U.S. patent application number 16/604455 was filed with the patent office on 2020-05-14 for decoupling sheet.
The applicant listed for this patent is EWALD DORKEN AG. Invention is credited to Thomas BACHON, Vasco GERACE, Ulrich GOERKE, Uwe KAISER, Tim Simon KROFFGES, Heinz Peter RAIDT, Birgit STRIEDER.
Application Number | 20200149291 16/604455 |
Document ID | / |
Family ID | 62245211 |
Filed Date | 2020-05-14 |
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United States Patent
Application |
20200149291 |
Kind Code |
A1 |
KAISER; Uwe ; et
al. |
May 14, 2020 |
DECOUPLING SHEET
Abstract
The invention relates to a decoupling sheet (1) having a carrier
plate (2) and a plurality of nubs (4) protruding from the carrier
plate plane (3). According to the invention, a plurality of
protrusions (21a) and/or recesses (21b) is provided on the side of
the nub base (10) of at least one nub (4) facing toward the nub
interior space (20) and/or a plurality of protrusions (21c) and/or
recesses (21d) is provided on the side of the carrier plate (2)
facing toward the nub interior space (20), especially wherein the
protrusion (21a) and/or the recess (21b) on the nub base (10)
and/or the protrusion (21c) and/or the recess (21d) on the carrier
plate (2) has a height and/or a depth greater than 1 .mu.m,
preferably greater than 100 .mu.m, further preferably between 100
and 1000 .mu.m and especially at least substantially between 300
and 500 .mu.m.
Inventors: |
KAISER; Uwe; (Herdecke,
DE) ; GERACE; Vasco; (Hagen, DE) ; KROFFGES;
Tim Simon; (Herdecke, DE) ; STRIEDER; Birgit;
(Bochum, DE) ; RAIDT; Heinz Peter; (Dortmund,
DE) ; GOERKE; Ulrich; (Herdecke, DE) ; BACHON;
Thomas; (Dusseldorf, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EWALD DORKEN AG |
Herdecke |
|
DE |
|
|
Family ID: |
62245211 |
Appl. No.: |
16/604455 |
Filed: |
April 23, 2018 |
PCT Filed: |
April 23, 2018 |
PCT NO: |
PCT/EP2018/060325 |
371 Date: |
October 10, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 15/182 20130101;
E04F 15/0215 20130101; E04F 15/186 20130101; E04F 15/185 20130101;
E04F 15/02194 20130101 |
International
Class: |
E04F 15/02 20060101
E04F015/02 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 26, 2017 |
DE |
10 2017 004 002.8 |
Claims
1. A decoupling sheet having a carrier plate and a plurality of
nubs protruding from the carrier plate plane, wherein a plurality
of protrusions and/or recesses is provided on the side of the nub
base of at least one nub facing toward the nub interior space
and/or a plurality of protrusions and/or recesses is provided on
the side of the carrier plate facing toward the nub interior space,
especially wherein the protrusion and/or the recess on the nub base
and/or the protrusion and/or the recess on the carrier plate has a
height and/or a depth greater than 1 .mu.m, preferably greater than
100 .mu.m, further preferably between 100 and 1000 .mu.m and
especially at least substantially between 300 and 500 .mu.m.
2. The decoupling sheet according to claim 1, wherein more than 20,
preferably more than 100, further preferably more than 1000,
preferably more than 10000 protrusions and/or recesses are
provided, wherein the protrusions and/or recesses, are arranged in
an irregular or unordered manner preferably on both the nub base
and on the carrier plate.
3. The decoupling sheet according to claim 1, wherein at the
protrusions and/or the recesses form a structured surface of the
nub base and/or the carrier plate and/or the protrusions and/or
recesses comprise different shapes and/or structures and/or at
least one protrusion at least one recess comprises at least one
shaping, especially a sickle shape and/or an arc segment shape
and/or a crescent shape, to form an undercut.
4. The decoupling sheet according to claim 1, wherein the nub has
multiple legs, especially wherein a plurality of protrusions and/or
recesses is provided on the leg bottom of a leg and/or nubs
immediately adjacent transversely to the lengthwise direction and
in the lengthwise direction of the carrier plate have a triaxial
nub base, especially one with at least three leg sides.
5. The decoupling sheet according to claim 1, wherein the
protrusion and/or recess on the nub base is formed in the shape of
a spiral and/or an arc segment and/or a protrusion in shape of a
spiral and/or recess is provided in the middle region of the nub
base.
6. The decoupling sheet according to claim 1, wherein protrusions
and/or recesses in the shape of an arc segment are provided about
the center point of the nub on the leg bottom, concentric to the
middle region, and/or the protrusions and/or recesses of the nub
base are web-like and/or have a rectangle shape and/or ellipse
shape.
7. The decoupling sheet according to claim 1, wherein web-like
and/or rectangular and/or elliptical protrusions and/or recesses on
the nub base are oriented transversely and/or longitudinally to the
lengthwise direction of the carrier plate and/or a plurality of
protrusions and/or recesses are provided on the carrier plate and
the protrusions and/or recesses are arranged in rows running
longitudinally and transversely to the lengthwise direction of the
carrier plate and/or the protrusions and/or recesses of the carrier
plate are web-like and/or of rectangle and/or ellipse shape and/or
the protrusions and/or recesses of the carrier plate are elongated
and oriented by their longitudinal extension solely transversely
and/or longitudinally to the lengthwise direction of the carrier
plate and/or protrusions and/or recesses running in a row
transversely and/or longitudinally to the lengthwise direction of
the carrier plate are arranged in alternating orientation.
8. The decoupling sheet according to claim 1, wherein at least one
nub having a triaxial nub base is provided with three long sides
and the middle region of the triaxial nub base is defined by a
circle which all the long sides contact tangentially.
9. The decoupling sheet according to claim 1, wherein the nub has a
concave shape on at least one long side.
10. The decoupling sheet according to claim 1, wherein at least one
shaping especially in the form of a sickle and/or an arc segment
and/or a crescent is formed in the region of the long side and/or
leg side of the nub in order to form an undercut on the interior of
the nub, wherein the shaping is particularly formed by a protrusion
protruding out from the nub interior space.
11. The decoupling sheet according to claim 1, wherein the
protrusion is provided in the region of the nub base, in particular
that it passes directly into the nub base and/or the shaping
extends for at least 40%, preferably between 50% and 100% and
especially between 60% and 90%, of the long side and/or the leg
side.
12. The decoupling sheet according to claim 1, wherein the end
region formed by two converging long sides is free of undercuts
and/or the nub is formed rounded and without corners at least at
one end region resulting from two converging long sides and/or the
radius of a long side is multiple times longer than the radius of
an end region, preferably the radius of a long side is twice as
large as the radius of an end region.
13. The decoupling sheet according to claim 1, wherein the nub
and/or the triaxial nub base has mirror symmetry with respect to a
center axis running at least substantially parallel to the
lengthwise direction and/or three spaced-apart legs are provided,
emerging from the middle region, wherein the angle of spaced-apart
leg axes is at least 90.degree. and/or the leg length of one leg,
especially that of the leg running parallel to the center axis, is
less than the other two leg lengths, and/or the angle of the leg
axis of the shorter leg with respect to the leg axis of the
adjacent leg is greater than 120.degree. and especially less than
130.degree..
14. The decoupling sheet according to claim 1, wherein nubs running
transversely to the lengthwise direction of the carrier plate are
arranged such that no straight line running transversely to the
lengthwise direction of the carrier plate is formed continuously on
the carrier plate and/or nubs running in the lengthwise direction
of the carrier plate are arranged such that no straight line
running in the lengthwise direction the carrier plate is formed
continuously on the carrier plate and/or nubs running
longitudinally and transversely to the lengthwise direction of the
carrier plate are arranged such that no straight line running at a
slant to the lengthwise direction of the carrier plate is formed
continuously on the carrier plate.
15. The decoupling sheet according to claim 1, wherein the nubs are
arranged in rows running in the lengthwise direction and transverse
direction, wherein the center points of the nubs running in the
lengthwise direction are arranged on a line running at least
substantially parallel to the lengthwise direction and/or the
center points of the nubs running transversely to the lengthwise
direction are arranged on a line running at least substantially
perpendicular to the lengthwise direction.
16. The decoupling sheet according to claim 1, wherein the shorter
leg of the nubs arranged in a row of successively arranged nubs
running at least substantially parallel to the lengthwise direction
is oriented in the lengthwise direction and the shorter leg of the
nubs arranged in the immediately adjacent row of successively
arranged nubs running at least substantially parallel to the
lengthwise direction is oriented opposite to the lengthwise
direction.
17. The decoupling sheet according to claim 1, wherein a flat
connection means is provided, in particular fastened, on the
outside of the nub base for connecting to the ground, and
preferably the connection means is embodied as a nonwoven and/or a
textile and/or paper and/or a scrim and/or a lattice, especially
across the entire surface and/or in a lattice shape.
18. The decoupling sheet according to claim 1, wherein the nub has
a height between 1 and 5 mm, preferably between 1 and 4 mm, further
preferably between 2.5 and 3.5 mm, and/or the clear gap between
adjacent nubs is greater than 2 mm, in particular, there is a clear
gap between 3 mm and 9 mm, preferably between 4 and 8 mm, further
preferably between 5 and 6 mm, and/or the ratio of the area of the
nub bases of all the nubs to the area of the carrier plate is
between 40% and 70%, preferably between 45% and 55% and especially
at least substantially 50%.
