Universal tile installation mat for uncoupling floor or wall tiles set in mortar from a support surface
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Solution Overview
Problem
Existing underlayment solutions for tile installations are costly and inefficient, requiring separate products for heated and non-heated surfaces, and often result in wire detachments and complex installation patterns, leading to expensive repairs and increased inventory costs.
Innovation Solution
A universal tile installation mat with a flexible base sheet and integrated support formations that uncouple tiles from the sub-floor, provide wire retention and guiding features, and facilitate easy installation of heating wires in various patterns, using a combination of circular mortar anchoring formations, guide posts, and anchoring passages to secure wires and mortar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate underlayment products are used for heated and non-heated surfaces, then wire retention and heating functionality are improved, but manufacturing cost, inventory cost, and installation complexity increase
Solution Approach 1:
The underlayment is designed with integrated support formations that serve dual functions: providing structural support for tiles and retaining electrical heating wires through specially shaped formations with recesses and flanges. This eliminates the need for separate underlayment products for heated and non-heated surfaces, reducing inventory complexity while maintaining reliable wire retention.
Solution Approach 2:
The patent combines the wire retention function and tile support function into a single underlayment product. The support formations include both structural elements for tile mounting and integrated wire retention features, merging what were previously separate functions into one unified product that reduces manufacturing and inventory complexity.
2Reliability
If complex wire retention formations are used, then wire detachment is prevented, but installation ease and pattern simplicity deteriorate
Solution Approach 1:
The underlayment features repeatedly spaced support formations arranged in organized patterns, with each formation containing segmented wire retention features including recesses and flanges. This segmentation allows wires to be easily routed through predefined paths while the repetitive pattern simplifies installation by providing consistent wire placement locations throughout the underlayment.
Solution Approach 2:
The support formations act as intermediary structures that mediate between the wire and the underlayment surface. The formations include recesses that receive wires and flanges that retain them, providing a simple interface that secures wires without requiring complex installation procedures.
3Reliability
If thicker underlayment is used to attach heating wires, then wire retention improves, but uncoupling effectiveness and cost increase
Solution Approach 1:
Instead of using uniformly thick underlayment, the patent incorporates support formations with varying thicknesses and geometries at specific locations. The formations include recesses and flanges that provide localized wire retention enhancement only where needed, while the rest of the underlayment maintains optimal thickness for uncoupling functionality, reducing overall material usage and manufacturing cost.
Data Source
AI summary
A universal tile installation mat is described for use in the construction of tiled floors and walls and wherein the mat is secured on a sub-floor surface formed of wood or concrete or a wall surface. The tile installation mat uncouples the mortar and the tiles set therein and disposed over the mat to prevent cracking of the mortar, the tiles and the grouted joints due to displacements in the support surfaces. The tile installation mat is formed from flexible plastics materials and has three different types of support formations integrally formed therein to anchor mortar and to retain heating wires captive in different patterns as desired to form a heated tiled floor or wall. The support formations facilitates ease of installation of heated wires and provides counter acting forces against a heating wire from escaping from anchoring passages formed by the support formations.