EP2408979B1 - Separation mat - Google Patents

Description

The invention relates to a decoupling mat, comprising a plurality of layers, which can be used for decoupling, sealing and impact sound insulation, and a structure comprising this decoupling mat.

Such decoupling mats are used in construction.

In the construction industry, especially in the manufacture of new floors, but also in the renovation of existing floors both in the interior and in the outdoor area again and again to material pairings that have different properties. Such pairings are for example concrete / wood or concrete / tiles, which are used in particular in new construction. When renovating old floors, a wooden floor is often placed on old tiles or vice versa. However, materials of this type are known to have different properties and so the different materials behave on externally applied loads and against temperature and humidity influences also different. Thus, in these pairings, internal stresses occur, which expand or contract the materials differently in particular in the XY plane, ie horizontally, and thus produce distortions or cracks.

It is therefore common practice to provide an insert between the two materials that can compensate for these different stresses in the XY plane. This insert must therefore be extensible extensively in the area. However, it must also be sufficiently load-bearing against the burdens of the floor. In particular, when laying rigid coverings, such. As tiles and slabs decoupling of the top surface from the substrate is mounted to mechanically separate the substrate and lining from each other. In addition, often plays in practice, except the decoupling of the coating, nor the sealing of the substrate against the ingress of water or the protection of the coating from rising water an important role. In particular, when laying tiles and slabs on balconies and terraces, sealing is an important additional measure for decoupling.

If both a decoupling and a sealing measure is provided, a structured plastic sheet or film is often used in practice under several possibilities.

Therefore, a structured plastic film is frequently used in which the structure on the upper side of the plastic film is formed from a multiplicity of identical, closely spaced and uniformly distributed cavities and webs extending between the cavities. On their underside, the cavities inevitably present as elevations and the webs as indentations. This structured plastic film is laid during processing with its underside in a mortar bed and passed on top of it with a layer of mortar. Then comes the cover material. Due to their low material thickness and the large number of cavities, the plastic film is able to work in the XY plane and to absorb the stresses acting in this direction. However, this plastic film is not sufficiently sustainable, because the sustainability of the plastic film results in the main from the structure of the plastic film with the raised webs on the one hand and the surveys on the other hand and the material thickness of the plastic film. In particular, the narrow webs and the low material thickness do not guarantee sufficient stability. The mortar applied on both sides also can not ensure a uniform pressure distribution, because the cavities and the interstices are kept relatively small and narrow and therefore can not be sufficiently filled with the mortar.

At www.schlueter.de, a decoupling track is introduced with the name Schlüter-Ditra. This decoupling web consists of a relatively rigid polyethylene web, which is provided on its upper side with square and dovetail undercut recesses and intervening, lattice-like webs. On the bottom of a carrier fleece is glued. The polyethylene sheet is designed relatively thick and the webs have a large width. This makes the polyethylene sheet very stable. On top of that, the depressions in the surfaces are designed to be very large, which can easily be filled with mortar or an adhesive. These fillings are also very resilient and so the load on the floor spreads both on the polyethylene sheet as well as on the fillings. This decoupling path is therefore very resistant to treading. However, this load capacity is at the expense of the flexibility of the polyethylene web. Due to the low flexibility of the web their handling during installation is difficult. The cutting into the desired shape is made more difficult and the web can only badly adapt to the possibly uneven ground. Furthermore, it has been shown in practice that the cavities which are necessary for full functionality on the underside become clogged with mortar residues over time. Another disadvantage of this decoupling web is also that the filling of the upper-side cavities must be done with a mortar or an adhesive exclusively on the site. This requires an additional operation, which increases the cost of the construction project.