19. A method for production of a decoupling sheet having a carrier
plate and a plurality of nubs protruding from the carrier plate
plane, wherein a plurality of protrusions and/or recesses is placed
in the side of the nub base of at least one nub facing toward the
nub interior space and/or a plurality of protrusions and/or
recesses is placed in the side of the carrier plate facing toward
the nub interior space.
20. The method for production of a decoupling sheet according to
claim 19, wherein in that the nub bases immediately adjacent nubs
have a triaxial shape transversely to the lengthwise direction and
in the lengthwise direction of the carrier plate.
21. The method according to claim 19, wherein the protrusion and/or
the recess is made by a laser process, a plasma process, a
machining process, preferably blasting, especially using sand
and/or nutshells, and/or by embossing during and/or after the
production of the decoupling sheet.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage application under 35
U.S.C. 371 of PCT Application No. PCT/EP2018/060325 having an
international filing date of 23 Apr. 2018, which designated the
United States, which PCT application claimed the benefit of German
Application No. 10 2017 004 002.8, filed 26 Apr. 2017, each of
which are incorporated herein by reference in their entirety.
SUMMARY
[0002] The invention relates to a decoupling sheet having a carrier
plate and a plurality of nubs protruding from the carrier plate
plane.
[0003] In the present application, the term "decoupling" is
understood to mean the reduction of shear stresses and/or stress
peaks between two layers arranged in a fixed laminate. An effective
decoupling thus prevents shear stresses and/or stress peaks which
are present in one of the layers from being transmitted to the
other layer of the laminate structure and possibly causing damage
there.
[0004] Decoupling sheets of the aforementioned kind are used for
example in the construction industry when laying floors, especially
for decoupling, sealing, and/or vapor pressure equalization. The
decoupling sheets are installed, in particular glued, on an ground
and form the bearing layer for flooring elements such as ceramic
tiles. The installation of tiles is performed in particular on
young screed in the thin-bed method. If no decoupling sheet is
installed between the tiling and the young screed, upon shrinkage
of the screed the tiles might not follow the movement of the screed
especially on account of their low coefficient of expansion, so
that shear stresses will be created, ultimately leading to the
detachment or even the breaking of the tiles. Decoupling sheets are
also required when installing flooring on especially critical
grounds, such as old wooden floors. A decoupling sheet of the
aforementioned kind compensates for these shear stresses by
deforming, so that no damage to the laminate structure is to be
feared. Usually the decoupling sheets are made from filmlike
plastic, i.e., from a flexible plastic layer, which is deformed
under the action of external forces. The material is generally
chosen to be low in emissions, especially as regards harmful
substances.
[0005] For the attachment of the flooring elements to the
decoupling sheet, a thin layer of a tile adhesive, also known as
adhesive mortar or a bonding layer, is usually applied to the
bearing plane of the decoupling sheet. It is understood that, in
place of a tile adhesive, an equally suitable adhesive or fastening
layer and/or a corresponding material can also be provided. Tile
adhesives are usually combed with a notched trowel or a toothed
smoothing trowel, and a different tile adhesive will be used
according to the area of application and/or the ground. For
example, a reactive resin adhesive, a thin-bed cement mortar, a
casein tile adhesive or a dispersion adhesive will be used as the
tile adhesive.
[0006] After applying the tile adhesive to a decoupling sheet, the
individual flooring elements and/or tiles will be installed on the
tile adhesive. During this application, the tile adhesive
penetrates into the recesses of the decoupling sheet and becomes
hardened.
[0007] In decoupling sheets of this kind, the joined flooring
elements are separated from the ground and mechanically decoupled.
Thanks to the arrangement of the nubs transversely to the
lengthwise direction and in the lengthwise direction of the carrier
plate, channels arise which extend over the entire carrier plate.
These channels interact with the nubs so that they intercept and
compensate for mechanical loadings and particularly shear stresses.
This loading of the flooring elements can be created by means of
temperature and moisture influences and/or by the application of
weight.
[0008] In the manufacture of decoupling sheets of this kind, a
molding die having protrusions corresponding to the recesses and/or
nubs is used. The stripping of the molding die from the decoupling
sheet is usually problematic, however. Furthermore, the decoupling
sheet may become damaged during the mold stripping, especially if
the protrusions of the die have sharp edges which cut into the
usually still-soft decoupling sheet material and/or rip it open.
There have been attempts to solve the latter problem in practice by
providing the corners of the mold protrusions with a radius.
[0009] Decoupling sheets of the aforementioned kind are known for
example from EP 2 372 041 B1 and from EP 2 246 467 B1.
[0010] EP 2 372 041 B1 relates to a method for the production of a
carrier plate as well as to a carrier plate for a sheet-clad floor,
wall or ceiling assembly in order to achieve a decoupling between
the ground and the surface covering to be placed on top of the
filmlike sheet, the carrier plate comprising a filmlike sheet with
a plurality of chambers formed by recesses from one plane of the
filmlike sheet, whose end faces form a first sheet side and
opposite to this a second sheet side. A bond-strengthening layer of
a sheet-like material is placed at least on one sheet side, lining
at least the recesses of the chambers. The bond-strengthening layer
is supposed to aid in better decoupling and, furthermore, to aid in
better attachment of the tile adhesive. The recesses serve to
receive the tile adhesive, which is placed on the top side on the
bond-strengthening layer of the decoupling sheet. In the known
decoupling sheet, round, cylindrical and/or pot-shaped shapings are
provided as the recesses.
[0011] Instead of a bond-strengthening layer and/or in addition to
this, it is known from EP 2 246 467 B1 that an improved adherence
of the tile adhesive should be possible by applying a multitude of
fibers to the top side of the decoupling sheet, facing toward the
tile adhesive. The nubs and/or recesses of this known decoupling
sheet have a round, cylindrical and/or pot-like shape and are
accordingly rounded. The fibers applied to the top surface of the
decoupling sheet are permanently joined to this surface. The tile
adhesive in this case is placed into the recesses of the carrier
plate.
[0012] The decoupling sheets known from EP 2 372 041 B1 and EP 2
246 467 B1 have regularly arranged round, cylindrical shapings
which are arranged in rows and columns. Thanks to the arrangement,
channels are formed between the rows of nubs, extending over the
entire decoupling sheet. These channels are open toward the ground
and intersect with other channels. When the tile adhesive is
applied, the channels are only partly covered with a thin coat of
the tile adhesive, so that they form a weakening line which favors
a deformation of the decoupling sheet along this weakening line. In
an unfavorable arrangement, the lay of the joint of adjacent
flooring elements would coincide with a weakening line and/or
predetermined breaking point, so that hairline cracks and/or larger
damaged areas will arise in the tile mortar layer and/or in the
joint itself.
[0013] The drawback to the known decoupling sheets is that they
have deficient decoupling properties between the flooring elements
and the ground without the use of the additional bond-strengthening
layer and/or without additional fibers. The production of such
decoupling sheets is costly, since an additional step of applying
the bond-strengthening layer and/or additional fibers is provided
in order to increase the adherence between the tile adhesive and
the surface of the decoupling sheet facing toward the tile adhesive
layer.
[0014] Now, the problem which the present invention proposes to
solve is to provide a decoupling sheet which achieves an improved
grip of the tile adhesive on the decoupling sheet.
[0015] Furthermore, the problem which the present invention in
particular proposes to solve is to provide a simple and efficient
method for the production of a decoupling sheet.
[0016] The aforementioned problem is essentially solved according
to the invention in a decoupling sheet of the kind mentioned above
in that a plurality of protrusions and/or recesses is provided on
the side of the nub base of at least one nub facing toward the nub
interior space and/or a plurality of protrusions and/or recesses is
provided on the side of the carrier plate facing toward the nub
interior space.
[0017] Preferably, the structuring and/or the recesses and/or the
protrusions of the nub base and/or of the carrier plate has a
height and/or a depth greater than 1 .mu.m, preferably greater than
100 .mu.m, further preferably between 100 and 1000 .mu.m and
especially at least substantially between 300 and 500 .mu.m. If a
protrusion directly adjoins a recess, with the protrusion
protruding from the plane of the nub base and/or the carrier plate
and the recess protruding into the nub base and/or the carrier
plate, the spacing between the lowest point of the recess and the
highest point of the protrusion is preferably greater than 50
.mu.m, further preferably greater than 100 .mu.m, further
preferably between 100 and 300 .mu.m and especially at least
substantially between 300 and 800 .mu.m.
[0018] In another advantageous embodiment of the idea of the
invention, it is provided that the protrusions and/or the recesses
on the nub base form a structured surface of the nub base and/or
the carrier plate.
[0019] Preferably more than 20, preferably more than 100, further
preferably more than 1000, preferably more than 10000 protrusions
and/or recesses are provided on the nub base and/or on the carrier
plate, wherein the protrusions and/or recesses are arranged
irregularly and/or without order preferably on both the nub base
and on the carrier plate. Thanks to a large number of protrusions
and recesses, a structured surface of the decoupling sheet is
produced.
