Uncoupling Mat with Undercut Indentations for Air-Free Mortar Filling
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Solution Overview
Problem
Existing uncoupling mats face challenges in improving uncoupling capability, clamping of the fleece or fabric, and air inclusion during thin bed mortar filling, which can lead to uncontrolled cavities.
Innovation Solution
The uncoupling mat features a flexible plastic layer with structuring that includes indentations with undercuts, cavities, and additional weakening zones, along with a fleece or fabric that allows for better air escape and improved uncoupling, using a thin bed mortar to anchor the slab covering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the uncoupling mat uses a flexible plastic layer with structuring to improve uncoupling capability, then stress absorption and deformation are enhanced, but air inclusions and uncontrolled cavities may form during thin bed mortar filling
Solution Approach 1:
The plastic layer is segmented into multiple functional zones: indentations with undercuts for mortar anchoring, cavities for air escape, and weakening zones for controlled deformation. This segmentation allows each zone to perform its specific function without interfering with others, enabling both effective uncoupling and air inclusion prevention
Solution Approach 2:
Different regions of the plastic layer are given different local properties: the indentation regions provide mechanical anchoring, the cavity regions provide air escape pathways, and the weakening zones provide controlled deformation capability. This local differentiation resolves the contradiction by ensuring that air escape is facilitated specifically where needed without compromising the overall uncoupling function
2Strength
If the uncoupling mat uses indentations with undercuts to anchor thin bed mortar, then clamping of the fleece or fabric is improved, but air escape during mortar filling becomes more difficult
Solution Approach 1:
The surface structure is segmented into indentations with undercuts for anchoring and separate cavities for air escape. This segmentation allows the mortar to be firmly anchored in the indentation regions while air can escape through the cavity regions, resolving the contradiction between anchoring strength and air escape
Solution Approach 2:
The cavities act as intermediary channels that facilitate air escape during the mortar filling process. These cavities provide a dedicated pathway for air to leave the system without interfering with the mortar anchoring function of the indentations, thus mediating between the conflicting requirements
3Reliability
If the uncoupling mat uses weakening zones to enhance stress absorption, then uncoupling capability is improved, but the structural integrity of the plastic layer may be compromised
Solution Approach 1:
The plastic layer is given different local qualities: weakening zones with reduced thickness for stress absorption and other regions with full thickness for structural integrity. This local differentiation allows the material to be weak where needed for uncoupling and strong where needed for overall structural stability
Solution Approach 2:
The plastic layer is segmented into weakening zones and non-weakening zones. The weakening zones are strategically placed to provide stress absorption capability while the remaining portions of the plastic layer maintain structural integrity. This segmentation allows the contradiction to be resolved by spatial separation of conflicting requirements
Data Source
AI summary
A slab covering installation includes a substrate (14) and an uncoupling mat (1) fastened to the substrate (14). A flexible plastic layer (2) is 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) covering 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). A thin bed mortar (16) is installed atop the uncoupling mat such that the thin bed mortar substantially fills the indentations (6) beneath the undercuts (5). A slab covering (15) can be fastened to the thin bed mortar atop the uncoupling mat.