Note: Descriptions are shown in the official language in which they were submitted.
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1
Decoupling web
The invention relates to a decoupling web with a carrier web and a plurality
of nubs pro-
jecting from the plane of the carrier web, the carrier web having as material
a, preferably
thermoplastic, plastic. The decoupling web is in particular intended for use
for a surface
covering structure which can be covered with covering elements, preferably for
tile cover-
ings.
The term "decoupling" is understood to mean the reduction of shear stresses
and/or
stress peaks between two layers arranged in a firm bond. Effective decoupling
thus pre-
vents shear stresses and/or stress peaks present in one of the layers from
being trans-
ferred to the other layer of the composite structure and causing damage there.
Decoupling webs of the aforementioned type are used, for example, in the
construction in-
dustry when laying floor covering elements, such as ceramic tiles, in
particular for decou-
pling, sealing and/or for vapour pressure compensation. In this case, the
decoupling webs
are laid on an underground, in particular glued, and form the supporting
surface for the
floor covering elements. Tiles are laid in particular on young screed using
the thin-bed
method. If no decoupling membrane is laid between the tiled floor and the
young screed,
then in the event of shrinkage of the screed the tiles, in particular due to
their low coeffi-
cient of expansion, could not follow the movement of the screed, so that shear
stresses
arise which could ultimately lead to detachment or even tearing of the tiles.
Decoupling
webs are also required when laying coverings on particularly critical
undergrounds, such
as old wooden floors. A decoupling web of the type mentioned above compensates
for
these shear stresses by deformation, which is why there is no need to fear
damage to the
composite structure. In most cases, decoupling membranes are made of foil-like
plastic, i.e.
a flexible plastic layer that deforms under the influence of external forces.
The material is
usually selected in such a way that it is low in emissions, especially with
regard to pollu-
tants.
On the side of the decoupling membrane facing away from the floor covering
elements, a
fleece is usually provided, which can be firmly bonded to the carrier web. The
fleece can be
arranged on an underground when the decoupling web is laid and can be bonded
to the
underground. An adhesive layer may therefore be provided between the underside
of the
decoupling membrane facing away from the covering elements and the
underground.
Subsequently, a thin layer of tile adhesive, also known as adhesive mortar or
bonding lay-
er, is usually applied to the support plane of the decoupling web to fix the
floor covering
elements to the decoupling web. It is understood that instead of a tile
adhesive, an equally
suitable adhesive or fastening layer and/or material may ultimately be
provided. In this
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regard, tile adhesives are usually combed with a toothed trowel or a toothed
smoothing
trowel and a different tile adhesive is used depending on the area of
application and/or
the underground. For example, a reactive resin adhesive, a cementitious thin-
bed mortar,
a casein tile adhesive or a dispersion adhesive is used as the tile adhesive.
After the tile adhesive has been applied to a decoupling web, the individual
flooring ele-
ments and/or tiles are laid on the tile adhesive. During application, the tile
adhesive pene-
trates into the depressions of the decoupling web and hardens.
With decoupling webs of this type, the connected floor covering elements are
separated
from the underground and mechanically decoupled. Due to the arrangement of the
nubs
transverse to the longitudinal direction and in the longitudinal direction of
the carrier
plate, channels result which extend over the entire carrier plate. These
channels interact
with the nubs in such a way that they absorb and compensate for mechanical
stresses and,
in particular, shear stresses. This stress on the flooring elements can be
generated due to
temperature and humidity influences and/or due to a weight load.
In the manufacture of such decoupling webs, a mould is used which has
projections corre-
sponding to the recesses and/or nubs. However, the demoulding of the moulding
tool and
the decoupling sheet is usually problematic. Furthermore, the decoupling web
can easily
be damaged during demolding, especially if the protrusions of the mold have
sharp cor-
ners that cut into and/or tear the usually still soft decoupling web material.
In practice, at-
tempts are made to solve the latter problem by providing the corners of the
tool projec-
tions with a radius.
The adhesive tensile strength of the nub membranes known in practice - without
the use
of additional layers - does not usually meet the requirements needed for the
use of the de-
coupling web.
Tensile adhesion strength, sometimes also referred to as pull-off strength, is
a characteris-
tic value used to evaluate the adhesion and/or bonding of layers to surfaces,
in particular
of the tile adhesive to the decoupling web. The adhesive tensile strength can
be deter-
mined by means of an adhesive tensile test.
It is now an object of the present invention to provide a decoupling web
having improved
adhesive tensile strength.
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According to the invention, the aforementioned task is at least substantially
solved in a de-
coupling web of the type mentioned above in that the carrier web comprises as
material a
copolymer comprising ethylene and vinyl acetate and/or consists thereof. Quite
prefera-
bly, the copolymer comprising ethylene and vinyl acetate is formed as a
copolymer of eth-
ylene and vinyl acetate, preferably ethylene-vinyl acetate (EVA, EVAC).
It goes without saying that special features, characteristics, designs and
embodiments as
well as advantages or the like which are set out below - for the purpose of
avoiding un-
necessary repetition - in relation to only one aspect of the invention,
naturally apply mu-
tatis mutandis in relation to the other aspects of the invention without the
need for ex-
press mention.