From the DE 20 2006 017 054 U1 Furthermore, a decoupling and drainage system is described, which is intended for outdoor use and therefore additional elements for the dissipation of moisture penetrated and to avoid the capillary action trapped moisture. The core of the decoupling system is an anchoring layer, which consists of a structural element with bars and evenly distributed between the grid bars cavities. The cavities are filled with a mixture of quartz sand and a binder, which is introduced in the wet state either mechanically during the preparation of the decoupling and drainage system or manually during installation at the installation site. After curing of the binder there is an adhesive bond between the individual grains of quartz sand and between the entire quartz sand filling and the bars of the structural element.
This decoupling and drainage system is suitable for indoor use only conditionally, because it builds up too much in height. As a composite sealing measure, z. B. with a tiled surface based on the valid in Germany ZDB leaflet "Instructions for the execution of seals in conjunction with linings and coverings of tiles and panels for indoor and outdoor", the system is not suitable because a composite seal with Help from z. As sealing tapes, etc. in the edge region of the system is not reliably possible, and thus it can lead to an infiltration of moisture.

The DE 20 2005 004 127 describes a carrier plate of foil-like plastic for a plate-covered floor construction. The carrier plate is intended to serve for decoupling. In the plastic film depressions are formed, whereby a plurality of chambers are formed. Both sides of the carrier plate are provided with a net-like fabric or fleece. The fabric or nonwoven on the side of the plurality of chambers is designed so that can be penetrate through the fabric or nonwoven into the chambers at the construction site when laying the support plate of the adhesive or mortar used. Here, it is disadvantageous that the decoupling effect is not optimal, since the adhesive or mortar forms a unit in the chambers of the support plate with the floor covering. In particular, the introduction of the mortar or adhesive in the chamber at the site is very laborious and it can continue to form air-filled cavities in the support plate, which reduce the compressive strength of the support plate and can even lead to a detachment of the covering.
Another disadvantage of the carrier plate is that it is less suitable for impact sound insulation. The sound is transferred from the floor covering by the adhesive or mortar via the chambers of the support plate directly to the substrate.
This is a common problem of the prior art decoupling mats or decoupling sheets.

The EP 1726715 describes an elastic base for floors and its manufacturing process. This base comprises two sheet-like structures, between which pockets are formed, the pockets being filled with a granular elastic material. The sheet-like structures in this case comprise a flow which is linked to a polyolefin layer. This structure is particularly suitable for sports floors and complies with FIFA standards, as the floor can absorb over 60% of the impact energy and has a vertical deformation of less than 8 mm.

Impact sound insulation is very important in building construction. Above all concrete constructions spread the impact sound. The impact sound is partially reinforced. Therefore, a footfall sound insulation is required. These are übticherweise first laid plastic foam boards in a thickness of 3 to 20 mm on the floor and poured over a screed. A common raw roof thickness is 160 mm, The screed thickness is generally 50 mm. As plastic foam boards are predominantly polyethylene plates use. Incidentally, the floor / ceiling construction depends on whether screed is applied. In this case, a foil is placed over the impact sound insulation, so that the floating screed does not flow into the joints between the plates of the impact sound insulation and can form sound bridges.

The invention is therefore based on the object to develop a generic decoupling mat, which has both a high decoupling capability and a high load capacity. Furthermore, the decoupling mat should simultaneously allow excellent footfall sound insulation and constitute a composite sealing measure. Further, the mat should allow for vapor pressure equalization at the back of moisture and be easy and cost effective to manufacture.

• α) Gewebe- oder Vliesschicht 1,
• β) Kunststofffolienschicht 2,
• γ) Kunststofffolienschicht 3 mit ebener, zusammenhängender Grundfläche 4 und einseitig tiefgezogenen Ausprägungen 5, wobei die zusammenhängende Grundfläche mit der Kunststofffolienschicht β) verbunden ist und wobei die Ausprägungen 5 mit einem Füllstoff 6 verfüllt sind,
• δ) Gewebe- oder Vliesschicht 7,

wobei die Entkopplungsmatte wasserundurchlässig ist.This object is achieved by a decoupling mat for sealing, decoupling and impact sound insulation comprising a plurality of layers in the following order

• α) woven or nonwoven layer 1,
• β) plastic film layer 2,
• γ) plastic film layer 3 with a flat, continuous base surface 4 and single-sided deep-drawn forms 5, wherein the contiguous base surface is connected to the plastic film layer β) and wherein the forms 5 are filled with a filler 6,
• δ) woven or nonwoven layer 7,

wherein the decoupling mat is water impermeable.

