Reinforced Floor Base Layer for Insulation and Load Distribution
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Solution Overview
Problem
Existing methods for producing floor substrates with insulating and stabilizing effects are complex, requiring multiple materials and layers, leading to high material and labor costs, and often fail to achieve an optimal combination of properties such as high strength, low weight, and good thermal insulation.
Innovation Solution
A floor substrate comprising a lightweight leveling mortar with a composite leveling compound containing mineral fibers, which penetrates into a scrim for reinforcement, providing a stable and uniform connection between the subfloor and floor covering, with a self-levelling composite compound that enhances thermal insulation and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layer structure with various materials is used to achieve good insulating properties, high stability, and mechanical load-bearing capacity, then the insulating effect and stability are improved, but the device complexity and processing time increase
Solution Approach 1:
The patent combines the insulating layer and leveling compound into a single integrated layer containing both lightweight insulating material and leveling properties, eliminating the need for separate insulating layers and reducing overall structure complexity while maintaining both thermal insulation and stability
Solution Approach 2:
The patent uses composite materials by incorporating mineral fibers into the leveling compound matrix, creating a reinforced composite that provides both structural stability and mechanical strength while maintaining a simplified layer structure
2Strength
If multiple materials and layers are combined to achieve optimal properties, then the mechanical load-bearing capacity is improved, but the quantity of material and labor required increase
Solution Approach 1:
The patent incorporates mineral fibers directly into the leveling compound to create a reinforced composite material that provides high mechanical load-bearing capacity and tensile strength within a single material system, reducing the need for additional reinforcing layers or materials
Solution Approach 2:
The leveling compound is designed to perform multiple functions simultaneously: providing mechanical strength, ensuring stable bonding, enabling self-leveling, and working with the insulating properties of the underlying layer, thereby reducing the need for separate specialized materials
3Reliability
If a multi-layer structure with primer and putty is used to ensure stable connection, then the bonding stability is improved, but the processing time and labor intensity increase
Solution Approach 1:
The patent integrates bonding stabilizing properties directly into the leveling compound formulation, eliminating the need for separate primer and putty layers, thereby reducing the number of processing steps and overall construction time while maintaining reliable bonding stability
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 enables a stable, uniform, and efficient connection with high resilience and strength, reducing material usage and processing time, while achieving effective thermal insulation and load distribution, allowing for quick installation of floor coverings.
Implementation Method 1
When the composite leveling compound is discharged in a non-hardened form, it is placed over the scrim laid out on the lightweight leveling mortar, so that due to the porosity of the scrim, the composite leveling compound penetrates into it and encloses it.
Implementation Method 2
The floor substrate should act as a load-distributing layer and often also as insulation, especially as heat insulation and impact sound insulation.
Data Source
Figure 1
AI summary
The substrate (3) has a light leveling mortar arranged over an under-floor. A layer (4) of composite balance mass is positioned above a layer (2) of the light leveling mortar. The layer of the composite balance mass is provided with a core (5) including inorganic fibers i.e. glass fibers, that are arranged with water soluble adhesive. The light leveling mortar comprises an aggregate made of foamed organic polymer i.e. polystyrene. A layer (6) of the floor is made of hardwood, laminate, carpet, plastic, ceramic or stone. An independent claim is also included for a method for manufacturing a floor substrate.