Furthermore, it goes without saying that in the following specification of
values, numbers
and ranges, the relevant specifications of values, numbers and ranges are not
to be under-
stood in a limiting manner; rather, it goes without saying for the person
skilled in the art
that, depending on the individual case or application, deviations from the
specified ranges
and/or specifications can be made without leaving the scope of the present
invention.
In addition, it applies that all values or parameters or the like mentioned in
the following
can in principle be determined or determined with standardized or explicitly
stated de-
termination methods or with determination methods familiar to the skilled
person in this
field.
Furthermore, it goes without saying that all weight or quantity-related
percentages are se-
lected by the person skilled in the art in such a way that the total results
in 100 %.
Having said this, the present invention will be described in more detail
below.
In particular, it is understood that the carrier web may also comprise the
copolymer corn-
prising ethylene and vinyl acetate, preferably EVAC, only "proportionally".
The material of
the carrier web can also comprise another, preferably thermoplastic, plastic.
Furthermore, it is particularly understood that a plurality, in particular at
least two, of fur-
ther, preferably thermoplastic, plastic materials may also be provided.
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According to the invention, it has been found, to the complete surprise of the
skilled per-
son, that the copolymer comprising ethylene and vinyl acetate can
significantly improve
the mechanical properties of the decoupling web compared to decoupling webs
known
from the prior art. Thus, on the one hand, a significantly better adhesion,
preferably by up
to 60%, can be achieved compared to decoupling webs known in practice. The
adhesion is
improved in particular to the fleece and/or to the tile adhesive. Moreover,
the decoupling
web is not only substantially more flexible, but also exhibits better
decoupling properties
than decoupling webs known in practice. Due to the flexibility, for example,
the packaging,
in particular into rolls, of the decoupling web can be made easier, which
reduces the effort
required for storing the decoupling web.
In particular, the improved adhesion of tile adhesive to the decoupling web
can also im-
prove the adhesive tensile strength of the entire decoupling web.
The term "ethylene vinyl acetate" (EVA, also known as EVAC) ultimately refers
to a group
of copolymers formed by the polymerization of ethylene and vinyl acetate.
Despite the
strong branching of the chain molecules, the structure of ethylene vinyl
acetate is crystal-
line only in a few places. With a corresponding vinyl acetate content, the
ethylene vinyl ac-
etate can be partially crystalline and thermoplastic. A translucent formation
of the eth-
ylene vinyl acetate is also known. The density and other properties are
particularly de-
pendent on the vinyl acetate content (VAC). At a lower vinyl acetate content
(VAC), the
ethylene vinyl acetate is more translucent, tougher, more flexible and more
dimensionally
stable under heat compared to PE-LD. A higher vinyl acetate content reduces
strength,
stiffness and chemical resistance.
The copolymer according to the invention comprising ethylene and vinyl acetate
exhibits a
flexibility at least substantially similar to rubber and ultimately resembles
soft polyvinyl
chloride, in particular in its property profile. At the same time, however,
tear and impact
resistance as well as light transmission and, in particular, gloss increase.
According to the invention, it is preferred that the properties of the
decoupling membrane
with respect to waterproofing, vapour pressure compensation and good drying
are further
ensured. The decoupling membrane according to the invention is waterproof,
enables
good vapour pressure compensation and also good drying. The vapour pressure
equalisa-
tion and the drying can also be improved by the fact that the channels
extending over the
decoupling web, which run between the adjacent studs, are connected to one
another indi-
rectly and/or directly for the entire nub web.
According to the invention, the decoupling effect is advantageously designed
in such a way
that, on the one hand, no cracks are formed in the surface of the covering
facing away from
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the decoupling web and, on the other hand, possible cracks in the underground,
which in
particular only occur after the decoupling web has been laid, do not show in
the tile adhe-
sive layer and/or the covering elements. Consequently, an improved load
distribution can
be achieved by the addition of EVA according to the invention.
5
Furthermore, the decoupling web according to the invention enables a high
winding capa-
bility, so that the decoupling web can be easily rolled up, preferably for
transport. Fur-
thermore, the decoupling web according to the invention can have a high
torsional stiff-
ness and/or a high torsional stiffness, so that the decoupling web cannot be
kinked and/or
twisted, in particular by 900.
Furthermore, it was found in tests carried out that, in addition to its
excellent decoupling
properties, the decoupling web according to the invention also exhibits very
good impact
sound insulation. This effect is also the result of the addition of the
copolymer comprising
ethylene and vinyl acetate according to the invention.
In a particularly preferred embodiment of the present invention, the carrier
web compris-
es at least one thermoplastic polymer and/or elastomer as a further material.
In particu-
lar, the thermoplastic polymer and/or elastomer may be hard polyethylene
(HDPE), poly-
ethylene (PE) and/or polypropylene (PP). Accordingly, the material of the
carrier web
may comprise another thermoplastic polymer material in addition to the
copolymer com-
prising ethylene and vinyl acetate. In particular, the copolymer comprising
ethylene and
vinyl acetate may be blended with the further material. Alternatively or
additionally, it is
possible according to the invention for the further material to have a mass
fraction in the
material of the carrier web of at least 20 wt.%, preferably between 30 wt.% to
99 wt.%,
more preferably between 40 wt.% to 95 wt.%, further preferably between 50 wt.%
to 80
wt.%.