The new decoupling mat eliminates the disadvantages of the prior art. From the multi-layered structure, in which the one-sided deep-drawn shapes are already filled with a filler, there is the particular advantage that the decoupling mat can be made completely factory and the cavities not only when laying with an adhesive or mortar must be filled. The decoupling mat invention also fulfills the task of a composite sealing measure according to ZDB leaflet "Hints for the execution of seals in conjunction with linings and coverings of tiles and panels for indoor and outdoor". Further, this allows through the underside open air channels a vapor pressure compensation at the rear exposure to moisture and a reduction of footfall sound.

The preparation of the plate can be done by simply filling the one-sided deep-drawn forms 5 of the plastic film layer 3 with the filler 6. Preferably, the filler 6 consists of a mixture of quartz sand and a binder. In particular, the filler 6 and the plastic film layer 3 can be glued together be. The binder is preferably a plastic-based binder which can form a solid bond with the plastic film layer 3 and possibly the plastic film layer 2. In this case, the binder may be a plastic which liquefies under the influence of heat so that it wets the entire surface of the individual grains of sand and all inner surfaces of the one-sided deep-drawn forms 5 of the plastic film 3. The plastic may further preferably be able to enter into a welded connection in the heated state and possibly under pressure with the plastic film 3 and cure during the cooling phase and to bond with the sand grains of the filler 6 and in particular polyethylene or an ethylene-vinyl acetate. copolymer. The filler 6 can thus be glued in its entirety and continue with the plastic film 3. Subsequently, the plastic film layer 2 is applied.

In a preferred embodiment, the deep-drawn forms on 5 flat undersides 8, which are aligned parallel to the flat, contiguous base 4 and in a plane. In particular, the undersides of the deep-drawn forms 8 correspond to at least 35% of the total area of the plastic carrier film. In this way, a high compressive strength of the decoupling mat can be achieved.

The layers β) and γ) can preferably be joined together by gluing or thermobonding. It is particularly preferred if the filler 6 comprises a binder, wherein the filler 6 used is also applied to the flat, continuous base surface 4. The binder contained here can serve as an adhesive for bonding the layers β) and γ). As a result, manufacturing costs can be saved. It is furthermore to be regarded as preferred that the woven or nonwoven layer 1 and the plastic film layer 2 are first connected to one another by gluing or thermobonding, particularly preferably by thermobonding and only subsequently the layers β) and γ) are connected to one another. The woven or nonwoven layer 7 and the plastic film layer 3 can likewise be connected to one another by gluing or thermobonding, preferably by thermobonding.

In particular, the woven or nonwoven layer 1 and 7 of the layer α) and δ) is a nonwoven fabric, a textile fabric, a fine mesh fabric or a fine mesh fabric. The fabric or nonwoven layers 1 and 7 may comprise or consist of individual synthetic fibers or synthetic yarns. The nonwoven fabric is preferably a nonwoven structure of polyester, polypropylene, or polystyrene. Furthermore, it may be a glass fiber fleece. Nonwovens are understood to mean textile surface fabrics which comprise individual fibers or threads as entanglement. In contrast, fabrics, knits and knits are made from regularly arranged threads or yarns. The tissue or Nonwoven layers are preferably designed so that they can be easily penetrated by a mortar or an adhesive and the decoupling mat can thereby enter into a firm bond with the ground and the covering. In particular, the fabric or nonwoven layer 7 is designed so that it prevents penetration of a mortar or an adhesive into the cavities 10. This makes it possible by the thus generated underside open air channels a vapor pressure compensation at the rear exposure to moisture.

