EP2812512A2

EP2812512A2 - Decoupling mat

Info

Publication number: EP2812512A2
Application number: EP12748417.8A
Authority: EP
Inventors: Winfried SUPANTSCHITSCH
Original assignee: Gebr Jaeger GmbH
Current assignee: Gebr Jaeger GmbH
Priority date: 2011-08-18
Filing date: 2012-08-09
Publication date: 2014-12-17
Anticipated expiration: 2032-08-09
Also published as: WO2013023990A2; ES2657925T3; WO2013023990A3; EP2812512B1; DE102012100004A1

Abstract

The invention relates to a decoupling mat (1) with a continuous, and if appropriate first, fleece layer (13) as support layer, on which island-like areas (14) of a solid material are formed, and with a cover sheet (15) covering the tops of the island-like areas (14), and also a decoupling mat (1) with a continuous plastic sheet (2) produced, for example, by thermoforming and having wells (3) open at one side, and a cover sheet (4) applied to the plastic sheet preferably in order to cover the wells, wherein the wells (3) are filled. In order to make available an advantageous decoupling mat, it is proposed that the wells (3) are filled with an absorbent hard material, for example expanded clay.

Description

isolation mat

The invention relates to a decoupling mat. Such decoupling mats, which are also referred to as support mats, have already become known in various respects. They are used in particular for laying ceramic coverings, such as tiles, in the thin bed process. The prior art is, for example, to refer to DE 38 37 564 AI. From this it is known to fill the bowls with ceramic bodies. From EP 1 726 715 AI it is known to make a filling with granular elastic material. From DE 299 24 180 Ul it is further known to fill the wells with mortar. Furthermore, a decoupling mat is known from WO 2010/105857 AI. The content of this document is hereby incorporated in full content in the disclosure of the present application, also to include features of the prior art document in claims of the present application. In particular, concerning the formation of the binder and / or the film layer having the cups and / or the cover layers and / or the sequence of the cover layers.

Based on the cited prior art, the invention is concerned with the task of specifying an advantageous decoupling mat. According to a first idea of the invention, a possible solution of the problem is given in a decoupling mat which has a continuous, optionally first nonwoven layer on which island-like regions of a solid material are exposed. are formed, and further one of the island-like areas on the top covering cover layer.

Such a decoupling mat is easy and inexpensive to produce. Nevertheless, it fulfills the basic requirements placed on such a decoupling mat.

A further possible solution of the problem is given according to a further inventive idea in a decoupling mat, which is formed with one, for example by deep drawing, one-sided open cups forming continuous plastic layer and a preferably applied to seal the cups on the plastic layer top layer, wherein the cups are filled. It is important that the wells are filled with an absorbent hard material such as expanded clay in particular. On the one hand, a desired stability is achieved by the hard material. On the other hand, the absorbency can help, especially if no completely moisture-tight closure of the wells is given to absorb residual moisture, possibly also residual moisture from the surrounding soil area. In particular, a kind of moisture buffer can be achieved hereby, which absorbs moisture in the event of an oversupply of these and in the case of periods of drought this then offset in time again.

In addition, an absorbent hard material may also be used to wick functional materials into the hard material. In particular, latent heat storage material, more preferably one based on paraffin and / or salt, is intended here. With regard to such possible latent heat storage materials, reference is made, for example, to WO 2004/061044 A1. The disclosure of this document in terms of composition the latent heat storage materials described therein is hereby incorporated in full in the disclosure of the present application, also to include features of this prior publication in claims of the present application.

With regard to the absorbent hard material, a gypsum material or silica, silicon dioxide, optionally also an aluminosilicate, such as kaolin, can be used, in particular a silica obtained from fossil diatoms (diatoms). In addition to such a mineral, fiber elements may also be included. For example, based on plastic, cellulose, ceramic, mineral wool, cotton or sheep's wool.

Additionally or alternatively, the invention also relates to a decoupling mat, preferably as it is assumed at the beginning, wherein it is important that the wells are filled with small-cut film and / or nonwoven material.

This material, as well as, in principle, the initially mentioned material, is further preferably provided with a binder, which possibly connects this to a cup filling an entire body when forming smaller body. In the case of said film parts or other example. Thermoplastic plastic parts, these parts can form the binder itself alone or in addition. By appropriate heating, they develop adhesive power to bake more parts together. Alternatively, the binder may also consist of a conventional adhesive, such as a polyurethane adhesive. A further teaching of the invention with respect to a decoupling mat, as provided above, also provides that the wells are filled with a material made of rigid foam. It may be particle foam or extruded rigid foam. The hard foam parts can be readily formed in adaptation to the shape of the cups. But they can also be composed of individual parts, which in turn are sintered together or connected to each other by means of a separate binder. Also preferred is a filling of a two-component hard foam.