[0020] Advantageously in this context, the most diverse forms
and/or structures of the recesses and/or protrusions are provided,
in particular wherein the shapes and/or structures of the
protrusions and/or recesses result from the manner of producing the
protrusions and/or recesses.
[0021] Finally, it is preferably provided according to the
invention that a structured surface is formed for better anchoring
of the tile adhesive, wherein a structuring of the surface results
by virtue of protrusions and/or recesses. As is explained below,
the protrusions and/or recesses may have a fixed geometrical shape,
in particular being embossed during the manufacturing of the
decoupling sheet, and/or they comprise the most diverse structures
and/or shapes, it being essential to the invention that the
protrusions and/or recesses have a maximum height and/or depth of
more than 1 .mu.m.
[0022] In another preferred variant embodiment, a shaping is
provided in order to form an undercut on the protrusions and/or
recesses. This shaping forms the undercut, especially wherein the
undercut serves for better anchoring of the tile adhesive to the
surface of the carrier plate and/or of the nub base, wherein the
tile adhesive preferably takes hold in the region of the undercut
and becomes anchored there.
[0023] Advantageously, it is provided for a structuring of the nub
base and/or the carrier plate that at least 30% of the free surface
of the nub base and/or the carrier plate is structured and/or
comprises recesses and/or protrusions. Preferably, over 50% of the
carrier plate and/or over 50%, preferably over 70%, further
preferably 80%+/-5%, of the overall surface of all nub bases is
structured and/or comprises recesses and/or protrusions. This
structured surface ensures a better anchoring of the tile adhesive
and an increased bond strength for the entire decoupling sheet.
Preferably, the surface of the carrier plate and/or the nub bases
is entirely roughened and/or structured.
[0024] Hence, it is provided that a plurality of projecting
protrusions are present on the nub base and/or the carrier plate,
between which recesses are provided, serving for the
gripping/bonding with the tile adhesive being applied to the
decoupling sheet on the tile side. The protrusions are simply
elevations and/or outcroppings of material. The recesses do not
involve breaches in the nub base and/or the carrier plate allowing
an exchange of air and/or moisture from the bottom side to the tile
side. The same holds for the protrusions, which likewise have no
openings or breaches and therefore likewise do not allow any
exchange of air or moisture from the bottom side to the tile
side.
[0025] The aforementioned embodiment of the invention enlarges the
exposed surface of the nub bases and the surface of the carrier
plate facing away from the nub bases, i.e., the surface of the webs
provided on the carrier plate between the individual nub openings
protruding into the nub interior spaces. The protrusions and/or
recesses and the accordingly enlarged surface provide an improved
grip of the tile adhesive. The protrusions and/or recesses
according to the invention also improve the mold stripping of the
overall decoupling sheet. The protrusions and/or recesses result in
particular in the decoupling sheet having increased bending
stiffness and/or torsional stiffness.
[0026] In the course of the creation of the invention, it was
ascertained in experiments which were conducted that the
protrusions and/or recesses in the nub base and/or in the carrier
plate produce an improved bond strength of up to 40% as compared to
the known decoupling sheet and consequently a significantly
improved grip of the tile adhesive to the decoupling sheet.
[0027] The aforementioned realization of the protrusions and/or
recesses and/or the structured surface of the carrier plate and/or
the nub base can be realized in the above-described manner on
basically every nub base and/or nub, regardless of the kind of
configuration of the nub and/or nub base. Thus, the nub looking
down on it in a top view may have for example an elliptical,
especially a round, or also a quadrangular, especially rectangular
and/or square, shape.
[0028] Preferably, adjacent nubs are arranged transversely to the
lengthwise direction of the carrier plate and in the lengthwise
direction of the carrier plate, especially in rows.
[0029] In an especially advantageous embodiment, it is provided
that the nub is multi-legged. The multi-legged formation of the nub
in combination with the arrangement of adjacent nubs transversely
to the lengthwise direction of the carrier plate and in the
lengthwise direction of the carrier plate enables in particular an
optimal distribution between the exposed surface of the carrier
plate and the nub surface. This ratio is critical to determining
the drainage and decoupling properties. With a multi-legged
formation of the nub, it has been established in the experiments
conducted that the decoupling properties can be improved many times
over. Preferably, a plurality of protrusions and/or recesses is
provided on the leg bottom of a leg.
[0030] Furthermore, in one advantageous embodiment of the idea of
the invention there is provided an arrangement of immediately
adjacent nubs transversely to the lengthwise direction and in the
lengthwise direction of the carrier plate, wherein immediately
adjacent nubs have a triaxial nub base, especially one with at
least three leg sides.
[0031] By a triaxial formation of the nub base is meant a
three-legged formation in a two-dimensional extension. The nub base
and/or the nub accordingly has three legs. For the
three-dimensional forming of the nub, it is provided that at least
one side wall adjoins the nub base in order to form the nub
interior space.
[0032] The triaxial nub shape is seen in a top view looking down on
the decoupling sheet.
[0033] First of all, the triaxial formation of the nub base is
distinguished in that a simple manufacturing of the decoupling
sheet according to the invention is ensured. This manufacturing
makes it possible in particular to accomplish high processing
speed, preferably by a so-called inline process, wherein the
decoupling sheet is manufactured continuously with a relatively
high production speed. The increased production speed is made
possible in particular by providing a quick and easy mold stripping
of the decoupling sheet according to the invention. An increased
processing speed results in particular in a decrease in the
production time and thus a savings on production costs.
[0034] The nubs according to the invention and the nub arrangement
according to the invention furthermore afford the possibility of an
easy buttering of the decoupling sheet with tile adhesive. This
buttering is especially simplified in that a triaxial form of the
nubs is chosen, so that the tile adhesive can be well distributed
within this nub form when applying the adhesive and placing it in
the nubs and the air can easily escape from the recesses.
[0035] In addition, a good drying and a very good vapor pressure
equalization is ensured, since the channels formed between adjacent
nubs in the decoupling sheet according to the invention are joined
together directly and/or indirectly over the entire nub sheet.
Thanks to the triaxial nub shape of the nub base, the channels are
preferably rounded and/or wavy, yielding a full-surface vapor
pressure equalization without interruption and at the same time a
good dehumidification and ventilation. Thanks to the configuration
of the decoupling sheet according to the invention, the decoupling
sheet can be placed in particular on a moist and possibly not fully
hardened ground without the moisture still present in the ground
becoming trapped and/or preventing or excessively delaying the
desired drying of the ground, especially thanks to the very good
vapor pressure equalization. Consequently, the decoupling sheet can
be installed soon after the production of the ground. This produces
the advantage in particular that the installation time of the
overall floor cover can be drastically reduced, a rapid work
sequence is ensured, and the production costs of the flooring are
accordingly reduced.
[0036] Furthermore, the nub sheet according to the invention has
improved decoupling properties, since an improved load distribution
is achieved by a triaxial nub shape of the nub base, preferably in
combination with the orientation of the nubs in rows in the
lengthwise direction and transversely to the lengthwise direction
of the carrier plate, with a middle region which is defined by a
circle. Furthermore, stress peaks are reduced or entirely avoided
in some cases. The shear stresses are transmitted to the decoupling
sheet and distributed in particular on the surface of the carrier
plate facing toward the nubs. The distinctly improved load
distribution is additionally achieved advantageously by the channel
structure. The decoupling effect is advantageously such that, on
the one hand, no cracks are created in the surface of the flooring
facing away from the decoupling sheet and on the other hand
possible cracks in the ground, which only arise in particular after
the installation of the decoupling sheet, do not become evident in
the tile adhesive layer and/or on the flooring elements.
[0037] In experiments that were conducted it was established that
the decoupling properties were improved by up to 30% when using the
nub having the triaxial nub base as compared to the decoupling
sheet known in the prior art.
[0038] Besides a distinctly improved mold stripping and enhanced
decoupling properties, the nub shape according to the invention
furthermore ensures a greater strength of the tile bonding, since
the tile adhesive is distributed very well in the recess produced
in this way and in the recesses between the protrusions, and an
interaction between the carrier plate and the nubs results in
greater strength. Along with this, the bond strength of the overall
decoupling sheet is increased. In particular, no additional
bond-strengthening layer or supplemental fibers are required, so
that in particular the production costs and/or the production time
can be reduced.
[0039] The bond strength serves as a parameter of the adhesion of
layers to grounds, especially concrete surfaces. It is determined
by means of special testing, also known as a bond strength test
and/or pull-off test. DIN EN 1348 contains instructions for
determining the bond strength under defined conditions.
[0040] Thanks to the increased strength of the tile bonding and the
improved decoupling properties, a lower overall layer assembly
height of the decoupling sheets according to the invention can be
selected as compared to the decoupling sheet known in the prior
art. This smaller overall layer assembly means, among other things,
that less tile adhesive is needed during the installation for the
bonding of the flooring elements to the decoupling sheet, so that
there are lower production costs for the flooring being laid.
[0041] The decoupling sheet according to the invention furthermore
has a high torsional strength, preferably while preserving a good
winding capability. The high torsional strength and/or torsional
stiffness means that the decoupling sheet cannot bend and/or twist,
especially by 90.degree.. Yet the preserved winding capability
means that the decoupling sheet can be rolled up, preferably for
transport.
[0042] In a further embodiment, it is provided that the decoupling
sheet has a low torsional strength, so that the decoupling sheet
can kink and/or twist in particular. Preferably, a rectangular
shape of the nub is chosen in this variant embodiment.
