Foam Underlay Plug Connection for Gap-Free Sealing
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Solution Overview
Problem
Existing insulating underlay systems for subfloor and walkable floor coverings face issues with secure connection, especially with thin elements, leading to gaps and reduced sound insulation and compressive strength due to shifting panels, which compromise the vapor barrier and soundproofing.
Innovation Solution
The underlay insulation covering elements feature laterally arranged plug-in connection means with structured or profiled surfaces on abutting edges, increasing friction through material compression and deformation, ensuring a secure connection without the need for adhesive tapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape is used to connect underlay panels, then a closed surface and vapor barrier can be achieved, but the underlay panels shift during handling and installation, creating gaps that compromise the vapor barrier and sound insulation
Solution Approach 1:
The underlay system is divided into modular panels with integrated connection elements. Each panel has plug-in connection means with structured surfaces that enable secure interlocking with adjacent panels, eliminating the need for separate adhesive tape application and preventing panel shifting during installation.
Solution Approach 2:
The connection elements are pre-integrated into the panel structure during manufacturing. The structured surfaces are formed on the plug-in connection means before installation, so that when panels are brought together, the friction-based connection is immediately activated, preventing any shifting before the vapor barrier function can be established.
2Weight of moving object
If thin underlay elements (1-7 mm) are used for insulation, then the underlay remains lightweight and easy to handle, but the plug-in connection becomes unstable and panels can loosen, causing displacement and gaps
Solution Approach 1:
The connection reliability is improved by changing the surface parameter of the plug-in connection means. Structured surfaces with increased roughness and deformation characteristics are implemented on the connection elements. This increases the friction coefficient and mechanical interlocking capability, providing stable connections even for thin, lightweight underlay panels without adding weight.
3Ease of manufacture
If smooth abutting edges are used on underlay panels, then the panels are easy to manufacture and assemble, but the connection between panels is insecure and allows shifting that creates gaps
Solution Approach 1:
The underlay panels have differentiated surface qualities: the main panel surfaces remain smooth for ease of manufacturing and installation, while only the localized abutting edges of the plug-in connection means have structured surfaces. This local structuring provides enhanced connection strength at the joints without complicating the overall manufacturing process or affecting the main panel functionality.
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
This design provides a stable and secure connection between underlay elements, maintaining sound insulation and compressive strength, even with thin elements, and allows for seamless integration with moisture protection films, preventing gaps and enhancing overall performance.
Implementation Method 1
increasing friction through material compression and deformation
Implementation Method 2
material compression and deformation
Data Source
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AI summary
The damping pad has a plug connection provided at two sides of underlying damping pad elements (1) for complete and laminar connection of the damping pad elements, where the pad consists of a foamed plastic. The plug connection has a structured and/or formed surface on a side at contact edges (2) engaging into one another in sections. Teeth of the damping pad elements are arranged as the plug connection at the contact edges. The plug connection is formed from trapezoidal slots (4) and projections (3).