U.S. patent application number 11/372674 was filed with the patent office on 2006-09-14 for carrier tile consisting of film-like plastic.
Invention is credited to Hermann Hartl, Werner Saathoff.
Application Number | 20060201092 11/372674 |
Document ID | / |
Family ID | 36580559 |
Filed Date | 2006-09-14 |
United States Patent
Application |
20060201092 |
Kind Code |
A1 |
Saathoff; Werner ; et
al. |
September 14, 2006 |
Carrier tile consisting of film-like plastic
Abstract
The invention relates to a carrier tile consisting of film-like
plastic for a floor, wall or ceiling structure, in particular a
tile-clad wall or floor structure, for achieving decoupling between
the base and a surface cladding to be applied to the film-like tile
which has a multiplicity of chambers which are formed by
depressions out of a plane of the carrier tile and the outer end
faces of which form the first tile side, the depressions being
designed for receiving a curing contact means, such as mortar or
adhesive, provided for forming a contact layer with the surface
cladding to be applied, and with a net-like fabric or nonwoven
arranged on the first tile side, wherein the chambers between the
first and an opposite tile side have an undercut-free wall portion,
and wherein a net-like fabric overlapping the depressions is
provided on the opposite tile side.
Inventors: |
Saathoff; Werner;
(Bodmann-Ludwigshafen, DE) ; Hartl; Hermann;
(Haiterbach, DE) |
Correspondence
Address: |
KRIEGSMAN & KRIEGSMAN
30 TURNPIKE ROAD, SUITE 9
SOUTHBOROUGH
MA
01772
US
|
Family ID: |
36580559 |
Appl. No.: |
11/372674 |
Filed: |
March 10, 2006 |
Current U.S.
Class: |
52/385 ;
52/389 |
Current CPC
Class: |
E04F 13/047 20130101;
E04F 15/186 20130101; E04F 15/18 20130101; E04F 13/00 20130101;
E04F 15/185 20130101; E04F 15/182 20130101 |
Class at
Publication: |
052/385 ;
052/389 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 11, 2005 |
DE |
20 2005 004 127.0 |
Claims
1. Carrier tile consisting of film-like plastic for a floor, wall
or ceiling structure, in particular a tile-clad wall or floor
structure, for achieving decoupling between the base and a surface
cladding to be applied to the film-like tile which has a
multiplicity of chambers which are formed by depressions out of a
plane of the carrier tile and the outer end faces of which form the
first tile side, the depressions being designed for receiving a
curing contact means, such as mortar or adhesive, provided for
forming a contact layer with the surface cladding to be applied,
and with a net-like fabric or nonwoven arranged on the first tile
side, wherein the chambers between the first and an opposite tile
side have an undercut-free wall portion, and wherein a net-like
fabric overlapping the depressions is provided on the opposite tile
side.
2. Carrier tile according to claim 1, wherein the wall portions of
the chambers are arranged vertically between those end faces of the
chambers which form one tile side and the surface portions which
connect the chambers and which form the opposite tile side.
3. Carrier tile according to claim 1, wherein wall portions between
those end faces of the chambers which form one tile side and
surface portions which connect the chambers and which form the
opposite tile side extend so as to narrow conically towards the end
faces of the chamber.
4. Carrier tile according to claim 3, wherein the inclination of
the wall portions is less than 20.degree..
5. Carrier tile according to claim 1, wherein the net-like fabric
covering the depressions is glued to the surface portions of the
tile side.
6. Carrier tile according to one of claims 1 to 4, wherein the
net-like fabric covering the depressions is welded to the surface
portions of the tile side.
7. Carrier tile according to claim 1, wherein the net-like fabric
covering the depressions is produced from a thermoplastic.
8. Carrier tile according to claim 7, wherein the net-like fabric
is made of high-density polyethylene.
9. Carrier tile according to claim 1, wherein the net-like fabric
covering the depressions has a mesh width of at least 0.04
mm.sup.2.
10. Carrier tile according to claim 1, wherein the net-like fabric
covering the depressions has a mesh width of 0.5 to 5 mm.sup.2.
11. Carrier tile according to claim 1, wherein the net-like fabric
covering the depressions is produced from rovings welded to one
another in a grid-like manner.
12. Carrier tile according to claim 11, wherein the rovings are in
twisted form.
13. Carrier tile according to claim 1, wherein the mesh width of
the net-like fabric or nonwoven is designed to be smaller than a
surface portion between two chambers.
Description
[0001] The invention relates to a carrier tile consisting of
film-like plastic for a floor, wall or ceiling structure, in
particular for a tile-clad wall or floor structure, for achieving
decoupling between the base and the surface cladding to be applied
to the film-like tile.