[0043] Furthermore, it has been established in experiments that
were conducted that, besides its excellent decoupling properties,
the decoupling sheet according to the invention also has very good
footfall muffling. This effect as well is a result of the special
nub shape and arrangement.
[0044] In an especially advantageous embodiment, it is provided
that the protrusion and/or recess on the nub base is formed in the
shape of a spiral and/or an arc segment. It has been established
that the spiral and/or rounded form of the protrusion and/or recess
in particular results in an improved grip of the tile adhesive.
Finally, it has been determined during experiments that it is
especially advantageous when the protrusion in the shape of a
spiral and/or recess is provided in the middle region of the nub
base.
[0045] Moreover, it is understood that a plurality of protrusions
and/or recesses can be provided on the nub base, so that the bond
strength between the decoupling sheet and the flooring elements is
increased.
[0046] Accordingly, in a further preferred embodiment in connection
with the three-legged nub and/or the nub having a three-legged nub
base, it is provided that the leg bottom of a leg of the nub has a
plurality of protrusions and/or recesses.
[0047] In another preferred embodiment of the invention, the
protrusions and/or recesses are arranged concentric to the middle
region and/or to the center point of the nub on the leg bottom.
[0048] Furthermore, it has been established that it is especially
advantageous for the protrusions and/or recesses of the nub base to
be web-like and/or have a rectangular and/or elliptical shape. In
this regard, it is especially preferable for the web-like and/or
rectangular and/or elliptical protrusions and/or recesses on the
nub base to be oriented transversely and/or longitudinally to the
lengthwise direction of the carrier plate. This arrangement of the
protrusions and/or recesses on the nub base enables in particular
an easy buttering of the decoupling sheet with the tile adhesive
along with good stripping of the nub sheet from the mold.
[0049] It is understood that not only can protrusions and/or
recesses be placed on the nub base, but also in a further preferred
embodiment protrusions and/or recesses may also be provided
alternatively or additionally to the protrusions and/or recesses on
the nub base likewise on the carrier plate and/or the carrier plate
webs between the nub openings protruding into the nub interior
spaces, and this both in the lengthwise direction of the carrier
plate and in the transverse direction of the carrier plate. This
arrangement of the protrusions and/or recesses on the carrier plate
produces good bond strength, especially in combination with a
preferred embodiment of the protrusions in web-like and/or
rectangular and/or elliptical shape.
[0050] Furthermore, in another preferred embodiment of the
invention it is provided that the protrusions and/or recesses of
the carrier plate are elongated and oriented by their longitudinal
extension solely transversely and/or longitudinally to the
lengthwise direction of the carrier plate. This orientation in
combination with the elongated shape brings about in particular a
better grip of the tile adhesive on the carrier plate.
[0051] In an especially preferred embodiment of the invention, a
special arrangement of the protrusions and/or recesses is provided
by which they run in rows transversely and/or longitudinally to the
lengthwise direction of the carrier plate and are arranged in
alternating orientation. Precisely such a formation and arrangement
produces a good grip of the tile adhesive on the carrier plate.
[0052] Preferably, at least one nub having a triaxial nub base is
provided with three long sides and the middle region of the
triaxial nub base is defined by a circle which all the long sides
contact tangentially. This geometrical configuration of the nub
and/or the nub base enables especially good decoupling properties
with an excellent drainage function at the same time.
[0053] In one advantageous embodiment of the idea of the invention,
the nub and/or the nub base has a concave shape on at least one
long side. This concave shape of the long side means that an
improved mold stripping can occur, since in particular no corners
are present between the long sides. An improved mold stripping
means an easier and/or improved manufacturing process.
[0054] Furthermore, in one preferred embodiment of the decoupling
sheet according to the invention at least one shaping is provided
in the region of the long side and/or leg side of the nub and/or
the nub base in order to form an undercut on the interior side of
the nub. It is understood that the long side is formed for example
by two and/or one leg side. The tile adhesive penetrates into the
undercut during the buttering, so that a better grip is produced.
This, in turn, results in a securing of the tile set and/or
flooring elements to be applied on the decoupling mat.
[0055] In one especially advantageous embodiment of the idea of the
invention, the shaping to form the undercut on the interior side of
the nub is in the form of a sickle and/or an arc segment and/or a
crescent. This arc segment formation results in particular in an
improved mold stripping during the manufacturing of the decoupling
sheet. By contrast with angular undercuts, in the case of a rounded
and/or sickle shape of the undercut there is advantageously ensured
an easier separation between the molding die and the decoupling
sheet. Thus, in particular, the decoupling sheet will not be
damaged when stripped from the mold. Moreover, the rounded
undercuts preferably serve for reducing the stress peaks of the
shear stress of the flooring elements and/or distributing them
evenly on the decoupling sheet.
[0056] In another embodiment according to the invention, the
shaping is formed by a protrusion protruding from the nub interior
space. In an especially advantageous embodiment, the protrusion is
provided in the area of the nub base, with the protrusion in
particular passing directly into the nub base. This immediate
passing of the protrusion into the nub base results in an improved
mold stripping, so that the molding die can be removed from the
decoupling sheet with no problem, especially even when the state of
the decoupling sheet material is not yet completely hardened, with
no fear of damaging the decoupling sheet during the mold
stripping.
[0057] This advantage also results in particular when the shaping
extends for at least 40%, preferably for between 50% and 100% and
especially for between 60% and 90% of the length of the long side
and/or the leg side. These dimensions mean that the end region of
the nub and/or the triaxial nub base formed by two converging long
sides is undercut-free and/or has no shaping in this region. In
this embodiment, the molding die may have sharp-edged corners in
the end region without causing damage to the decoupling sheet
during the mold stripping.
[0058] In another embodiment of the idea of the invention, it is
provided that the end region of the nub and/or the triaxial nub
base formed by two converging long sides is rounded and without
corners. In one preferred configuration of the embodiment of the
decoupling sheet, the radius of a concave long side is multiple
times longer than the radius of an end region, with the radius of a
concave long side preferably twice as large as the radius of an end
region. Thanks to the concave long sides and the rounded and/or
convex end regions of the long sides, a curved nub shape is
produced, which significantly reduces and/or in some cases totally
prevents stress peaks from arising. These end regions, which in
particular are free of undercuts, work against air inclusions and
thus make the buttering easier.
[0059] Moreover, it has been established in experiments that were
conducted that it is especially advantageous for the nub and/or the
triaxial nub base to have mirror symmetry with respect to a center
axis running substantially parallel to the lengthwise direction.
This mirror-symmetrical nub axis is advantageous not only in terms
of manufacturing technology, but also decisively advantageous in
regard to the product properties of the decoupling sheet, as shall
be discussed in the following.
[0060] In another advantageous embodiment of the idea of the
invention, it is provided that the angle of the leg emerging from
the middle region between the respectively adjacent, spaced-apart
leg axes is at least 90.degree..
[0061] In order to ensure an optimized arrangement of the nubs on
the decoupling sheet, it is provided in another embodiment
according to the invention that the leg length of one leg,
especially that of the leg running parallel to the lengthwise
direction of the decoupling sheet, is less than the other two leg
lengths. It is especially advantageous when the angle situated
between the leg axis of the shorter leg and the leg axis of the
adjacent leg is greater than 120.degree. and especially less than
130.degree.. Thanks to a preferred mirror-symmetry arrangement, two
larger angles are provided for the nub and/or for the triaxial nub
base and the angle which is enclosed between the leg axes of the
longer legs is accordingly less than 120.degree.. As compared to
the usual rectangular and/or rotationally symmetrical geometries
customary in the prior art, this geometry affords the benefit in
particular of improved decoupling properties of the entire
decoupling sheet when using the nub with the aforementioned
properties.
[0062] It should be pointed out in this context that especially
improved decoupling properties result when there is provided on the
decoupling sheet a plurality of nubs according to the invention
with the triaxial nub base. In one preferred exemplary embodiment,
it is provided that the nubs running transversely to the lengthwise
direction of the carrier plate are arranged such that no straight
line running transversely to the lengthwise direction of the
carrier plate is formed continuously on the carrier plate, and/or
nubs running in the lengthwise direction of the carrier plate are
arranged such that no straight line running in the lengthwise
direction of the carrier plate is formed continuously on the
carrier plate, and/or nubs running longitudinally and transversely
to the lengthwise direction of the carrier plate are arranged such
that no straight line running at a slant to the lengthwise
direction of the carrier plate is formed continuously on the
carrier plate. The term "continuously" here means a connection from
one edge of the decoupling sheet to the opposite edge of the
decoupling sheet on the other lengthwise or transverse side of the
decoupling sheet. According to the invention, this is accomplished
in particular in that a nub having a triaxial nub base with the
aforementioned properties is used and thus makes possible this
configuration thanks to the arrangement and thus the interaction of
the nubs.