In tests carried out, it has been found that by adding the copolymer
containing ethylene
and vinyl acetate to thermoplastic materials known in practice for the carrier
web, the es-
sential properties of the decoupling web, in particular the decoupling
properties and the
adhesive tensile strength, can be significantly improved, preferably by up to
50%.
Preferably, the copolymer comprising ethylene and vinyl acetate, in particular
the eth-
ylene-vinyl acetate (EVAC), has a mass fraction in the material of the carrier
web of at least
5 wt.%, preferably between 10 wt.% and 80 wt.%, more preferably between 20
wt.% and
60 wt.%, and in particular at least substantially between 25 wt.% and 55 wt.%.
Depending
on the proportion of the copolymer comprising ethylene and vinyl acetate in
the material
of the carrier web, in particular in relation to the further thermoplastic
material, the prop-
erties, in particular the adhesive tensile strength and/or the decoupling
properties, of the
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decoupling web can be adjusted accordingly. Individual adaptation to the
respective cus-
tomer requirements and/or the properties intended for the respective use can
then be
readily possible.
Furthermore, in another preferred embodiment of the invention, it is provided
that the
copolymer comprising ethylene and vinyl acetate has a vinyl acetate content of
at least 5%,
preferably between 10% to 50%, more preferably between 12% to 40%, further
prefera-
bly between 16% to 30%, and in particular at least substantially between 25%
to 29% , in
particular based on the copolymer comprising ethylene and vinyl acetate.
Depending on the proportion of vinyl acetate, the properties of the copolymer
can be ad-
justed or varied accordingly, in particular depending on the respective
customer require-
ments, use specifications or the like. Macroscopically, the modulus of
elasticity of the ma-
terial, in particular of the copolymer comprising ethylene and vinyl acetate,
should de-
crease with an increasing proportion of vinyl acetate (VAC). At a vinyl
acetate of about 40
to 70 wt.%, the copolymer comprising ethylene and vinyl acetate is largely
amorphous,
whereas at a vinyl acetate of below 30 to 40 wt.%, the copolymer comprising
ethylene and
vinyl acetate is semi-crystalline and thermoplastic. Preferably, it is
provided that the co-
polymer comprising ethylene and vinyl acetate is thermoplastic, so that in
particular the
vinyl acetate content is below 40 wt.%, based on the copolymer comprising
ethylene and
vinyl acetate.
In experiments carried out, it has been found in the course of the invention
that with a vi-
nyl acetate content of 28% +/- 2%, the properties of the overall decoupling
web could be
further improved as compared to other vinyl acetate contents. Moreover, the
copolymer
containing ethylene and vinyl acetate with a vinyl acetate content of 28% is
not only inex-
pensive but also readily available, which greatly simplifies the production of
the carrier
web. The copolymer comprising ethylene and vinyl acetate, in particular
ethylene-vinyl
acetate, having a vinyl acetate of about 28% is also referred to as "EVA28".
In addition, it has been found during the development of the invention that
the decoupling
properties and/or the adhesion, in particular the adhesive tensile strength,
can be signifi-
cantly improved by a multilayer structure of the carrier web compared to the
decoupling
webs known in the prior art. In this regard, a multilayer structure of the
carrier web may
comprise layers differing from one another with respect to adhesion, adhesive
tensile
strength, elasticity and/or elongation at break. Consequently, it is possible
to selectively
adjust the mechanical properties of the decoupling web by means of the layer
structure of
the carrier web, in particular as a function of individual customer
requirements.
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Preferably, the carrier web has an at least two-layer layer structure, wherein
at least two
layers (A, B) have a material composition that differs from one another. The
differing ma-
terial composition has an effect in particular with regard to differences in
flexibility, elas-
ticity, adhesion and/or adhesive tensile strength.
Accordingly, this aspect of the multilayer construction of the carrier web is
particularly
advantageous in combination with the addition of the copolymer comprising
ethylene and
vinyl acetate to the material of the carrier web and/or as the material of the
carrier web.
Accordingly, the copolymer comprising ethylene and vinyl acetate can be
incorporated
both in the entire carrier web, in particular in each layer of the carrier
web, or also only in
at least one layer of the carrier web. This allows a high adaptability of the
carrier web to
different purposes or but also environments of use. For example, the outer
side of the car-
rier web facing the nonwoven and/or the tile adhesive can be provided with
and/or mixed
with the copolymer comprising ethylene and vinyl acetate, whereby the adhesion
to the
nonwoven and/or the tile adhesive can be significantly improved.
Particularly preferably, at least one layer - either layer A and/or layer B -
of the carrier
web comprises and/or consists of the copolymer comprising ethylene and vinyl
acetate, in
particular ethylene-vinyl acetate (EVAC). Particularly preferably, at least
one outer layer
comprises and/or consists of the copolymer comprising ethylene and vinyl
acetate, as
previously mentioned. Preferably, a layer structure in the form A-B-A or A-B
is provided.
In a layered structure of the form A-B-A, the outer layers A, A may be at
least substantially
identical in construction - i.e. the same material composition and/or the same
layer thick-
ness.