With regard to the rigid foam, preference is given in particular to one having a density of from 25 kg / m ³ to 110 kg / m ³ , preferably in the range from 30 kg / m ³ to 90 kg / m ³ .

Additionally or alternatively, the filling may also be made of a biopolymer material. For example. one based on cellulose.

It can also be provided that the wells are alternately filled with different material, ie a bowl or a row of wells with, for example, hard foam, another bowl or a further row of wells with expanded clay, etc.

In particular, it can also be provided that individual wells are filled with one of the materials described here, others with another of the materials described here, again further, if appropriate, also with a conventional material, as mentioned above. With regard to the initially mentioned design, which has the named island-like regions of a solid material, it is further preferred that the cover layer is a second nonwoven layer. In addition to the second nonwoven layer, with regard to the cover layer, a continuous plastic film layer providing a desired moisture-proofing may also be provided. This plastic film layer is preferably below the second nonwoven layer, more preferably directly connected, for example, adhesively bonded, provided with the end face of the island-like regions provided. In addition, it can preferably be provided that a cover layer covering this first nonwoven layer is applied on the first nonwoven layer on the side facing away from the island-side regions. Thus, two layers are preferably provided directly above one another in this respect. This cover layer may be one, optionally third, nonwoven layer.

With regard to the island-like areas, an embodiment of foam is also preferred. Reference is made to the above-characterizing features for rigid foam, which is also preferred here. In particular, it can be expanded foam, for example expanded polypropylene or expanded polystyrene foam.

Instead of the first nonwoven layer may also be provided a textile layer such as a fabric layer. Also a grid situation. Also, in addition or alone, a so-called scrim position can be provided. With a mesh size of 6 x 6 mm. Suitable nonwovens are, for example, thermally bonded nonwovens, chemically bonded nonwovens, needled nonwovens or water-jet needled nonwovens. Likewise, a combination of fleece and reinforcing textile layer can be used. The fibers of the textile layer, in particular of a net-like structure, may be natural fibers, metal fibers or synthetic fibers and, for example, acrylic, polyethylene, polypropylene, polyester, polyamide or carbon fibers or combinations thereof. Preferably, the fibers are selected from the group of polyester fibers, polyester-polyethylene bicomponent fibers, and combinations thereof. Good results have been achieved with polyester fibers. It has been found that polyester fibers make a good bond with the binder and the foam.

With respect to the foam, the backsheet is preferably occupied by at least 50 percent, more preferably 70 percent of the total surface area or more, up to 98 percent.

The foam portions may be arranged in a certain pattern. For example, they may be provided in a regular or irregular form distributed on the carrier layer. For example, the island-like areas may have a square, rectangular or hexagonal basic shape.

With regard to the formation of the island-like regions, it is also not necessary for any material, in particular no foam material, to be present in interspaces between the island-like regions. It is only preferred that there be less thickness or density of the material such that there is flexibility with respect to these gaps. For example, it is preferred that the proportion of material in the interspaces is less than 10 percent, more preferably less than 5 percent, of the average material content in the foam island regions. The width of the interspaces between two island-like regions is preferably less than 50 mm, more preferably less than 10 mm, and more preferably less than 5 mm. A minimum distance can be seen for example at 0.1 or 0.2 mm.

The thickness of the island-like regions, ie transversely to an extension plane of the carrier layer, of the first nonwoven layer is preferably less than 50 mm, more preferably less than 25 mm and moreover preferably less than 15 mm. A minimum thickness can be seen at 0.2 to 0.5 mm.

For example, a largest width of an island-like region may be 2 to 20 mm.

The expanded foam particles more preferably comprise a binder. The binder helps to hold the foam material parts together and to bind to the carrier material, ie in particular the nonwoven material. The binder material may be selected from thermoplastic binders, such as PVA or thermoplastic acrylates. It is also possible to use biodegradable binders, such as, for example, starch or starch-based, PLA or certain PVA varieties for this purpose. Furthermore, a flame retardant can be provided.

Also in the above-described embodiment, a moisture-impermeable layer may be provided. For example, the first and / or second nonwoven layer may already be set to be moisture-impermeable, but be impregnated example. In addition, however, in addition to the first and / or second nonwoven layer, associated with this layer, a plastic film layer may be provided continuously. It is further preferred that the decoupling mat, irrespective of how it is otherwise constructed and which filling may have said cups, is under and / or, preferably, provided on the upper side with a layer which has a self-adhesive layer. This self-adhesive layer faces outwards. Furthermore, the self-adhesive layer can be provided with a cover layer, which is removed before installation.