[0002] Tile coverings are often laid by what is known as the
thin-bed method, a suitable contact adhesive being used in order to
fix the tile coverings to the base. On account of different thermal
expansions of the cladding and of the base and the associated
stresses, cracks may occur in the surface cladding and may cause
parts of the surface cladding to come loose.
[0003] To reduce such stress differences, according to DE 37 04 414
A1, a carrier plate consisting of film-like plastic was proposed,
which comprises dovetailed grooves which are open alternately on
both sides and which can be moved transversely with respect to the
run of the grooves under compressive and tensile stress. A net-like
nonwoven is provided on one side of the carrier tile, in order to
connect the carrier tile to the base, such as, for example, screed,
and to achieve higher adhesion with an adhesive. This carrier tile
has the disadvantage that it is expandable or compressible only in
a limited direction, to be precise transversely with respect to the
longitudinal extent of the dovetailed grooves. The necessary stress
reduction is often not possible by means of such a carrier
tile.
[0004] In order to allow stress reduction in both directions,
according to DE 299 24 180 U1, a carrier tile was proposed, which
comprises on one tile side intersecting embossings which in each
case form circumferentially closed chambers. The chambers serve for
receiving an adhesive or mortar, thus giving rise to an intimate
bond with the adhesive or mortar layer and with the surface
cladding applied to it. By virtue of these intersecting embossings,
a film-like tile is proposed which is expandable or contractable at
least to a slight extent in both directions of its plane of extent,
so that stress differences arising from the base and the cladding
can be absorbed by the carrier tile. In addition, the chambers have
undercuts, with the result that the adhesive or mortar stilts
introduced into the chambers hook together with the undercuts of
the chambers.
[0005] This embodiment has the disadvantage that, in the region of
the undercut, the mortar stilts have a necking with respect to the
contact surface in the bottom of the chambers, and that, in the
region of the undercut, there is a cracking of the contact elements
introduced in the chambers, these contact elements coming loose
from the mortar layer lying above them. The positive cramping
achieved initially by means of the undercut is loosened due to the
formation of cracks in the necking plane. The intimate bond is no
longer afforded, and the stress reduction between the base and the
cladding is no longer possible.
[0006] The object on which the invention is based is, therefore, to
propose a carrier tile consisting of film-like plastic for floor,
wall or ceiling construction, in particular for tile-clad wall or
floor construction, by means of which an improvement in the
decoupling or reduction of different stresses between the base and
surface cladding becomes possible.
[0007] This object is achieved, according to the invention, by
means of a carrier tile according to the features of claim 1. This
carrier tile according to the invention has chambers formed from
depressions and possessing undercut-free wall portions, the
depressions of the chambers being covered or overlapped by a
net-like fabric. As a result of the undercut-free design of the
wall portions, there is in the respective chamber no
cross-sectional narrowing of mortar or adhesive stilts which enters
the chamber in spite of the net-like fabric. There is therefore an
improved force flux for dissipating the forces under vertical loads
acting from above, and cracking in the transitional region between
the mortar stilts and the sheet-like mortar layer is prevented. The
net-like fabric ensures that the adhesive or mortar layer, which is
suitable, for example, for flags, fine-stoneware slabs, ceramic or
clay tiles or tiles consisting of further materials, such as
plastics, wood, cork or the like, bonds with the tile side to which
the net-like fabric is applied. What is additionally achieved is
that the net-like fabric is stretched out or tied in between the
mortar or adhesive layer receiving the surface cladding and the
contact elements or mortar stilts and forms a cramping.
Alternatively, a surface cladding, such as, for example, plaster,
can also be applied directly, which is anchored firmly with the
net-like fabric and is decoupled from the base. By virtue of this
embodiment according to the invention of the carrier tile, an
optimum reduction of stresses which occur and permanent decoupling
between the base and a surface cladding are achieved.
[0008] According to a first advantageous embodiment of the
invention, there is provision for the chamber-wall portions to
extend vertically between the end faces forming one tile side and
the opposite tile side which is formed by surface portions
connecting the chambers. Column-shaped contact elements can thereby
be formed. The area in horizontal projection or the form of the
chamber may in this case be configured with any desired geometry.
For example, triangular or polygonal or even round areas in
horizontal projection of the chambers may be formed.
[0009] According to an alternative embodiment of the invention,
there is provision for the wall portions to have a conical run
between one tile side and the opposite tile side, these wall
portions narrowing from one tile side, which is formed by the
surface portions connecting the chambers, to the other tile side,
which is formed by the end faces of the chambers. These conical
surfaces make it easier for the mortar or adhesive to be introduced
completely into the chambers for complete filling-up with mortar or
adhesive.