In principle, a layered structure in the form A-B-C would also be conceivable,
in which case
an outer layer C would be different from the outer layer A. In this case, the
outer layer C
can have a different proportion of the copolymer comprising ethylene and vinyl
acetate or
contain no copolymer at all comprising ethylene and vinyl acetate.
The aforementioned layer structures enable, according to the invention, that
the copoly-
mer containing ethylene and vinyl acetate is ultimately used in those layers -
and contrib-
utes to the improvement of the mechanical properties there - where it is also
"needed".
For example, it is not immediately necessary to integrate the copolymer
comprising eth-
ylene and vinyl acetate in the middle layer (layer B), although this is of
course not exclud-
ed according to the invention.
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The outer sides and/or outer layers of the backing sheet may comprise the
copolymer
comprising ethylene and vinyl acetate, it being possible, if required, for
only one outer side
and/or one outer layer of the carrier web to comprise the copolymer comprising
ethylene
and vinyl acetate. By integrating the copolymer comprising ethylene and vinyl
acetate into
the outer layers, in particular the adhesion of the carrier web to nonwoven
and/or the ad-
hesion to the tile adhesive, in particular the adhesive tensile strength of
the carrier web,
can be significantly improved compared to the decoupling webs known in the
prior art.
In a further preferred embodiment, it is provided that only one outer layer
(A) and/or the
outer layers ((A, A) and/or (A, C)) comprise(s) the copolymer comprising
ethylene and vi-
nyl acetate. Alternatively, according to the invention, it is possible that
each layer ((A, B)
and/or (A, B, C)) of the layered structure (for example, A-B, A-B-A and/or A-B-
C) of the
carrier web comprises and/or consists of the copolymer comprising ethylene and
vinyl
acetate. Ultimately, the copolymer comprising ethylene and vinyl acetate can
be input
and/or introduced precisely into the layers in which the properties, in
particular the me-
chanical properties, are to be improved.
In tests carried out, it has been determined that the layer (A, B, C)
comprising the copoly-
mer comprising ethylene and vinyl acetate has a mass fraction of the copolymer
compris-
ing ethylene and vinyl acetate in the material of the layer (A, B, C) of at
least 5 wt.%, pref-
erably between 10 wt.% and 80 wt.%, more preferably between 20 wt.% and 60
wt.%, fur-
ther preferably between 25 wt.% and 55 wt.%. According to the invention, it
has been
found that the aforementioned mass fractions of the copolymer comprising
ethylene and
vinyl acetate particularly improve the adhesion and the decoupling properties
of the en-
tire decoupling web and in particular of the carrier web. In particular, at
least one thermo-
plastic polymer and/or elastomer is provided as further material in the layer
(A, B, C)
comprising the copolymer comprising ethylene and vinyl acetate. Very
preferably, HDPE,
PE and/or PP is provided as the thermoplastic polymer.
Preferably, the copolymer comprising ethylene and vinyl acetate is blended
with the fur-
ther material of the layer (A, B, C) comprising the copolymer comprising
ethylene and vi-
nyl acetate with the further thermoplastic material. The further material may
in turn have
a mass fraction of the material of the carrier web and/or of the mass fraction
of the mate-
rial of the layer (A, B, C) of at least 20 wt.%, preferably between 30 wt.% to
99 wt.%, more
preferably between 40 wt.% to 95% by weight, further preferably between 50
wt.% to 80
wt.%.
Very preferably, it is provided that the mass fractions of the further
thermoplastic material
added to the mass fractions of the copolymer comprising ethylene and vinyl
acetate in the
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layer (A, B, C) comprising the copolymer comprising ethylene and vinyl acetate
add up to
100% by weight. This means that the layer (A, B, C) comprising the copolymer
comprising
ethylene and vinyl acetate comprises only one other thermoplastic material in
addition to
the copolymer comprising ethylene and vinyl acetate.
Furthermore, in a very particularly preferred embodiment of the present
invention, it is
provided that the outer layer (A) and/or the outer layers (A, A) and/or the
outer layers (A,
C) have at least 10%, preferably between 10% to 90%, further preferably
between 40% to
60% and in particular at least substantially 50%, of the layer thickness of a
further, in par-
ticular central, layer (in particular layer B). The advantage of the above-
mentioned ratios
is that the outer layers (layer A or layer C) can have a smaller layer
thickness and thus a
smaller proportion of material - measured in terms of the total proportion of
material of
the carrier web - in comparison with the "main layer" or central layer B. In
the course of
the development of the invention it has been found that for the improvement of
the adhe-
sion and the decoupling properties according to the invention by the addition
of the co-
polymer containing ethylene and vinyl acetate, an addition in the outer layers
of the layer
structure is sufficient.
A multilayer structure of the carrier web can be readily produced by extrusion
molding.
Thus, a coextrusion die and/or a multilayer die may be used for applying or
producing the
carrier web. Alternatively or additionally, it may be provided that the
carrier web can be
produced by thermoforming thermoplastic material.
In particular, the extrusion die may be a multi-layer die which provides a
layer structure in
the form A-B-A or A-B-C or A-B.
Alternatively or additionally, according to the invention, it may be provided
that a multi-
layer blown film is produced which is formed in a thermoforming process, in
particular af-
ter its production.