[0063] Thanks to the aforementioned configuration, weakening lines
and/or predetermined breaking edges of the nub track exceeding the
overall nub diameter, especially exceeding it by a multiple, are
avoided. The arrangement of the nubs in the aforementioned manner
produces channel segments between the nubs which have a trend,
especially a meandering trend, in right and left curves, so that
the channel segments extend over the carrier plate in a preferably
wavy manner. By avoiding a straight trend of the individual
channels, one can advantageously prevent the formation of weakening
lines running straight across the decoupling sheet. Finally, it is
not relevant how the decoupling sheet is installed in a room, so
that in any given direction a channel segment running in this
direction will come up against a nub if extended in a straight
line, so that the weakening line segment formed by the respective
channel segment will be interrupted, thus preventing in particular
the formation of longer weakening lines. Accordingly, regardless of
the orientation of the decoupling sheet during its installation, it
can be ensured that the joints formed in the installed floor
covering will always extend across nubs for a segment, so that no
joints will be congruent with a longer channel segment of the
decoupling sheet.
[0064] The carrier plate according to the invention, especially
when using the triaxial nub, preferably has only such channels as
extend from one side edge to another side edge of the carrier plate
and run in right and left curves, relative to the transverse
direction of the decoupling sheet and/or the carrier plate. Each
space between two adjacent nubs represents a channel segment and is
part of a channel, so that weakening lines and/or predetermined
breaking edges between spaced-apart nubs running in a straight line
across the carrier plate are precluded.
[0065] Finally, it is understood that, in a further embodiment,
especially when using a square and/or elliptical and/or rectangular
nub, such weakening lines and/or predetermined breaking edges of
the decoupling sheet may arise.
[0066] In another preferred embodiment, the nubs are arranged in
rows running in both the lengthwise direction and transverse
direction, wherein the center points of the nubs running in the
lengthwise direction are arranged on a line running at least
substantially parallel to the lengthwise direction of the
decoupling sheet and wherein the center points of the nubs running
transversely to the lengthwise direction are arranged on a line
running at least substantially perpendicular to the lengthwise
direction. This arrangement of the nubs results in manufacturing
technology benefits, since this preferably symmetrical arrangement
of the nubs can be produced by an embossing mechanism, preferably a
nub roller, by means of molding dies in a filmlike material which
is fed to the embossing mechanism as the base material of the
decoupling mat. The molding dies are arranged on the nub roller, so
that the embossing of the nubs can occur in a continuous
manufacturing process.
[0067] Another possible and supplemental aspect of the present
invention is that the shorter leg of the nubs and/or the nub base
arranged in a row of successively arranged nubs running
substantially parallel to the lengthwise direction is oriented in
the lengthwise direction. In an immediately adjacent row of nubs
running at least substantially parallel to the lengthwise
direction, the shorter legs of the nubs are oriented opposite to
the lengthwise direction. In particular, it is possible in this
case to avoid the aforementioned weakening lines across the
decoupling sheet by not having the resulting channel segments in a
straight line between the adjacent nubs. The shorter legs according
to the invention ensure in this case that the nubs are arranged in
lengthwise and transverse rows to the carrier plate, yet without
having and/or forming a weakening line.
[0068] Preferably, in another embodiment of the idea of the
invention, it is provided that the arrangement of the nubs on the
carrier plate is embodied such that the shortest distance between
two adjacent nubs is always roughly equally large, especially with
a deviation of +/-20%, preferably +/-10%. This creates in
particular an identical or approximately identical channel width,
wherein thanks to the nub shape the channels extend in meandering
fashion across the carrier plate. Advantageously, one leg of the
nubs is to be configured shorter in order to form identical channel
widths and/or to ensure an at least substantially shortest constant
segment between two adjacent nubs.
[0069] In another preferred embodiment of the idea of the
invention, it is provided that the nubs are arranged and/or
configured such that roughly the same flow cross section results in
the channels, especially with a deviation of +/-20%, preferably
+/-10%.
[0070] Basically, it is understood that a flat connection means can
be provided on the outside of the nub bases for connecting between
the decoupling sheet and the ground. Preferably, this connection
means is fastened to the nub bases, and the connection means is
preferably embodied as a nonwoven and/or a textile and/or a scrim
and/or a lattice and/or paper, especially formed over the entire
surface and/or in a lattice shape. The connection means according
to the invention ensures that the nub base is fixedly joined via
the connection means to the ground, so that in particular its bond
strength is increased. Preferably, the connection means is directly
incorporated into the outside of the nub bases during the
manufacturing process of the decoupling sheet. Thanks to the fixed
connection of the decoupling sheet to the ground by means of the
connection means, a shifting between the flooring layer and the
decoupling sheet is preferably avoided.
[0071] The arrangement of the connection means on the nub bases is
preferably designed so that the channels and/or channel segments
are produced between the outsides of the nubs and the connection
means, by which a dehumidification and/or a ventilation is
possible. The connection means is usually facing toward the ground
on which the decoupling sheet is placed. The openings into the
individual nubs are oriented toward the installation side, so that
the tile adhesive can be placed into the nubs and/or the nub
interior spaces.
[0072] In another preferred embodiment of the present invention,
the height of the nubs is between 1 and 5 mm, preferably between 2
and 4 mm, further preferably between 2.5 and 3.5 mm. This
relatively low nub height enables a low overall layered structure
and entails a reduced amount of tile adhesive needed for the
bonding between the decoupling sheet and the flooring elements.
However, due to the special nub shape and formation, a firm bond is
achieved between the tile adhesive and the decoupling sheet while
at the same time accomplishing an excellent decoupling effect.
[0073] In another preferred embodiment, the clear gap between
adjacent nubs has a width greater than 2 mm, in particular, between
3 mm and 9 mm, preferably between 4 and 8 mm, further preferably
between 5 and 6 mm. This clear gap also determines the width of the
channel segment and thus defines the free space between adjacent
nubs. The channel segment in this case, due to the width which is
present, accomplishes not only a good dehumidification and
ventilation of the subfloor, but also a uniform heat distribution,
especially in system designs with underfloor heating.
[0074] Furthermore, in another preferred embodiment it is provided
that the ratio of the area of the nub bases of all the nubs to the
carrier plate is preferably between 40% and 70%, further preferably
between 45% and 55% and especially at least substantially 50%. It
has been established in experiments that were conducted that, by
observing the aforementioned ratio, especially good decoupling
values are achieved at the same time as an especially firm
attachment of the tile adhesive to the decoupling sheet. Along with
the nub height, the aforementioned ratio also critically defines
the required amount of tile adhesive used for the joining of the
decoupling sheet and the flooring element. In particular, a load
distribution of the occurring shear stress on the carrier plate is
made possible by the channels, wherein preferably a compensation of
the occurring stresses is accomplished. Finally, it has been
established in experiments that the ratio of 40% to 60%, preferably
45% to 55%, is especially advantageous and has good decoupling
properties as well as a good bond strength.
[0075] Furthermore, a method is provided for production of a
decoupling sheet having a carrier plate and a plurality of nubs
protruding from the carrier plate plane. In the method according to
the invention, it is provided that a plurality of protrusions
and/or recesses is placed in the side of the nub base of at least
one nub facing toward the nub interior space and/or a plurality of
protrusions and/or recesses is placed in the side of the carrier
plate facing toward the nub interior space, especially wherein the
surface is roughened.
[0076] Preferably, therefore, a structured and/or roughened surface
is created. The structured surface may comprise protrusions and
recesses which are arranged in an irregular and unorganized
manner.
[0077] Preferably, the nub bases of immediately adjacent nubs have
in particular a triaxial shape transversely to the lengthwise
direction and in the lengthwise direction of the carrier plate.
Ultimately, however, it is understood that other nub structures may
be provided according to the invention.
[0078] In one preferred design of the process according to the
invention, it is provided that the protrusion is made by a laser
process, a plasma process, a machining process, preferably
blasting, especially using sand and/or nutshells, and/or by
embossing during and/or after the production of the decoupling
sheet. It has been established that the aforementioned processes
produce an ideally roughened surface for the later processing of
the decoupling sheet.
[0079] Finally, it is understood that the protrusions and/or
recesses can be placed into the decoupling sheet and/or the carrier
plate and/or the nub base after the production of the decoupling
sheet, in particular in a separate step.
[0080] In terms of manufacturing technology, it is convenient to
perform the embossing of the protrusions and/or recesses in the
decoupling sheet directly during the production of the decoupling
sheet, so that the protrusions and/or recesses are positioned
directly by means of recesses and/or elevations on the molding dies
and/or the embossing mechanism and/or the nub roller.
[0081] In another embodiment, it is provided that the embossing is
performed after the production of the decoupling sheet by an
additional and/or further embossing roller, one which is heated in
particular. This additional embossing roller is adjacent in the
production direction to the actual nub roller by which the
decoupling sheet per se is created.
[0082] The surface modification or structuring may alternatively be
done by mechanical methods, such as blasting, for example when
using sand and/or nutshells. A roughening of the surface during
mechanical methods can be done by using brushes and/or abrasive
paper, for example.
[0083] The drawback to a mechanical roughening by means of
sandpaper, brushes and/or a material ablation by means of abrasive
paper is the relatively large material ablation, which results in a
weakening of the nubs and the decoupling sheet as a whole.
Surprisingly, it has been found that the manufacturing methods of
laser radiation, plasma radiation, embossing and/or blasting can
reduce the material ablation as compared to sandpaper and/or
brushes by up to 30%. In particular, the structured surface can be
specifically designed and implemented by the production methods
according to the invention, which is not possible with brushes and
sandpaper.