[0010] The inclination of the conically running wall portions is
advantageously provided at an angle of less than 20.degree.. This
optimizes force absorption, on the one hand, and the filling of the
chambers, on the other hand.
[0011] The net-like fabric covering the depression of the chambers
is advantageously glued to the surface portions of the one tile
side which connect the chambers. As a result, different materials
may be selected for the net-like fabric and for the carrier tile
consisting of film-like plastic. Furthermore, gluing affords the
advantage that the net-like fabric projects slightly with respect
to the surface portions, and additional meshing with the adhesive
or mortar layer adhering to the surface cladding becomes
possible.
[0012] According to an alternative embodiment of the invention,
there is provision for the net-like fabric covering the depressions
to be welded to the surface portions connecting the chambers. It
thereby becomes possible for the net-like fabric and the carrier
tile to be connected, in the contact regions, so as to form a unit,
with the result that very high strengths can be achieved. At the
same time, the advantages of the glued-on embodiment of the
net-like fabric can be preserved. Alternatively, there may also be
provision for the net-like fabric to be embedded at least partially
into the tile side during the welding-on process.
[0013] To produce a fusion-welded joint between the net-like fabric
and the carrier tile, there is advantageously provision for the net
fabric to be produced from a thermoplastic. Such thermoplastics are
acid-resistant and have high strength.
[0014] According to a further advantageous embodiment of the
invention, there is provision for the net-like fabric overlapping
or covering the depressions to have a mesh width of at least 0.04
mm.sup.2, in particular 0.5 to 5 mm.sup.2. It thereby becomes
possible easily to introduce or fill the chambers with an adhesive
or mortar layer and with further flowable and curable materials. At
the same time, however, it is ensured that a sufficient number of
meshes overlap the depression or the chambers, in order to make it
possible to fix the adhesive or mortar stilts within each chamber.
Preferably, there is provision for at least two meshes to be
provided for each chamber. The size of the chamber and the mesh
width of the net-like fabric or nonwoven can in this case be
adapted to one another so as to afford optimum cramping.
[0015] The net-like fabric for covering the depressions is
preferably produced in the manner of a grid from rovings welded to
one another. In this case, there is provision for the net-like
fabric to have identical tensile strengths in both directions of
the plane of extent, in order to allow a uniform stress
reduction.
[0016] The rovings for the net fabric are preferably formed from
twisted individual fibres, in order to have a high compressive
strength.
[0017] According to a further embodiment of the invention, there is
provision for the mesh width of the net-like fabric or nonwoven to
be designed to be smaller than a surface portion between two
chambers. As a result, at least two intersecting fibres of the
fabric or at least one warp and one weft of the fabric can be
welded or glued to the surface portion. The free orifice of the
chamber can thereby be spanned by a tauter fabric or nonwoven
portion.
[0018] The invention and further advantageous embodiments and
developments of this are described and explained in more detail
below by means of the examples illustrated in the drawings. The
features to be gathered from the description and the drawings may
be used, according to the invention, individually in themselves or
severally in any desired combination. In the drawings:
[0019] FIG. 1 shows a perspective illustration of the carrier tile
according to the invention,
[0020] FIG. 2 shows a diagrammatic top view of the carrier
tile,
[0021] FIG. 3 shows a diagrammatic sectional illustration of a
carrier tile according to the invention in an installation
situation for the decoupling of stress differences, and
[0022] FIG. 4 shows a diagrammatic sectional illustration of an
alternative embodiment of the carrier tile in an installation
situation according to FIG. 1.
[0023] A carrier tile 11 according to the invention is illustrated
in perspective in FIG. 1. The carrier tile 11 consists of a plastic
film which has a multiplicity of chambers 12 formed by depressions
14 of the plastic film. The chambers 12 are produced, for example,
by vacuum forming or deep drawing. The carrier tile 11 has a
multiplicity of chambers 12, which are arranged in a plurality of
rows and columns or in defined patterns with respect to one
another. Surface portions 16 which connect the chambers 12 to one
another are formed between the depressions 14. According to the
first embodiment, wall portions 18 arranged perpendicularly with
respect to these surface portions 16 extend from the latter and
merge into a bottom 19 forming with an outer end face 21 a first
tile side 22. The end faces 21 of the chambers 12 have glued to
them a net-like fabric or nonwoven 23 which serves for cramping the
carrier tile 11 in a contact layer applied to a base. The net-like
fabric or nonwoven 23 is designed as a fine-mesh grid fabric or as
a perforated nonwoven and is secured to the end faces 21 of the
chambers 12 by means of an adhesive bond. The fabric or nonwoven is
produced, for example, from polypropylene.
[0024] A second tile side 26 is formed, opposite the first tile
side 22, by the surface portions 16 connecting the chambers 12.