Furthermore, the aforementioned preferred ratios of the layer thicknesses of
the layer
structure of the carrier web can ensure the lowest possible material
consumption of the
copolymer comprising ethylene and vinyl acetate, while at the same time
ensuring the im-
provements according to the invention associated with the copolymer comprising
eth-
ylene and vinyl acetate compared to the prior art.
Preferably, the carrier web, in particular the decoupling web, has an adhesive
tensile
strength of greater than 0.1 N/mm2, preferably greater than 0.2 N/mm2, more
preferably
between 0.2 N/mm2 and 5 N/mm2.
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The adhesive tensile strength is determined by means of a special test, which
is also called
adhesive tensile test and/or tear-off test. DIN EN 12004:2017-05 has a
specification for
determining the adhesive tensile strength under defined conditions.
5
Adhesive tensile strengths of the order of magnitude mentioned above enable,
in particu-
lar, good adhesion to the underground and also ensure good adhesion to the
tile adhesive.
According to the invention, the adhesive tensile strength of the carrier web
can be in-
creased by adding the copolymer comprising ethylene and vinyl acetate.
In a further preferred embodiment of the present invention, it is provided
that the carrier
web, in particular the decoupling web, has a modulus of elasticity of less
than 100 GPa,
preferably less than 10 GPa, more preferably between 0.01 to 5 GPa and
preferably be-
tween 0.05 to 2.5 GPa. The modulus of elasticity is a material characteristic
value from ma-
terials engineering, which ultimately describes the proportional relationship
between
stress and strain during the deformation of a solid body in the case of a
linear-elastic be-
havior. The modulus of elasticity is the proportional elastic constant in
Hooke's law. The
higher the modulus of elasticity, the less elastic and/or flexible the solid
body.
In particular, the modulus of elasticity can be determined according to EN ISO
527-1 (as of
May 2019). The aforementioned standard is a European standard for plastics for
the de-
termination of tensile properties, which can be determined by a tensile test
with a tensile
testing machine.
Furthermore, the decoupling web may comprise a fabric and/or non-woven layer,
in par-
ticular on the side opposite of the carrier web plane. The fabric and/or non-
woven layer
may be firmly bonded to the carrier web, in particular wherein the fabric
and/or non-
woven layer is laminated to the carrier web. The adhesion to the nonwoven
layer can be
improved, preferably by up to 30%, compared to the prior art, in particular by
using the
copolymer comprising ethylene and vinyl acetate. A spunbonded nonwoven can be
used as
the nonwoven, in particular wherein a spunbonded nonwoven comprising a
thermoplastic
is provided, preferably a polypropylene spunbonded nonwoven.
The nonwoven may ultimately correspond to the nonwovens already known in
practice,
which are arranged on a carrier web.
Furthermore, in another embodiment of the invention, it may be provided that
the nubs
are spaced apart and, preferably, transverse to the longitudinal direction and
in the longi-
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11
tudinal direction of the decoupling web. In this respect, the nubs may be
spaced from the
carrier web plane and from a lower nub plane formed by the nub end face.
Ultimately, the
nubs constitute so-called "depressions" in the carrier web, so that ultimately
an upper car-
rier web plane results which comprises a plurality of depressions formed by
the nubs, so
that the nub end faces form the lower nub plane. According to the invention,
the afore-
mentioned formation of the nubs enables "channels" to be formed which
contribute to de-
coupling.
According to the invention, different shapes of the nubs are conceivable. For
example, an
at least substantially cuboidal nub may be used. A nub with an at least
substantially three-
legged shape - as seen in cross-section - is also conceivable.
In particular, elliptical, preferably round and/or oval, shapes - seen in
cross-section - of
the nub are also conceivable.
The nubs formed as recesses ultimately form side walls of the nubs, which
connect the nub
end faces to the carrier web plane.
Very particularly preferably, it is provided that the nubs and/or at least one
nub have, at
least in sections, an undercut, preferably on at least one side wall of the
nub. The undercut
serves to improve the adhesion and/or the bonding of the tile adhesive.
According to the invention, it is understood that the decoupling web is filled
after being
laid on an underground, in particular wherein the outer side of the carrier
web comprising
the fleece or fabric layer is arranged against the underground. Filling out
can be carried
out in particular with tile adhesive. A surface covering, in particular tiles,
can then be ar-
ranged on the tile adhesive. The tile adhesive can preferably be introduced
into the nubs
and/or into the depressions formed by the nubs and filled out over the
decoupling web.
The tile adhesive penetrates the undercut during the filling process,
resulting in improved
adhesion. This in turn leads to a fixation and/or positive locking of the tile
sheet and/or
covering elements to be applied to the decoupling web.
In a particularly preferred embodiment of the invention, the formation for
forming the
undercut on the inside of the nub is crescent-shaped or arcuate and/or arcuate-
section-
shaped and/or crescent-shaped. In particular, this arcuate section-shaped
formation re-
sults in improved demolding during the manufacture of the decoupling web. In
contrast to
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12
angular undercuts, a rounded or sickle-shaped form of the undercut
advantageously en-
sures an easy separation between the forming tool and the decoupling web.