By filling the deep-drawn forms 5 with a filler 6 supporting body are obtained, which are determined by the shape of the deep-drawn forms 5 and lead to a high compressive strength of the film. At the same time cavities 10 are produced by the one-sided deep-drawn forms 5 in the layer γ), which are stabilized by the support body and can act as drainage. From the structure, however, results in a preferred embodiment, a further advantage. Thus, when using a filler 6 containing a binder permanently realized that the support body and the side walls 11 and the flat bottom surfaces 8 of the plastic film are made in one piece. This increases the stability of the decoupling mat, because the inherent stability of the upright side walls of the plastic film 11 adds up with the inherent stability of the support feet. The decoupling mat preferably has a load capacity of greater than 20 t / m ² or a compressive strength of greater than 0.2 N / mm ² . In this case, the flexibility of the decoupling mat remains unaffected, because this results solely from the thickness of the plastic films 2 and 3 and the distance of the edges of the deep-drawn forms 9 on the flat, contiguous base to each other.

It is to be regarded as preferred in this case that in the plastic film layer γ), the distance of the edges of the deep-drawn forms 9 on the flat, contiguous base 4 to each other is at least 3 mm.

The geometry of the deep-drawn forms 5 in the horizontal cross section (XY direction, see FIG. 2 and 3 ) can be freely designed in many areas. In order to ensure a favorable production of the decoupling mat, in particular a square or rectangular cross section is preferred. However, it may also be a round or ellipsoidal cross-section, wherein on a decoupling mat also different horizontal cross-sectional geometries can be realized side by side. In the arrangement of the deep-drawn forms 5 on the decoupling mat, it is possible that they are in the X-direction in series and in the Y-direction gap to the adjacent deep-drawn forms 5. In an alternative embodiment of the plate, the deep-drawn forms 5 may be arranged so that they are in the X-direction and in the Y-direction in series with the adjacent deep-drawn forms 5. The maximum diameter 12 of the deep-drawn forms 5 in the XY direction on the flat, contiguous Base 4 should preferably be less than 25 mm.

Due to the construction according to the invention, there is thus a separation of the two functions of the step resistance and the flexibility of the decoupling mat, whereby both the carrying capacity and the flexibility of the decoupling mat can be optimally and independently designed according to the respective requirements.

When sizing the decoupling mat, the flexibility is therefore initially assumed, and from this an optimum film thickness for the plastic foils 2 and 3 is determined. With the strength of the plastic films 3 thus determined, the stability of the side walls 11 of the deep-drawn forms 5 can then be calculated. From the difference of the predetermined stability of the decoupling mat and the calculated stability of the plastic film can then determine the exact dimensions of the support feet. The optimized decoupling mat saves material, processing time and ensures high functionality.

For the present invention, it is particularly advantageous if the plastic film 3 of the plastic film layer γ) has a thickness of 100 to 500 μm. The plastic film 3 may be made of polyethylene or a copolymer of ethylene and vinyl acetate. As a result, a sufficient stability and a very good flexibility can be achieved. The high flexibility of the decoupling mat allows for rolling up and thus a space-saving transport to the construction site. It is excluded by the plastic film layer 2 that the filler 6 can dissolve out during the transport or subsequent processing of the plastic film 3 and can be lost. Complete factory prefabrication also saves costs during on-site processing as it eliminates the need to manually coat a thin bed of mortar. In a preferred embodiment, the layer γ) has a thickness of 3 to 50 mm, preferably 5 to 15 mm.

It is expedient if the filler 6 consists of a bonded mixture of quartz sand and a binder, wherein a thermoplastic such as polypropylene or ethylene-vinyl acetate copolymer can be used as a binder. This mixture has already been tested in practice as viable. It is particularly useful if the binder that is used for the bonding of the filler 6, at the same time with the plastic film 3 is welded. This makes the manufacturing process effective, because both the bonding and the welding or the thermobonding can be made factory and in a single operation. It is also to be regarded as preferred that at least two layers of the decoupling mat are bonded together by gluing, wherein the adhesive is preferably a thermoplastic such as polypropylene or ethylene-vinyl acetate copolymer. Furthermore, it is preferred that at least two layers of the decoupling mat are connected by thermobonding.

