Extruded Polymer Monofilament Web for Mortar Bed Thickness Control
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Solution Overview
Problem
Existing methods for creating a uniform mortar bed thickness in flooring installations are inefficient, as they lack a reliable and accurate means to ensure the correct thickness of the mortar bed, leading to potential substrate deflection and uneven surface finishes.
Innovation Solution
A mortar bed gauge device and system utilizing a web of extruded polymer monofilaments with indentations, which serves as both a reinforcement and a gauge to establish a predetermined mortar bed thickness by being placed between a substrate and finish layer, allowing for precise measurement and distribution of mortar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods are used to create mortar bed, then installation process is simple, but mortar bed thickness is uneven and inaccurate
Solution Approach 1:
The patent applies preliminary action by pre-forming the web with specific thickness and incorporating reinforcement elements before installation. The web is manufactured with controlled thickness (0.125±0.015 inches) and pre-reinforced with polymer monofilament networks, allowing it to serve as both a thickness gauge and structural reinforcement during mortar bed installation.
Solution Approach 2:
The patent uses the web as an intermediary element between the substrate and the mortar bed. This intermediate web with predetermined thickness acts as a thickness reference and structural support, ensuring uniform mortar bed thickness without requiring complex measurement and adjustment tools during installation.
2Stability of the object's composition
If no reinforcement is added to mortar bed, then installation is simpler, but substrate deflection increases
Solution Approach 1:
The patent creates a composite structure by combining the web material with polymer monofilament reinforcement networks. The web itself serves as a base material, and the heat-welded or bonded monofilament pattern (with 0.5-2.0 inch spacing) creates a reinforced composite that resists substrate deflection while maintaining installation simplicity.
Solution Approach 2:
The reinforcement is segmented into a pattern of discrete polymer monofilament elements spaced at specific intervals (0.5-2.0 inches apart). This segmented reinforcement pattern provides adequate structural support and deflection resistance while using less material than a continuous reinforcement layer, balancing strength with installation efficiency.
3Manufacturing precision
If mortar bed thickness is not controlled, then application is faster, but surface finish becomes uneven
Solution Approach 1:
The web performs self-service by acting as its own thickness gauge. The predetermined web thickness (0.125±0.015 inches) automatically establishes the correct mortar bed thickness without requiring external measurement tools or skilled judgment, ensuring consistent surface finish while maintaining rapid installation pace.
Solution Approach 2:
The patent controls the critical parameter of web thickness with high precision (0.125±0.015 inches) during manufacturing. This tight parameter control ensures that the web provides accurate thickness guidance, resulting in uniform mortar beds and even surface finishes without slowing down the installation process.
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 ensures a uniform and accurate mortar bed thickness, reducing substrate deflection and enhancing the stability and evenness of the flooring surface by providing a predetermined thickness that matches the preselected web thickness, thus improving the overall installation quality.
Implementation Method 1
the polymer monofilaments being heat welded at junctions to form a matrix of tangled monofilaments
Data Source
AI summary
The present disclosure provides a mortar bed gauge device, system, and method that create a predetermined mortar bed thickness. The mortar bed gauge device includes a web of extruded polymer monofilaments having indentations on a surface of the web. The mortar bed gauge system includes the web located between a substrate layer and a finish layer. The mortar bed gauge method includes supplying the web, laying the web onto the substrate layer, placing a mortar composition onto the web, and measuring the amount of composition being placed on the web by the thickness of the web.