Thus, the de-
coupling web in particular cannot be damaged during demoulding. Moreover, the
rounded
undercuts preferably serve to ensure that the stress peaks of the shear stress
of the lining
elements are reduced and/or evenly distributed on the decoupling web.
Very particularly preferably, it is provided that the nubs, in particular all
the nubs, are at
least substantially identical in construction.
In another preferred embodiment, the height of the nubs is between 1 mm and 5
mm,
preferably 2 mm to 4 mm, more preferably 2.5 mm to 3.5 mm. This comparatively
low
stud height allows for a low overall layer build-up and implies the reduced
amount of tile
adhesive required for the connection between the decoupling web and the
covering ele-
ments. Nevertheless, due to the addition of the copolymer comprising ethylene
and vinyl
acetate according to the invention, a strong bond is achieved between the tile
adhesive
and the decoupling web while simultaneously achieving an excellent decoupling
effect.
In another preferred embodiment, the clear distance between adjacent nubs has
a width
greater than 2 mm, in particular between 3 mm to 9 mm, preferably between 4 mm
to 8
mm, more preferably between 5 mm to 6 mm. This clear distance also determines
the
width of the channel section and definition with the free space to the
adjacent nubs.
In addition, in a further preferred embodiment, it is provided that the ratio
of the area of
the nub bottoms and/or nub end faces of all studs to the carrier web plane is
preferably
between 40% and 70%, further preferably between 45% and 55%, and in particular
at
least substantially 50%. In tests carried out, it has been found that, if the
aforementioned
ratios are observed, particularly good decoupling values can be achieved with
a simulta-
neously particularly firm fixing of the tile adhesive to the decoupling web.
The aforemen-
tioned ratios, together with the nub height, also decisively define, among
other things, the
required quantity of tile adhesive used to bond the decoupling web and the
covering ele-
ment. On the carrier plate, in particular, a load distribution of the
occurring tensile stress
is made possible by the channels, because preferably a compensation of the
occurring
stress is carried out. In tests, it was ultimately found that the ratio of 40%
to 60%, prefer-
ably 45% to 55%, is particularly advantageous and exhibits good decoupling
properties
and good adhesive tensile strength.
Moreover, it is understood that any intermediate intervals and individual
values are in-
cluded in the aforementioned intervals and range limits and are to be
considered disclosed
as essential to the invention, even if these intermediate intervals and
individual values are
not specifically indicated.
Date recue / Date received 2021-12-16
CA 03143883 2021-12-16
13
Further features, advantages and possible applications of the present
invention will be ap-
parent from the following description of examples of embodiments with
reference to the
drawing and the drawing itself. In this connection, all the features described
and/or illus-
trated constitute, individually or in any combination, the subject-matter of
the present in-
vention, irrespective of their summary in the claims and their relation back.
It shows:
Fig. 1 a schematic representation of a layered structure of the
carrier web accord-
ing to the invention,
Fig. 2 a schematic representation of a further embodiment of a
layered structure
of the carrier web according to the invention,
Fig. 3 a schematic representation of a further embodiment of a
layered structure
of the carrier web according to the invention,
Fig. 4 a schematic representation of a further embodiment of a layered
structure
of the carrier web according to the invention,
Fig. 5 a schematic cross-sectional view of a decoupling web according
to the in-
vention for use for a tile covering,
Fig. 6 a schematic perspective view of a decoupling web according to
the inven-
tion,
Fig. 7 a schematic perspective view of a further embodiment of a
decoupling web
according to the invention, and
Fig. 8 a schematic perspective view of a further embodiment of a
decoupling web
according to the invention.
Date recue / Date received 2021-12-16
CA 03143883 2021-12-16
14
Fig. 6 shows a decoupling web 1. The decoupling web 1 has a carrier web 3 and
a plurality
of nubs 5 projecting from the carrier web plane 4. The carrier web 3 has as
material a plas-
tic and/or consists of a plastic. In particular, the carrier web 3 may
comprise a thermo-
plastic material.
Fig. 5 shows that the decoupling web 1 is provided for use for a surface
covering structure
2 which can be covered with covering elements, in the illustrated embodiment
example
with tiles 14. Fig. 5 shows that a tile covering is provided as the surface
covering structure
2.
The carrier web 3 shown in the embodiment examples has as material a copolymer
con-
taining ethylene and vinyl acetate and/or consists thereof. In particular, the
copolymer
comprising ethylene and vinyl acetate is formed as a copolymer of ethylene and
vinyl ace-
tate, preferably as ethylene-vinyl acetate (EVA, EVAC).
The carrier web 3 may comprise as further material at least one thermoplastic
polymer
and/or elastomer. In particular, the thermoplastic polymer and thus the
further material
may be HDPE, PE and/or PP. The copolymer comprising ethylene and vinyl acetate
may be
blended with the further thermoplastic material. Moreover, the further
thermoplastic
plastic material of the carrier web 3 may have a mass fraction of the material
of the carrier
web 3 between 40 to 95 wt.%. The proportion of the material of the carrier web
3 of the
further thermoplastic plastic material, in particular in relation to the
copolymer compris-
ing ethylene and vinyl acetate, can be selected depending on the application
environment
or the intended use.
Not shown is that the copolymer comprising ethylene and vinyl acetate may have
a mass
fraction of the material of the carrier web 3 of at least 5 wt.%, and in
further embodiments
between 25 wt.% to 55 wt.%.