Furthermore, the present invention relates to a structure, in particular for a plate-covered floor structure, wherein the decoupling mat according to the invention with the side on which the deep-drawn forms are applied to a substrate and the decoupling mat, an adhesive or mortar is applied, which optionally with Plates, especially with concrete blocks, natural stone or tiles is occupied.

The substrate may be, for example, concrete, screed or a tile and plate covering, wherein the decoupling mat is preferably connected by a mortar or adhesive to the substrate. As a substrate, virtually any material is suitable.

By decoupling mat according to the invention a very good impact sound insulation is achieved. Without being bound by theory, it is believed that this is achieved in comparison to the prior art decoupling mats, in particular by the separation of the filler 6 from the deposited coating by the plastic film layer 2. By this invention essential design of the decoupling mat formation of sound bridges is avoided. Sound bridges, ie vibratory connections between sound-producing components, such as those produced by walking on the floor covering, transmit the vibrations to the ground, where the sound propagates as structure-borne sound and may possibly propagate throughout the structure. The combination of the plastic film layer 2 with the fabric or nonwoven layer 1 effectively prevents the formation of sound bridges. In a preferred embodiment, a decay noise reduction (ISO 140-8) of ΔL _w > 5 dB, preferably ΔL _w > 7.5 dB (assessed in accordance with ISO 717-2), is achieved by the decoupling mat according to the invention with a thickness of the mat of 10 mm.

Another object of the present invention is the use of the decoupling mat according to the invention for decoupling, sealing and impact sound insulation, wherein the decoupling mat is preferably used in a construction according to the invention.

The panel according to the invention is suitable for both the interior and the exterior and can be used for example in the interior of buildings as well as balconies and terraces.

The invention will be explained in more detail with reference to embodiments.

• Figur 1: einen Querschnitt durch die erfindungsgemäße Entkopplungsmatte entlang der Linie B-B aus der Figur 2 und
• Figur 2: einen Längsschnitt durch die Entkopplungsmatte entlang der Linie A-A aus der Figur 1 und
• Figur 3: einen Längsschnitt durch eine weitere Ausführungsform einer Entkopplungsmatte entlang der Linie A-A aus der Figur 1.

To show:

• FIG. 1 FIG. 2: a cross section through the decoupling mat according to the invention along the line BB from FIG FIG. 2 and
• FIG. 2 FIG. 2: a longitudinal section through the decoupling mat along the line A - A of FIG FIG. 1 and
• FIG. 3 FIG. 2: a longitudinal section through a further embodiment of a decoupling mat along the line AA of FIG FIG. 1 ,

After that the decoupling mat ( FIG. 1 ) made of a closed plastic film 3, which has a material thickness between 100 and 500 microns and is thus carried out rollable. The plastic film 1 is pressed into a specific structure. In this case, this structure results from a plurality of unilaterally deep-drawn forms 5, which are open to one side. Each unilaterally deep-drawn forms 5 is in cross section ( FIG. 2 ) has a circular shape and has a conically extending side wall 11 and a flat underside 8 (FIG. FIG. 1 ). These one-sided deep-drawn forms 5 ( FIG. 2 ) are arranged on several, in line to the line BB parallel cutting planes in series and at equal distances from each other. The one-sided deep-drawn forms 5 of an adjacent to the line BB parallel cutting planes CC are arranged offset from one another that the one-side deep-drawn forms 5 a sectional plane BB to the one-side deep-drawn forms 5 of the other sectional plane CC are in gap to each other. The diameter 12 of the one-sided deep-drawn forms 5 is so large and the distance 9 of two adjacent one-sided deep-drawn forms 5 so closely chosen that a flat, continuous base 4 is formed, all distances 9 have approximately the same width. Furthermore, the plastic film 3 ( FIG. 1 ) Cavities 10 resulting in a contiguous space.