The self-adhesive layer may be, for example, a layer of butyl rubber. The decoupling mat can also be designed to be complementary as a heating device. For example, further integrated, for example, between the plastic layer and the cover layer, an electrical resistance heating be included. This approximately consisting of a grid-like arrangement of heating wires. Also, for example, a heating coil for the passage of heating fluid, such as water, as it is basically known from underfloor heating, be integrated. This heating coil can initially also be arranged, for example, between the plastic layer and the cover layer. It can also be arranged using the spaces between the wells on the outside of the plastic layer.

Alternatively or additionally, the decoupling mat can also be designed to be favorable in terms of footfall sound insulation and / or damping. So it is preferred, above and below a soft elastic layer, possibly also replace the cover layer, to arrange. The soft-elastic layer may also be a lattice part. It may also be a composite layer, such as a nonwoven layer and a rubber or foam layer

In the following, the invention will be explained further with reference to the attached drawing, which, however, represents only one embodiment. 1 shows a typical section of a decoupling mat of a first

Embodiment, partially unfolded with regard to the layers, in a perspective view;

FIG. 2 shows an illustration of a filling body for a cup in a single representation; FIG. a cross section through a decoupling mat, in the installed state, second embodiment; 4 is a cross-sectional view of a decoupling mat of another embodiment; and

Fig. 5 is a plan view of the article according to Figure 4, after removal of the cover layer.

Shown and described is a decoupling mat 1, which consists in the embodiment of a plastic layer 2, in which, in the embodiment by deep drawing, 3 wells are formed, the one of here partially unfolded cover layer 4 are covered. They are thereby also closed. The plastic layer 1 may be formed starting from a plastic film. For example, a film with a thickness of 0.2 to 2 mm. Below the wells 3, based on the embodiment of Figure 1, a final layer 5 is provided as the lowest layer, which is formed in the embodiment as a nonwoven layer. It may, for example, also be a fabric layer. On the upper side, over the cover layer 4, a further cover layer 6 is provided, which is also formed in the embodiment as a nonwoven layer or, for example, fabric layer.

The cups 3 can now be filled in different ways.

Such a filling body 7 resulting from filling, and possibly also arrest according to a binder provided in the filling material, passing through this, is shown in FIG. 2. Preferably, the filling body 7 results only within and in cooperation with the wells 3. It can also be prepared as a separate body, as shown in Fig. 2, and are used to fill the wells 3 in this.

Also, the filler 7 in the manufacturing state by an upper layer 8, which may be initially made in one piece with the packing 7, be connected. The layer 8 may also be formed only net-like. In particular, they can also be formed from the same material from which the filling bodies are made.

Such a filler 7 may consist of an absorbent hard material such as expanded clay in particular. Expanded clay is a clay material that preferably calcareous. Incorporate first contained organic ingredients, so that the material inflates. It may, for example, reach four to five times the initial volume. While a core of such expanded clay granules, which is usually more or less spherical, may be closed-pored, the surface is porous. Such expanded clay granules may have a diameter of 2 mm to 40 mm, for example, with regard to individual granulate bodies.

Furthermore, the filling material may consist of a small-scale composite material made of plastic film and / or nonwoven. In particular circled such material.

The expanded clay material as well as the said further material may be connected to the filler body 7 with a binder. The binder can be an adhesive, such as a polyurethane adhesive or a

Polyolefin-based adhesive, act. But it may also be heated to plasticity parts of the composite itself. Also, a pressure-sensitive adhesive can be used. Furthermore, the bonding can be achieved by appropriate heating of blended thermoplastic plastics, in particular plastic small parts.

In the case of a filling of hard foam material, in particular of the mentioned particle foam or extruded foam, preferably no binder is contained in the filling. As is known, in the case of particle foam, the parts are sintered to one another.

Furthermore, in particular, the parts mentioned could be prefabricated from rigid foam and used only in the wells. You can, however, then also be glued to it by means of an adhesive with the wells. But you can also be welded to the wells, for example by thermal loading. In the embodiment and arrangement shown schematically in Fig. 3 in the installed state of a decoupling mat 9 second embodiment, the trained in the plastic layer 2 wells 3 are arranged opening down. They are covered on the underside by a nonwoven layer 10, which allows a corresponding moisture exchange with the fillers 7 located in the wells 3. In particular, said capillary material such as expanded clay thus allows a moisture exchange with the ground, in particular an absorption of excess moisture.

With regard to the embodiment according to FIG. 3, although this may also be provided in the embodiment according to FIG. 1, it is also indicated that the cover layer 4 has a butyl layer 11 suitable for self-adhesion on the upper side. This butyl layer 11 is again covered by a decal 12.

With reference to FIGS. 4 and 5, a further embodiment of a decoupling mat is explained.