Furthermore, it is not shown that the copolymer comprising ethylene and vinyl
acetate has
a vinyl acetate content of at least 5% and, in further embodiments, between
16% and 30%
- based on the copolymer comprising ethylene and vinyl acetate. In particular,
the copol-
ymer comprising ethylene and vinyl acetate is thermoplastic.
In Fig. 1, it is shown that the carrier web 3 has a single-layer structure and
is thus formed
by the material layer A. In this context, it is understood that this layered
structure can also
be produced by a multi-layer extrusion die, wherein the layer A can
consequently be ap-
Date recue / Date received 2021-12-16
CA 03143883 2021-12-16
plied in several layers of the same material composition. Ultimately, the
material layer A
has an at least substantially homogeneous material distribution.
Fig. 2 shows that the carrier web 3 has at least a two-layered layer structure
6. In Fig. 2,
5 layers A and B are provided, wherein both layer A and layer B are formed
as outer layers,
i.e. form an outer side of the carrier web 3. The layers A and B have a
different material
composition from each other. The layer A, shown in Fig. 2, may face the tile
adhesive.
Furthermore, at least one layer A and/or B of the carrier web 3 may comprise
the copoly-
10 mer comprising ethylene and vinyl acetate. In particular, the outer
layer A comprises the
copolymer comprising ethylene and vinyl acetate. In Fig. 2, a layer structure
in the form A-
B is shown. Here, the layer B may or may not have the copolymer comprising
ethylene and
vinyl acetate.
15 Fig. 3 shows a layered structure in the form A-B-A, wherein the outer
layers A may be of
the same or identical design with respect to their layer thickness 7 and/or
their material
composition. The layers A shown in Fig. 3 may have a material composition
differing from
that of the layer B.
Fig. 4 shows a layer structure 6 with the layer sequence A-B-C. Here, the
layer C may have
a material composition and/or layer thickness 7 that differs from the outer
layer A and/or
from the layer B. In particular, the outer layer C has a modified proportion
of the copoly-
mer comprising ethylene and vinyl acetate or no proportion at all of the
copolymer com-
prising ethylene and vinyl acetate.
In further embodiments, it may be provided that only an outer layer A and/or
the outer
layers A, A or A, C comprise and/or have the copolymer comprising ethylene and
vinyl ace-
tate. In this context, the further layer B provided between the outer layers
(A or A, A or A,
C), in particular the centrally enclosed layer B, may not comprise any portion
of the copol-
ymer comprising ethylene and vinyl acetate.
Furthermore, in further embodiments it may be provided that each layer A, B or
A, B, C of
the layer structure 6 of the carrier web 3 may comprise the copolymer
comprising eth-
ylene and vinyl acetate, wherein the individual layers may be different with
respect to
their material composition, their properties and/or their layer thicknesses 7.
In principle,
it is of course also possible that, in addition to the layers A, B, C, a
plurality of further lay-
ers can be provided which differ with respect to or from the layers A, B
and/or A, B, C by
their material composition, their properties and/or their layer thickness 7.
Date recue / Date received 2021-12-16
CA 03143883 2021-12-16
16
The layer A, B and/or C comprising the copolymer comprising ethylene and vinyl
acetate
may have a mass fraction of the copolymer comprising ethylene and vinyl
acetate in the
material of the respective layer A, B and/or C of at least 5% by weight. In
particular, the
mass fraction of the copolymer comprising ethylene and vinyl acetate in the
outer layer A
and/or in the outer layer C is between 30 to 50 wt.%. In the aforementioned
layers A, B, C,
as a further material - in addition to the copolymer comprising ethylene and
vinyl acetate
- at least one thermoplastic plastic material (in particular a polymer and/or
elastomer)
may be provided. The plastic material may be HDPE, PE and/or PP. The copolymer
com-
1 0 prising ethylene and vinyl acetate may be blended with the further
plastic material. The
further plastic material may have a mass fraction of between 50 to 90 wt.% of
the material
of the carrier web 3 and/or of the material of the layer A, B and/or C
comprising the co-
polymer comprising ethylene and vinyl acetate. Very preferably, the mass
fraction of the
further plastic layer in layer B is greater than the mass fraction of the
copolymer compris-
ing ethylene and vinyl acetate.
Furthermore, in further embodiments, it may be provided that the mass fraction
of the co-
polymer comprising ethylene and vinyl acetate in the outer layers A and/or C
is greater,
preferably by at least 50%, than the mass fraction of the copolymer comprising
ethylene
and vinyl acetate in the central and/or further layer B, respectively.
In Figs. 2 to 4 it is shown that the outer layer A and/or the outer layers A,
A and/or A, C
have at least 10 %, in the embodiment example shown at least substantially
50%, of the
layer thickness 7 of a further, in particular central, layer B. Accordingly,
the material of the
layer B may have a significantly higher proportion of the total material of
the carrier web 3
or of the layer structure 6 of the carrier web 3, in particular of up to 80%
and/or of at least
40%.
It is not shown that the carrier web 3, in particular the decoupling web 1,
has an adhesive
tensile strength of greater than 0.1 N/mm2, in further embodiments between 0.2
N/mm2
to 5 N/mm2.