The decoupling mat consists of a plurality of one-sided deep-drawn forms 5 which are filled with a filler 6 ( FIG. 1 ), wherein the filler is connected by a binder with the plastic film 3. The filler 6 is composed of a mixture of quartz sand and a binder. The filler 6 is thus bonded in its entirety and continue with the plastic film 3 and the plastic film 2. On the top and the bottom of the decoupling mat results in a flat and closed surface of the fabric or nonwoven layers 1 and 7.

In FIG. 3 becomes one too FIG. 2 illustrated alternative embodiment of the decoupling mat. Each one-sided deep-drawn expression 5 is executed in cross-section square. The one-sided deep-drawn forms 5 are on several in the line BB ( FIG. 3 ) parallel cutting planes arranged in series and at equal distances from each other. Here, the one-sided deep-drawn forms 5 of an adjacent to the line BB parallel cutting planes CC are arranged so that the one-sided deep-drawn forms 5 of a sectional plane BB to the one-side deep-drawn forms 5 of the other sectional plane CC are in series. The diameter 12 of the one-sided deep-drawn forms 5 is so large and the distance 9 of two adjacent one-sided deep-drawn forms 5 so closely chosen that a flat, continuous base 4 is formed, all distances 9 have approximately the same width.

Claims (12)

1. Decoupling mat for sealing and decoupling, and for solid-borne-sound insulation, comprising a plurality of layers in the following sequence:

   α) textile layer or non-woven layer (1),

   β) plastics film layer (2),

   γ) plastics film layer (3) with flat, coherent main area (4) and with, on one side, depressed areas (5) and cavities (10), where the coherent main area has been bonded to the plastics film layer (β), and where the depressed areas (5) have been filled with a filler (6), and the filler (6) is composed of a mixture of quartz sand with a binder,

   δ) textile layer or non-woven layer (7),

   where the decoupling mat is impermeable to water.
2. Decoupling mat according to Claim 1, characterized in that the depressed areas (5) have flat undersides (8) oriented parallel to the flat, coherent main area (4) and in a single plane.
3. Decoupling mat according to Claim 1 or 2, characterized in that the filler (6) and the plastics film layer (3) have been adhesive-bonded to one another.
4. Decoupling mat according to any of Claims 1 to 3, characterized in that in the plastics film layer γ) the distance between the edges of the depressed areas (9) on the flat, coherent main area (4) is at least 3 mm.
5. Decoupling mat according to any of Claims 1 to 4, characterized in that the thickness of the plastics film (3) of the plastics film layer γ) is from 100 to 500 µm.
6. Decoupling mat according to any of Claims 1 to 5, characterized in that at least two layers have been bonded to one another by adhesive bonding.
7. Decoupling mat according to any of Claims 1 to 6, characterized in that at least two layers have been bonded by thermobonding.
8. Decoupling mat according to any of Claims 1 to 7, characterized in that the textile layer or non-woven layer (1) and (7) of the layer α) and δ) are composed of a non-woven fabric, a textile, a fine-mesh woven fabric or a fine-mesh drawn-loop knitted fabric.
9. Decoupling mat according to any of Claims 1 to 8, characterized in that the thickness of the layer γ) is from 3 to 50 mm, preferably from 5 to 15 mm.
10. Decoupling mat according to any of Claims 1 to 9, characterized in that the compressive strength of the decoupling mat is greater than 0.2 N/mm².
11. Structure, in particular for a floor structure with top layer of material in sheet-, panel-, or tile-like form, characterized in that the decoupling mat according to any of Claims 1 to 10 has been applied, by way of side on which the depressed areas are located, to a substrate, and an adhesive or mortar has been applied to the decoupling mat.
12. Use of a decoupling mat according to any of Claims 1 to 10 for decoupling and sealing, and for solid-borne-sound insulation.

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