The cross section in Figure 4 shows a decoupling mat with a lower first nonwoven layer 13 as a carrier layer. On the carrier layer 13 are island-like areas

14 trained. These island-like regions 14 are made of expanded foam particles, for example EPP.

Above the island-like region 14 and this overlapping is a cover layer

15 attached. The cover layer 15 is also glued or fused with the End face of the island-like regions 14. The island-like regions 14 are also glued or fused to the carrier layer thirteenth

The cover layer 15 in the embodiment also consists of a nonwoven layer.

FIG. 5 shows the article according to FIG. 15, with the cover layer 15 removed.

It can be seen that the island-like regions 14 have a hexagonal outline. Between two island-like regions 14, a gap 16 is formed. The intermediate space 16 is circumferential, preferably in each case, provided with respect to an island-like region 14.

The layers indicated by the reference symbols 17 and 18 are intended first to illustrate only the connection, in particular bonding, between the first nonwoven layer 13 and the cover layer 15 with the island-like regions 14. It may be at the bearing 17 and / or the layer 18 to a separate adhesive layer. However, it can also be just a connection directly between the island-like areas and the first nonwoven layer 13 or the top layer 15 according to lamination. For example, by thermal melting of thermoplastic fibers in the nonwoven layer, which then result in a direct connection to the island-like areas.

Between the island-like regions 14 and the first nonwoven layer 13 or facing away from the island-like regions 14 on the first nonwoven layer 13, a continuous plastic film layer may also be provided for moisture separation. Such a plastic film layer can be complementary or alternative also be provided between the top of the island-like regions 14 and the underside of the cover layer 15 and / or the top side on the cover layer 15.

With regard to disclosure, the specified ranges or value ranges also include all intermediate values, in particular in one-tenth

Steps of the respective dimension, so also possibly dimensionless, for example, in terms of the density, for example, a range of 25.1 kg / m ³ to 110 kg / m ³ or 25 kg / m ³ to 109.9 kg / m ³ or 25.1 kg / m ³ to 109.9 kg / m ³ , etc., the same also applies, for example, with regard to the indicated film thickness and other dimensions and weights or ratios which are specified, on the one hand to delimit the stated range limits from below and / or above, alternatively or additionally, but also with regard to the disclosure of one or more singular values from a respective specified range.

All disclosed features are essential to the invention. The disclosure of the associated / attached priority documents (copy of the prior application) is hereby also incorporated in full in the disclosure of the application, also for the purpose of including features of these documents in claims of the present application. The subclaims characterize in their optional sibling version independent inventive development of the prior art, in particular to make on the basis of these claims divisional applications. Reference list

1 decoupling mat

2 plastic layer

3 bowls

4 top layer

5 final position

6 top layer

7 packing

8 location

9 decoupling mat

10 fleece layer

11 self-adhesive layer

12 decal

13 carrier layer

14 island-like area

15 top layer

16 space

17 location

18 location

Claims

1. decoupling mat (1) with a continuous, possibly first, nonwoven layer (13) as a carrier layer on which island-like regions (14) of a solid material are formed, and one of the island-like regions (14) covering the upper side cover layer (15).

2. decoupling mat (1) with a, for example by deep drawing, one-sided open wells (3) having continuous plastic layer (2) and preferably applied to seal the cups on the plastic layer cover layer (4), wherein the wells (3) filled are, characterized in that the cups (3) are filled with an absorbent hard material such as expanded clay.

3. decoupling mat according to the features of the preamble of claim 2 or claim 2, characterized in that the wells (3) with small cut plastic material film and / or fleece are filled.

4. decoupling mat according to the features of the preamble of claim 2 or according to any one of claims 2 or 3, characterized in that the cups (3) are filled with a material made of rigid foam.

5. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the rigid foam is a particle foam.

6. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the rigid foam is extruded foam.

7. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the cover layer is a second nonwoven layer.

8. decoupling mat according to one or more of the preceding claims or in particular, characterized in that on the first nonwoven layer on the island-like areas (14) facing away from this first nonwoven layer (13) covering cover layer is applied.

9. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the cover layer is an optionally third, nonwoven layer.

10. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the in-like regions (14) are formed from foam.

11. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the island-like regions (14) are formed from a rigid foam.

12. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the rigid foam is an expanded foam such as EPP or EPS.

13. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the cover layer (6) is a nonwoven layer.

14. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the cups (3) in the installed state are downwardly open and only by a moisture-permeable upper layer (5) are separated from the ground.

15. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the cover layer (4) with a self-adhesive layer (11) is provided.

16. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the self-adhesive layer (11) is a butyl layer.

17. decoupling mat according to one or more of the preceding claims or in particular according thereto, characterized in that the filling of the cups (3) is provided with a binder.