[0084] The aforementioned methods result in a structured surface
and/or a profiling of the surface, so that in particular an
increased roughness is produced. The roughening and/or structuring
of the surface by means of nutshell blasting has proven to be
especially advantageous in the experiments that were conducted.
[0085] In the plasma method, high-energy electrons and ions are
generated in particular directly from the surrounding atmosphere by
means of strong electric fields and used to generate a plasma. In
this way, the surface structure of the decoupling sheet is attacked
accordingly. The laser method preferably involves treatment of the
surface of the decoupling sheet with a pulsed laser beam source,
which can be directed preferably with high beam intensity onto the
surface of the decoupling sheet.
[0086] When installing the decoupling mat on an ground, a
bond-strengthening layer can be placed between the decoupling sheet
and the flooring elements, preferably by spreading and/or spraying
and/or brushing it onto the decoupling sheet. Basically, it is also
conceivable to apply a bond-strengthening layer to the decoupling
sheet by spreading and/or spraying and/or brushing it on already
during the manufacturing of the decoupling sheet.
[0087] Hence, the invention relates to a decoupling sheet with a
carrier plate and a plurality of nubs protruding from the carrier
plate, wherein adjacent nubs are arranged transversely to the
lengthwise direction of the carrier plate and in the lengthwise
direction of the carrier plate, wherein to improve the decoupling
properties and to increase the bond strength a plurality of
protrusions and/or recesses is provided on the nub bases and/or the
surface of the carrier plate facing away from the nub bases.
Finally, the invention also relates to a method for production of a
decoupling sheet, especially one having the protrusions and/or
recesses according to the invention.
[0088] Moreover, it is understood that the aforementioned intervals
and range limits include any intermediate intervals and individual
values and are to be seen as being disclosed as essential to the
invention, even if these intermediate intervals and individual
values are not specifically indicated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0089] Further features, benefits and application possibilities of
the present invention will emerge from the following description of
exemplary embodiments with the aid of the drawing, and from the
drawing itself. All of the described and/or depicted features in
themselves or in any given combination form the subject matter of
the present invention, regardless of their statement in the claims
or their reference back to the claims.
[0090] FIG. 1 shows a schematic top view of a portion of a
decoupling sheet,
[0091] FIG. 2 shows a schematic cross sectional view along line I-I
of FIG. 1,
[0092] FIG. 3 shows a schematic top view of a nub having a triaxial
nub base,
[0093] FIG. 4 shows a schematic top view of another embodiment of a
nub,
[0094] FIG. 5 shows schematic top views of further nubs having a
triaxial nub base,
[0095] FIG. 6 shows a schematic top view of another variant
embodiment of a decoupling sheet,
[0096] FIG. 7 shows a perspective schematic view of one embodiment
of a decoupling sheet according to the invention,
[0097] FIG. 8 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
[0098] FIG. 9 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
[0099] FIG. 10 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
[0100] FIG. 11 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
[0101] FIG. 12 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
[0102] FIG. 13 shows a schematic cross sectional view of a
decoupling sheet according to the invention along line II-II of
FIG. 11,
[0103] FIG. 14 shows a schematic top view of another variant
embodiment of a decoupling sheet,
[0104] FIG. 15 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
[0105] FIG. 16 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
[0106] FIG. 17 shows a perspective schematic view of another
embodiment of a decoupling sheet according to the invention,
and
[0107] FIG. 18 shows a schematic cross sectional view of a
decoupling sheet according to the invention per FIG. 17.
DETAILED DESCRIPTION
[0108] FIG. 1 shows a portion of a decoupling sheet 1 with a
carrier plate 2 and a plurality of nubs 4 protruding from the
carrier plate plane 3. Adjacent nubs 4 are arranged transversely to
the lengthwise direction 5 (in the transverse direction 15) of the
carrier plate 2 and in the lengthwise direction 5 of the carrier
plate 2. Furthermore, FIG. 1 illustrates that immediately adjacent
nubs 4 transversely to the lengthwise direction 5 (in the
transverse direction 15) and in the lengthwise direction 5 of the
carrier plate 2 have a triaxial nub base 10.
[0109] FIG. 14 shows that other shapes and/or structures can also
be provided for the nub 4 in other variant embodiments. FIG. 14
illustrates that an elliptical, especially a cylindrical nub 4, and
a diamond-shaped nub 4 are provided on a decoupling sheet 1.
Finally, it is understood that only cylindrical and/or only
diamond-shaped and/or only rectangular nubs 4 are present in other
variant embodiments on the decoupling sheet 1. However, it is not
shown in FIG. 14 that the decoupling sheet 1 comprises protrusions
21a, 21c and/or recesses 21b, 21d. These protrusions 21a, 21c
and/or recesses 21b, 21d may have different shapes and structures
in other variant embodiments (not shown), in particular forming a
structured surface of the nub base 10 and/or the carrier plate 2.
Moreover, it is not shown that the protrusions 21a, 21c and/or
recesses 21b, 21d may be present on decoupling sheets 1 together
with different shapes of the nub 4. Further, it is not shown that
the nub 4 may have multiple legs, wherein it may have two or more
legs. In the variant embodiments of FIGS. 1 to 13, the three-legged
shape of the nub 4 and/or the nub base 10 is provided.
[0110] The triaxial formation of the nub 4 and/or the nub base 10
means that three legs 12, 13 are provided. The triaxial formation
of the nub base 10 is evident in the top view looking down on the
decoupling sheet 1 and hence in a top view looking down on the nub
4. The immediate proximity of the nubs 4 in the lengthwise
direction 5 and in the transverse direction 15 occurs in the case
of a group of at least three nubs 4. This means that at least three
immediately adjacent nubs 4 comprise a triaxially shaped nub base
10 in the lengthwise direction 5 and in the transverse direction
15. In the arrangement of the nubs 4 on the carrier plate 2 it is
provided that the nubs 4 and the nub bases 10 neither intersect nor
overlap. Finally, it is understood that in an embodiment of the
decoupling sheet 1 according to the invention (not shown), it may
be provided that different nub shapes and/or forms of the nub base
10 both triaxial and any given shapes may be used on the decoupling
sheet 1. In this variant embodiment (not shown), a group of at
least three immediately adjacent nubs 4 with a triaxial nub base 10
is preferably formed.
[0111] Alternatively and/or additionally to the triaxial formation
of immediately adjacent nubs 4 in the lengthwise direction 5 and in
the transverse direction 15, it is provided that at least one nub 4
having a triaxial nub base 10 with three long sides 6a is present
on the decoupling sheet 1. FIGS. 3 and 4 show that the middle
region 7 of the nub 4 and/or the nub base 10 is defined by a circle
which all the long sides 6 contact tangentially.
[0112] FIGS. 3 and 4 show various embodiments of the triaxial nub
shape with different triaxial nub bases 10 having three long sides
6a.
[0113] Moreover, FIG. 1 shows the arrangement of the nubs 4 per
FIG. 4 on a decoupling sheet 1, wherein all the nubs 4 have a
triaxial nub base 10.
[0114] In a variant embodiment (not shown), only one nub shape
having a triaxial nub base 10 with three long sides 6a per FIG. 3
or 4 is provided and placed in a carrier plate 2, with the other
nubs 4 having familiar nub structures, such as cylindrical and/or
pot-shaped.
[0115] Moreover, FIGS. 3 and 4 show that the long side 6 of the nub
4 and/or the nub base 10 is concave. In a variant embodiment (not
shown), only one long side 6a of the nub 4 or two long sides 6a of
the nub 4 are concave.
[0116] A nub interior space 20 is formed by the nub base 10 and at
least one side wall adjoining the nub base 10, wherein the at least
one side wall produces the three-dimensional shape of the nub
4.
[0117] FIG. 2 shows that in the exemplary embodiment illustrated,
an undercut 8 is present at the nub interior side. This nub
interior undercut 8 is formed by the shaping 8, wherein the shaping
8 in the exemplary embodiment shown is sickle-shaped and/or shaped
as an arc segment and/or as a crescent. The shaping 8 is
furthermore formed by a protrusion 9 sticking out from the nub
interior space 20. The shaping 8 in FIGS. 3 and 4 is provided in
the area of the long side 6a of the nub 4. It is clear with the aid
of FIG. 2 that the protrusion 9 in the exemplary embodiment shown
is arranged in the area of the nub base 10 and passes into the nub
base 10. Moreover, FIGS. 3 and 4 show that the shaping 8 extends
for around 90% of the long side 6a. In an embodiment (not shown),
it is provided that the shaping 8 extends for at least 40%,
preferably in further embodiments between 50 and 100% and
especially between 60 and 90%, of the long side 6a.
[0118] Further, FIGS. 3 and 4 show that the end region 11 produced
by two converging long to sides 6a is undercut-free and thus has
neither an undercut 8 nor a protrusion 9 to form the undercut 8. In
addition, in the exemplary embodiment shown, the resulting end
region 11 is rounded and formed without corners, with the rounding
being described by means of a circular arc segment. The radius
characterizing the concavity of the long side 6a is multiple times
larger than the radius determining the circular arc segment of the
end region 11.
[0119] In addition, FIGS. 3 and 4 show that the nub 4 and/or the
triaxial nub base 10 has mirror symmetry with respect to a center
axis running at least substantially parallel to the lengthwise
direction 5. This mirror symmetry is also clearly shown by FIG. 1.
