Uncoupling mat with heating elements

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Solution Overview

Problem

Existing uncoupling mats face challenges in enhancing uncoupling capability, improving clamping of the fleece or fabric with thin bed mortar, and preventing air inclusions during mortar application.

Innovation Solution

The uncoupling mat features a flexible plastic layer with structuring that includes indentations with undercuts on one side and cavities between them on the other, along with a fleece or fabric securely connected to the bottom side. Additionally, the plastic layer has weakening zones that extend between opposing side edges, and the fleece or fabric has through holes to facilitate mortar flow and prevent cavity clogging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the plastic layer is made more flexible to improve uncoupling capability, then the uncoupling capability is improved, but the structural stability deteriorates

Engineering Contradiction:

Improveuncoupling capabilityVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The plastic layer is segmented into multiple regions with different flexibility characteristics. The weakening zones create discrete areas of increased flexibility while the rest of the structure maintains stability. This segmentation allows the mat to uncouple effectively in specific areas while maintaining overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the plastic layer are given different local qualities - the weakening zones have higher flexibility for uncoupling, while other regions maintain greater stability. The indentations with undercuts provide localized clamping zones that differ from the surrounding areas, creating optimal local conditions for both uncoupling and stability.

Inventive Principle:

Principle #3Local quality

2Strength

If the fleece or fabric is tightly connected to the bottom side to improve clamping effect, then the clamping effect is improved, but air inclusion during mortar application increases

Engineering Contradiction:

Improveclamping effectVSAvoidair inclusions

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The fleece or fabric is designed with through holes creating a porous structure that allows air and mortar to pass through during application. This porosity prevents air inclusions while maintaining the clamping effect, as the mortar can flow through the fabric rather than being trapped against a solid surface.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The through holes in the fleece allow the mortar to skip through the fabric layer quickly during application, preventing air from being trapped. The mortar rushes through the porous structure rather than being forced to displace air, eliminating the harmful air inclusion effect.

Inventive Principle:

Principle #21Skipping (Rushing through)

3Strength

If the indentations are deepened to improve mortar clamping, then the mortar clamping is improved, but air entrapment during mortar filling increases

Engineering Contradiction:

Improvemortar clampingVSAvoidair entrapment

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Instead of creating closed deep cavities that trap air, the design uses open indentations with undercuts that allow air to escape. The undercut geometry inverts the expected air-trapping effect by creating a shape where air can be pushed out during mortar filling, while the indentation still provides strong mechanical interlocking for mortar clamping.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS12297651B2Uncoupling mat with heating elements

Publication Date: 2025.05.13 SCHLUTER SYST LP

AI summary

An uncoupling mat includes a flexible plastic layer (2) made of plastic film with structuring that defines indentations (6) provided with undercuts (5) on a first, top side (4) and cavities (8) positioned between the indentations (6) on an opposite second, bottom side (7). A fleece or fabric (3) is securely connected to the bottom side (7) and covers the cavities (8). A cross-section of the indentations (6) in at least some corner regions (10) increases from the bottom side (7) toward the top side (4).