Decoupling Mat Stability Without Sand Filling
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Solution Overview
Problem
Existing decoupling mats for ceramic coverings lack inherent stability and require filling with materials like quartz sand and binding agents, which complicates manufacturing and increases weight, while also needing additional thin-bed mortar for stability, and may not effectively prevent moisture penetration.
Innovation Solution
A decoupling mat with a continuous plastic layer and integrated fleece or textile layers, where the plastic layer is thick enough to provide stability without filling, and the fleece or textile layers ensure water and vapor tightness, eliminating the need for additional filling materials and enhancing moisture management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the plastic layer is made thin to reduce weight and simplify production, then manufacturing cost and weight are reduced, but the stability and load-bearing capacity of the decoupling mat deteriorates
Solution Approach 1:
The plastic layer is segmented into multiple sub-layers (first plastic sub-layer, second plastic sub-layer) with different thicknesses and properties. The first sub-layer provides structural stability while the second sub-layer provides flexibility and decoupling function, allowing the overall structure to achieve both stability and light weight without requiring thick uniform material.
Solution Approach 2:
The decoupling mat uses composite construction combining different plastic materials with complementary properties. The first plastic sub-layer uses stiffer material for structural support, while the second plastic sub-layer uses more flexible material for decoupling and vibration isolation, creating a composite structure that optimizes both weight and stability.
2Stability of the object's composition
If filling materials like quartz sand and binders are added to the cups to improve stability, then the stability and load-bearing capacity improve, but the manufacturing complexity and weight increase
Solution Approach 1:
The invention extracts and eliminates the need for filling materials (quartz sand, binders) by designing the plastic layer structure itself to provide the necessary stability and load-bearing capacity through its multi-layer configuration and geometric design, thereby simplifying manufacturing and reducing weight.
Solution Approach 2:
The plastic layer structure is designed to be self-sufficient, where the multi-layer plastic construction itself provides the structural support and stability functions that would otherwise require external filling materials. The structure serves its own stabilizing function without needing additional additives.
3Strength
If the plastic layer thickness is increased to provide sufficient stability without filling, then the stability and strength improve, but the weight and production cost increase
Solution Approach 1:
The plastic layer is divided into multiple sub-layers with different thicknesses and material properties. The first plastic sub-layer has greater thickness for structural strength, while the second plastic sub-layer has smaller thickness for flexibility and decoupling, achieving sufficient strength without requiring uniform thick material throughout.
Solution Approach 2:
Different regions of the plastic layer have different thicknesses and material properties optimized for their specific functions. The first plastic sub-layer uses thicker, stiffer material where structural strength is needed, while the second plastic sub-layer uses thinner, more flexible material where flexibility and vibration isolation are prioritized.
4Object-affected harmful factors
If conventional decoupling mats are used without integrated fleece layers, then production is simpler, but water and vapor tightness are insufficient allowing moisture penetration
Solution Approach 1:
The fleece layer is merged with the plastic layer structure, where the fleece layer is integrated between the plastic sub-layers and bonded to their outer surfaces. This combination creates a unified structure that provides both the decoupling function of the plastic and the moisture barrier function of the fleece, eliminating the need for separate components.
Solution Approach 2:
The decoupling mat uses composite construction combining plastic materials with fleece material. The fleece layer provides hydrophobic properties and vapor tightness, while the plastic layers provide structural support and decoupling function, creating a composite structure that addresses both structural and moisture protection 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
The solution simplifies production, reduces weight, and provides effective decoupling, sealing, and impact sound insulation, while ensuring the mat is waterproof and vapor-tight, preventing moisture penetration into the building structure.
Implementation Method 1
In the case of a nonwoven fabric, a hydrophobic finish may be applied. This ensures that there is no permeability to water.
Implementation Method 2
the decoupling mat is both watertight and vapor-tight, preventing moisture from penetrating the building structure
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a decoupling mat (1) comprising a continuous plastic layer (2) having, for example, deep-drawn cups (3) open on one side or nubs or hollow chambers formed from solid material, and a continuous cover layer (4) applied to the plastic layer (2) which closes the cups (3) or nubs on the underside, and a final layer (5) directly bonded to the free end faces of the cups (3) or nubs, wherein the cover layer (4) and/or the final layer (5) can consist of a nonwoven fabric, wherein the plastic layer (2) is further formed with such thickness (d) and strength, and the cups (3) or nubs with such dimensions and wall thickness that the required stability is achieved, wherein the cups (3) can also have a filled or unfilled free space, optionally filled with an anti-mold agent.