In the triaxial nub shape of the nub base 10 per FIGS. 3 and 4,
three legs 12, 13 are provided spaced apart from each other and
emerging from the middle region 7.
[0120] FIGS. 3 and 4 make it clear that a leg length 14 of one leg
13 running parallel to the center axis is shorter than the other
two leg lengths 14 of the leg 12. Furthermore, in the exemplary
embodiment shown, different angles of the leg axes are also
provided. Basically, in all nub shapes shown for the nub 4, angles
between two adjacent leg axes greater than 90.degree. are provided.
In the configuration of the nub 4 according to the invention in
FIGS. 3 and 4, it is provided that the angle of the leg axis of the
shorter leg 13 with respect to the leg axis of the adjacent leg 12
is greater than 120.degree., being around 123.degree. in the
exemplary embodiment shown. Consequently, the angle between the leg
axes of the legs 12 is less than 120.degree., around
114.degree..
[0121] The configuration of the nub 4 with a triaxial nub base 10
makes possible the nub arrangement of FIG. 1. In this exemplary
embodiment, it is provided that the nubs 4 running transversely to
the lengthwise direction 5 of the carrier plate 2 are arranged such
that no continuous straight line running transversely to the
lengthwise direction 5 of the carrier plate 2 and thus in the
transverse direction 15 of the carrier plate 2 is formed on the
carrier plate 2 and/or the carrier plate plane 3. Furthermore, it
is also provided that the nubs 4 running in the lengthwise
direction 5 of the carrier plate 2 are arranged such that no
continuous straight line running in the lengthwise direction 5 of
the carrier plate 2 is formed on the carrier plate 2. However, not
only are straight lines avoided in the lengthwise direction 5 and
in the transverse direction 15, but also the nubs 4 running
longitudinally and transversely to the lengthwise direction 5 of
the carrier plate 2 are arranged such that no continuous straight
line running at a slant to the lengthwise direction 5 of the
carrier plate 2 is formed on the carrier plate 2. Consequently, no
straight line is produced on the decoupling sheet 1, since
respective individual line segments are interrupted by the nubs 4.
The channel segment with the clear gap 19 occurring between two
nubs 4 is arranged such that it extends in a meandering manner per
FIG. 1 across the decoupling sheet 1. The lines possibly produced
in the channel segment cannot continue in a straight line across
the carrier plate 2. In each case, a leg 12, 13 of an adjacent nub
4 protrudes into the channel segment between two nubs 4.
[0122] Furthermore, it is understood that this can also be realized
when using a different nub shape. Other triaxial nub shapes of the
nub base 10 of the nub 4 are represented by FIG. 5 and denoted as
variant embodiments 1 to 13. The arrangement of these possible nub
shapes on the carrier plate 2 can be embodied such that the
aforementioned continuous straight lines do not occur on the
carrier plate 2. The triaxial embodiments 1 to 13 of FIG. 5 each
exhibit at least three leg sides 6b, whereby it is understood that
the long side 6a is formed by at least one leg side. It is not
shown that the variant embodiments 1 to 13 may have an undercut 8
in the area of the long side and/or that the shaping 8 may extend
for at least 40% of the long side 6a and/or along the leg side
6b.
[0123] FIG. 6 shows that, when using a triangular nub shape for the
nub base 10 of the nub 4, an arrangement on the carrier plate 2 is
provided such that no continuous straight line of the channel
segment of adjacent nubs 4 results on the carrier plate 2. The
center points of the nubs 4 and/or the nub bases 10 per FIG. 3 are
arranged on straight lines running parallel to the lengthwise
direction 5 and on lines running parallel to the transverse
direction 15.
[0124] Also in the triaxial configuration of the nub base 10 in
FIGS. 3 and 4, these nubs 4 are arranged on the carrier plate 2
such that an arrangement per FIG. 1 is produced, wherein the nubs 4
are arranged running in rows in the lengthwise direction 5 and in
the transverse direction 15. The center points of the nubs 4
running in the lengthwise direction 5 are arranged on a line
running at least substantially parallel to the lengthwise direction
5. In addition, the center points of the nubs 4 running
transversely to the lengthwise direction 5 are arranged on a line
running at least substantially perpendicular to to the lengthwise
direction 5 and thus in the transverse direction 15. This
arrangement of the nubs 4 produces a symmetrical series of nubs
within the respective row, wherein this arrangement in particular
makes it possible for the aforementioned continuous straight lines
and/or weakening lines not to occur on the carrier plate 2.
[0125] However, not only are the center points of the nubs 4 and/or
the nub bases 10 arranged in rows on the decoupling sheet 1 of FIG.
1, but also the arrangement is such that the nubs 4 arranged in
succession in a row running at least substantially parallel to the
lengthwise direction 5 extend in such a way that the shorter leg 13
of the nubs 4 is oriented in the lengthwise direction 5. In an
immediately adjacent row running at least substantially parallel to
the lengthwise direction 5, the nubs 4 arranged in succession are
oriented such that the shorter leg 13 of the nubs 4 is oriented
opposite to the lengthwise direction 5. This produces an
alternating nub orientation in a row running at least substantially
parallel to the transverse direction 15.
[0126] For the arrangement of the decoupling sheet 1 on an ground
18, a connection means 17 is provided per FIG. 2. This connection
means 17 is placed on the outside 16 of the nub bases 10. In the
exemplary embodiment shown, the connection means 17 is secured to
the outside 16 of the nub bases 10. A nonwoven has been used as the
connection means 17 in the exemplary embodiment shown. It is
understood that in further variant embodiments (not shown), one
could also use a textile and/or paper and/or a scrim and/or a
lattice. The connection means 17 is provided with a lattice-like
configuration in the exemplary embodiment shown. In an embodiment
(not shown), besides the lattice-like formation, a formation is
also possible over the entire surface.
[0127] Furthermore, the nub 4 of FIG. 2 has a height of 3 mm. In
further embodiments, which are not shown graphically, a height
between 1 and 4 mm, further preferably between 2.5 and 3.5 mm, is
provided. Further, the clear gap 19 between adjacent nubs 4 in the
exemplary embodiment shown is greater than 2 mm. The clear gap 19
between the nubs 4 varies on the decoupling sheet 1 of FIG. 1, so
that a clear gap 19 between roughly 3 mm and 9 mm can be provided,
preferably between 4 and 8 mm, further preferably between 5 and 6
mm. Moreover, FIG. 1 shows that the ratio between the area of the
nub bases 10 of all the nubs 4 and the area of the carrier plate 2
is at least substantially around 50%. In further embodiments, the
ratio can be between 40% and 70%, preferably between 45% and
55%.
[0128] Moreover, FIG. 2 shows that tiles 23 are provided on top of
the carrier plate 2. Joints 24 result between adjacent tiles 23.
For connecting the tiles 23 to the decoupling sheet 1, a tile
adhesive is provided, which is applied both in the nub interior
space 20 and on the carrier plate 2. This catches inside the
undercut 8 and/or penetrates into the protrusion 9. Regardless of
the orientation of the decoupling sheet 1 on an ground 18, the
joints 24 between the tiles 23 do not coincide with a weakening
line and/or a continuous line on the carrier plate 2. The possible
continuous line produced between two nubs 4 cannot continue across
adjacent nubs 4.
[0129] In further exemplary embodiments per FIGS. 7 to 13, it is
provided that protrusions 21a, 21c and/or recesses 21b, 21d may be
present both on the nub base 10 and on the carrier plate 2. It is
understood that recesses 21b, 21d are respectively provided between
adjacent protrusions 21a, 21c. Ultimately, basically one recess is
adjacent to a protrusion 21a, 21c and/or recess 21b, 21d.
[0130] FIGS. 7 to 12 show a carrier plate 2 and nubs 4, wherein the
nub interior space 20 is open toward the carrier plate 2. The
protrusions 21a and/or recesses 21b may be provided on the side of
the nub base 10 facing toward the nub interior space 20 in FIGS. 9
to 11. In the exemplary embodiments shown, the protrusions 21a in
FIGS. 9 to 11 are provided on all nub bases 10 shown for the
decoupling sheet 1.
[0131] A perforation of the carrier plate 2 with the protrusions
21c and/or recesses 21d is shown in the exemplary embodiment of
FIGS. 7 to 8 and FIGS. 11 to 12. The protrusions 21c here are
provided on the side facing toward the nub interior space 20.
Accordingly, recesses are provided on the side of the carrier plate
2 facing away from the nub interior space 20 and/or the nub base
10, corresponding to the protrusions 21c. Finally, it is understood
that a recess 21d may be provided next to each protrusion 21c on
the side of the carrier plate 2 facing toward the nub interior
space 20.
[0132] In the exemplary embodiments, a plurality of protrusions 21c
is provided on the carrier plate 2.
[0133] The exemplary embodiments show that more than 20, preferably
more than 100, protrusions 21a, 21c and/or recesses 21b, 21d are
provided. In further embodiments, further preferably more than
1000, preferably more than 10000 protrusions 21a, 21c and/or
recesses 21b, 21d are provided.