This tile side 26 has applied to it a further net-like fabric 27 or
nonwoven which differs from the net-like fabric or nonwoven 23
applied to the first tile side 22. This net-like fabric or nonwoven
27 applied to the second tile side 26 is designed with a coarse
mesh and is connected to the surface portions 16 by means of an
adhesive bond or a welded joint. The net-like fabric 27 extends
with its meshes over the depressions 14 of the chambers 12.
Preferably, the net-like fabric 27 is produced from the same
material as the carrier tile 11. For example, HDPE plastic is used.
The tearing or tensile strength of the fabric 27 is at least 250
N/5 cm. Furthermore, the fabric 27 preferably has an expandability
of at least 5%, so that there is some elasticity for decoupling and
in the event of temperature fluctuations.
[0025] The chambers 12 illustrated in FIG. 1 have a circular bottom
19 and an end face 21 and are of column-like or cylindrical design.
Alternatively to the round area in horizontal projection,
triangular, square or polygonal areas in horizontal projection or
lozenge-shaped or trapezoidal areas in horizontal projection may
also be provided.
[0026] FIG. 2 illustrates a top view of the carrier plate 11
according to the invention, as shown in FIG. 1. The net-like fabric
27 on the second tile side 26 has a mesh width which makes it
possible to introduce mortar or adhesive into the chamber 12
virtually without obstruction. A mesh width of the fabric of at
least 0.04 mm.sup.2 is preferably provided. For the easy
introduction of a tile adhesive or mortar, in particular, a mesh
width of 0.5 mm.sup.2 to 5 mm.sup.2 is provided. That surface of
the depression 14 which is to be covered is adapted to the mesh
width of the fabric 27, so that at least two meshes overlap the
depression 14. A sufficiently taut overlap of the depression 14 by
the net-like fabric 27 thereby becomes possible.
[0027] FIG. 3 illustrates a diagrammatic sectional illustration of
the carrier tile 11 according to the invention, as shown in FIGS. 1
and 2, in an installation situation. An adhesive or mortar 32 is
applied to a base 31. After this, the carrier tile 11 is laid out
with the fine-mesh net-like nonwoven 23 on the base 31. The mortar
32 is cramped in the fine-mesh net-like nonwoven 23 which may be
produced from a plastic or natural fibre material. The net-like
nonwoven 23 is designed in such a way that, when the carrier tile
11 is laid out, there is no penetration of the mortar into regions
33. Air circulation in these free spaces 33 can thereby take
place.
[0028] After the carrier tile 11 has been laid out and secured on
the base 31, an adhesive or mortar 34 is introduced on to the
carrier tile 11 and may deviate in consistency from the mortar or
adhesive 32. In this case, the mortar 34 is introduced through the
coarse-mesh net-like fabric 27 for filling into the chamber 12. At
the same time, the mortar layer is hooked on the grid-like
coarse-mesh fabric 27 which is provided on the surface portions 16.
After this, tiles 36 for forming a surface cladding 37 are applied
to the mortar layer 34. After the curing of the mortar 34, the
surface cladding 37 is finished by the introduction of joints
38.
[0029] The mortar layer 34 forms, in the chambers 12, contact
elements or mortar stilts which allow load dissipation.
Furthermore, shear forces which occur between the base 31 and the
surface cladding 37 are decoupled by means of the carrier tile 11.
The net-like fabric 27 crosses the mortar stilt and makes it
possible to stabilize and stiffen the mortar stilt, since the
net-like fabric 27 acts as a reinforcement. As a result, the
strength of the bond can be increased, and at the same time the
formation of cracks can be reduced due to the stress
decoupling.
[0030] FIG. 4 illustrates an installation situation of an
alternative embodiment of the carrier tile 11 according to the
invention. This carrier tile 11 deviates from the carrier tile 11
according to FIG. 2 in the form of the chambers 12. The other
features are identical, and therefore reference is made to the
preceding figures. The carrier tile 11 according to FIG. 4 has
conical wall portions 18 which narrow towards the bottom 19. Thus,
as seen in cross section, in the case of a round bottom 19
frustoconical chambers 12 are formed. Alternatively, triangularly
or polygonally designed forms of the bottom 19 and of the
depression 14 or orifice to the depression 14 may also be produced.
As a result of the even slight reduction in the bottom area 19 with
respect to the depression 14 in the region of the surface portion
16, the complete filling of the chamber 12 with mortar 34 can be
facilitated. These cross-sectional forms of the chambers 12
likewise allow optimum load dissipation, a decoupling of stress
differences and a reduction or prevention of the formation of
cracks in the layer formed by the adhesive or mortar 34.
* * * * *