufactured with standard shapes, but the mat does not effectively adapt to uneven support surfaces
Solution Approach 1:
The decoupling mat features localized three-dimensional formations (protrusions and recesses) distributed across its surface, creating regions of varying height and geometry that adapt to local irregularities in the support surface. These formations are not uniform but vary in shape and position to match local surface conditions while maintaining manufacturability through standardized production processes.
2Adaptability or versatility
If decoupling mats with complex three-dimensional features are used, then surface adaptation improves, but handling during installation becomes more difficult
Solution Approach 1:
The decoupling mat is constructed as a thin, flexible plastic film that can be easily rolled, transported, and handled during installation. Despite its thinness and flexibility, the film incorporates three-dimensional formations that provide surface adaptation. The flexibility allows the mat to be manipulated easily while the three-dimensional features remain intact to adapt to the support surface.
3Ease of operation
If the plastic layer is made thinner to improve flexibility and handling, then ease of operation improves, but the structural integrity and support capability may be compromised
Solution Approach 1:
Rather than uniformly thickening the plastic layer, the invention creates localized three-dimensional formations (protrusions and recesses) that provide structural support and surface adaptation where needed. The bulk of the plastic layer remains thin for flexibility, while the three-dimensional features concentrate the necessary structural properties at specific locations.
Solution Approach 2:
The invention transitions from a two-dimensional thin film to a three-dimensional structure by adding protrusions and recesses that extend vertically from the plastic layer. This dimensional addition provides structural integrity and surface adaptation capabilities without significantly increasing the overall material thickness, maintaining flexibility while enhancing strength.
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a decoupling mat (1) with a continuous plastic layer (2), produced, for example, by deep drawing, having elongated rib-like projections (3) on a first broad side (B1), wherein the projections (3) simultaneously form groove-like recesses (5) on a second broad side (B2) opposite the first broad side (B1). For a practical advantage, the projections (3) are limited in their longitudinal extent (1) by sections (9) of reduced height (h') and/or width (c'), which also simultaneously form sub-areas (10) of reduced depth (s') and/or width (d') that are limited with respect to the recesses (5). Furthermore, the invention relates to a floor construction, particularly in a building, with a decoupling mat (1).