[0134] FIGS. 15 to 17 show schematically that the protrusions 21a,
21c and/or recesses 21b, 21d are arranged in an irregular and/or
unordered manner, preferably on both the nub base 10 and the
carrier plate 2. FIG. 15 shows schematically a structured surface
of the carrier plate 2, which is created by irregular and at least
partly unequal protrusions 21a, 21c and/or recesses 21b, 21d. FIG.
16 shows a structuring of the nub base 10 wherein the surface of
the nub base 10 has been roughened. Finally, FIG. 17 schematically
shows a structured surface of the nub base 10 and the carrier plate
2, where all the nub bases 10 shown are structured and the
structuring extends over the entire surface of the carrier plate
2.
[0135] The protrusions 21a, 21c and the recesses 21b, 21d are shown
schematically in FIGS. 15 to 18, since the structuring of the nub
base 10 and/or the carrier plate 2 is in part hardly noticeable by
the naked eye on account of the relatively short height of the
protrusions 21a, 21c and the recesses 21b, 21d of around 500+/-300
.mu.m.
[0136] The roughened surface of the carrier plate 2 and the nub
base 10 in FIGS. 15 to 18 is accordingly shown schematically and
extends preferably over the full surface of the nub bases 10 and/or
the carrier plates 2.
[0137] FIGS. 15 to 18 schematically show that the protrusions 21a,
21c and the recesses 21b, 21d produce a structured and roughened
surface wherein the protrusions 21a, 21c and the recesses 21b, 21d
are arranged irregularly. In FIGS. 15 to 17, nubs 4 with a triaxial
nub base 10 are shown exclusively. It is not shown that the
decoupling sheet 1 may have an irregular structuring of the carrier
plate 2 and/or the nub bases 10 with different nub shapes, such as
cylindrical or cuboidal nubs 4.
[0138] FIG. 18 schematically shows a cross section along the
decoupling sheet 1 represented in FIG. 17. The decoupling sheet 1
is irregularly structured on the nub base 10 and on the surface of
the carrier plate and accordingly comprises protrusions 21a, 21c
and/or recesses 21b, 21d. The recesses 21b on the nub base 10 are
arranged on a connection means 17, while the tile adhesive for the
connecting of the tiles 23 to the decoupling sheet 1 and/or the
carrier plate 2 penetrates into the protrusions 21c of the carrier
plate 2 and/or into the recesses 21b of the nub 4.
[0139] The protrusions 21a, 21c and/or recesses 21b, 21d may take
on various geometrical shapes and structures. For example, several
of the depicted embodiments shall be explained in the following. It
is understood here that different protrusions 21a, 21c with
different structures may be provided according to the invention in
other embodiments (not shown). Ultimately, it is decisive for the
protrusions 21c and/or recesses 21b that the tile adhesive for
connecting the tiles 23 to the decoupling sheet 1 can penetrate
into the protrusions 21c and/or recesses 21b and fill them up
completely. This is illustrated with the aid of FIG. 13.
[0140] In the embodiments shown, a multitude and/or plurality of
protrusions 21a, 21c and/or recesses 21b, 21d is provided either on
the carrier plate 2 or on the nub base 10 or on both. The
protrusion 21a on the nub base 10 is formed in the shape of a
spiral and/or an arc segment according to FIGS. 9 and 11. This
trend in the shape of a spiral of the protrusion 21a emerges from
the middle region 7 of the nub base 10. A multitude of protrusions
21a per FIG. 10 may be provided not only on the nub base 10 itself,
but also on the leg bottom 22 of a leg 12, 13.
[0141] Ultimately the protrusions 21a, 21c and/or recesses 21b, 21d
act to produce a structured surface of the nub base 10 and/or
carrier plate 2.
[0142] In FIG. 8, the protrusions 21c of the carrier plate 2 have a
shaping designed to create an undercut. In a further embodiment not
shown, it is provided that the protrusions 21a and/or the recesses
21b of the nub base 10 also have a shaping to create an
undercut.
[0143] Moreover, in another embodiment (not shown), it is provided
that the protrusions 21a, 21c and/or the recesses 21b, 21d have a
height and/or a depth greater than 1 .mu.m, preferably greater than
100 .mu.m, further preferably between 100 and 1000 .mu.m and
especially between 300 and 500 .mu.m.
[0144] Ultimately, it is understood that the protrusions 21a and/or
recesses 21b of the nub base 10 may also pass directly into the
protrusions 21c and/or recess 21d of the carrier plate 2, wherein
in particular the structure and/or shape of the protrusions 21a,
21c and/or the recesses 21b, 21d can be interrupted when the
carrier plate 2 has a recess on account of the nub 4 and/or when
the carrier plate 2 passes into the nub 4. It is also understood
that the protrusions 21a and/or the recesses 21b on the nub base 10
interrupt its geometrical structure, especially when the nub wall
of the nub 4 passes into the protrusion 21a and/or the recess 21b
of the nub base 10.
[0145] FIG. 9 shows that protrusions 21a in the shape of an arc
segment are provided on the leg bottom 22 concentrically to the
middle region 7 around the center point of the nub 4 and/or the nub
base 10.
[0146] FIG. 10 shows a further geometrical shape of the protrusions
21a, wherein the protrusions 21a are formed on the nub base 10 as
webs and/or at least as substantially rectangular and/or elliptical
in shape. The web-like and/or at least substantially rectangular
and/or elliptical protrusions 21a on the nub base 10 of FIG. 10 are
provided transversely and/or longitudinally to the lengthwise
direction 5 of the carrier plate 2.
[0147] In addition, FIG. 7 shows that a plurality of protrusions
21c and/or recesses 21d is present on the carrier plate 2 in the
exemplary embodiment shown, wherein the protrusions 21c are
arranged in rows running transversely to the lengthwise direction 5
of the carrier plate 2. FIG. 7 represents web-like and/or
rectangular protrusions 21c on the carrier plate 2. The elongated
protrusions 21c shown in FIG. 7 extend with their lengthwise
dimension solely transversely and/or longitudinally to the
lengthwise direction 5 of the carrier plate 2. The protrusions 21c
in the exemplary embodiment of FIG. 7 are arranged in a row with
alternating orientation, running longitudinally and/or transversely
to the lengthwise direction 5 of the carrier plate 2.
[0148] FIG. 8 shows that the protrusions 21c are rectangular in
shape. In an embodiment (not shown), the protrusions 21c of the
carrier plate 2 are elliptical in shape. It is understood that
ultimately recesses 21d may also have the geometrical shapes of the
protrusions 21c.
[0149] FIG. 13 shows a cross sectional view along section II-II of
FIG. 11, showing that the recesses 21b are arranged on the nub base
10 on a connection means 17, wherein the tile adhesive for
connecting the tiles 23 to the decoupling sheet 1 and/or the
carrier plate 2 penetrates into the protrusions 21c of the carrier
plate 2 and/or into the recesses 21b of the nub 4.
[0150] Moreover, a method is also provided for the production of a
decoupling sheet 1 in the exemplary embodiment shown, wherein the
decoupling sheet 1 comprises a carrier plate 2 and a plurality of
nubs 4 protruding from the carrier plate 2, wherein adjacent nubs 4
are provided transversely to the lengthwise direction 5 of the
carrier plate 2 and in the lengthwise direction 5 of the carrier
plate 2 per FIG. 1 and per FIGS. 6 to 12. It is provided, according
to the embodiment shown, that the nub bases 10 of immediately
adjacent nubs 4 are triaxial in shape and a plurality of
protrusions 21a and/or recesses 21b is placed in the side of the
nub base 10 of at least one nub 4 facing toward the nub interior
space 20 and/or a plurality of protrusions 21c and/or recesses 21d
is placed in the side of the carrier plate 2 facing toward the nub
interior space 20. The protrusions 21a, 21c placed into the nub
base 10 and/or the carrier plate 2 is illustrated by FIGS. 7 to 12.
However, it is understood that in other embodiments (not shown) a
different structure other than the triaxial formation of the nub
base 10 of the nub 4 may be chosen within the method for production
of a decoupling sheet 1.
[0151] In an embodiment (not shown), it is provided that the
protrusions 21a, 21c and/or recesses 21b, 21d are made by a laser
process, a plasma process, a machining process, preferably
blasting, especially using sand and/or nutshells, and/or by
embossing during and/or after the production of the decoupling
sheet 1, wherein the protrusion 21a, 21c and/or the recess 21b, 21d
is incorporated into the carrier plate 2 and/or into the nub 4 on
the nub base 10.
LIST OF REFERENCE NUMBERS
[0152] 1 Decoupling sheet [0153] 2 Carrier plate [0154] 3 Carrier
plate plane [0155] 4 Nubs [0156] 5 Lengthwise direction [0157] 6a
Long side of nub [0158] 6b Leg side of nub [0159] 7 Middle region
[0160] 8 Undercut/shaping [0161] 9 Protrusion to form the undercut
[0162] 10 Nub base [0163] 11 End region [0164] 12 Leg [0165] 13
Short leg [0166] 14 Leg length [0167] 15 Transverse direction
[0168] 16 Outside of nub base [0169] 17 Connection means [0170] 18
Ground [0171] 19 Clear gap [0172] 20 Nub interior space [0173] 21a
Protrusion of nub [0174] 21b Recess of nub [0175] 21c Protrusion of
carrier plate [0176] 21d Recess of carrier plate [0177] 22 Leg
bottom [0178] 23 Tile [0179] 24 Joint
* * * * *