Furthermore, it is not shown that the carrier web 3, in particular the
decoupling web 1,
has a modulus of elasticity of less than 100 GPa, in further embodiments
between 0.05 to
2.5 GPa.
Fig. 5 shows that the decoupling web 1 comprises a fabric and/or non-woven
layer 8. In
the illustrated embodiment example, a non-woven layer 8 is provided. The non-
woven
layer 8 is firmly connected to the carrier web 3. In this regard, the non-
woven layer 8 may
Date recue / Date received 2021-12-16
CA 03143883 2021-12-16
17
be laminated to the carrier web 3. In the illustrated embodiment example, the
non-woven
layer 8 is arranged at the nub end faces 10 and/or at the nub plane 11.
The non-woven layer 8 is arranged on an underground 17, as can be seen in Fig.
5. There-
by, the non-woven layer 8 may be bonded to the untereground 17 via an adhesive
layer. In
the illustrated embodiment example, the non-woven layer 8 is bonded to the
underground
17 by means of the tile adhesive 13.
In the embodiment example shown in Fig. 5, it may be provided that the tile 14
has a
height of about 5 mm +/- 3 mm. The height of the nubs 5 may be about 4 mm. The
tile ad-
hesive 13 applied to the top of the carrier web 4 may for example have a
height of between
2 to 10 mm, in particular between 3 to 6 mm. The thickness of the carrier web
3 and/or
the non-woven layer 8 may be about 0.5 mm. On the underside of the non-woven
layer 8,
the tile adhesive layer may have a height of between 3 and 6 mm.
Figs. 6 to 8 show that the nubs 5 are arranged at a distance from one another.
The nubs 5
extend both in the longitudinal direction L and transversely to the
longitudinal direction L.
In the present case, the nubs 5 have an ordered arrangement. However, this
need not be
the case. Unordered arrangements of the nubs 5 are also possible. The nubs 5
have a dis-
tance 9 from the upper carrier web plane 5 and a lower nub plane 11 formed by
the outer
nub end faces 10. The nub plane 11 is formed by the nub end faces 10.
Fig. 6 shows that the nubs 5 form an at least substantially cube-shaped
depression. Figs. 7
and 8 show that the nubs 5 have an at least substantially three-legged cross-
sectional
shape. In principle, however, other shapes are also possible.
The distance 9 from the upper carrier web plane 5 is ultimately defined by the
height of
the side walls 16 of the nub 5, the side walls 16 connecting the carrier web
plane 4 to the
nub plane 11. The side walls 16 ultimately define the nub interior 15 of the
nubs.
Fig. 5 shows that the nubs 5 and/or at least one nub 5 has an undercut 12 at
least in sec-
tions. In the illustrated embodiment example, the undercut 12 is formed in the
shape of a
crescent or an arcuate section. An undercut 12 having an at least
substantially rectangular
cross-sectional shape is also possible in principle.
In Fig. 8, it is shown that projections 18 are provided on the nub end faces
11. Ultimately,
the projections 18 can have any shape and ultimately serve to structure the
nub base.
Date recue / Date received 2021-12-16
18
Execution example
A number of embodiments according to the invention are given below, which are
com-
pared with a comparative example 0 (not according to the invention).
The embodiments according to the invention to be compared with each other and
the
comparative example 0 not according to the invention have an at least
substantially iden-
tical construction of the shape of the decoupling web, the nub shapes of the
examples cor-
responding to each other in geometrical form. The embodiments ultimately
differ only
with respect to their material composition.
The carrier webs of the decoupling web are manufactured by extrusion of
thermoplastic
material and subsequent shaping on a vacuum deep roll. To form a decoupling
web, a
spunbonded polypropylene fleece is laminated to the carrier web on the nub
plane. The
extrusion is carried out with a multi-layer die, wherein the "single-layer
structure" is also
obtained by the multi-layer extrusion die, although the same material
composition is ulti-
mately present in the applied layers, so that the multi-layer extrusion die
can then pro-
duce a single-layer structure.
Furthermore, the embodiments to be compared have at least substantially the
same over-
all layer thickness of the carrier web, and in the case of a multilayer
structure, the ratio of
the layers is indicated in the table below. The nub shape of the embodiments
corresponds
at least substantially to the square nub shown in Fig. 6.
Furthermore, the materials EVA28, EVA18 and HDPE of the embodiments correspond
to
each other.
The embodiments have the following material composition:
7125868
Date recue/Date received 2023-05-15
19
Example Layer A Layer B Ratio A:
B : A
Comparison example 0 100 % HDPE / /
Example 1 70 % HDPE / /
30 % EVA28
Example 2 60 % HDPE / /
40 % EVA28
Example 3 50 % HDPE / /
50 % EVA28
Example 4 70 % HDPE 100 % HDPE 0,25 :
0,5 : 0,25
30 % EVA28
Example 5 60 % HDPE 100 % HDPE 0,25 :
0,5 : 0,25
40 % EVA28
Example 6 50 % HDPE 100 % HDPE 0,25 :
0,5 : 0,25
50 % EVA28
Example 7 70 % HDPE 90 % HDPE 0,25 :
0,5 : 0,25
30 % EVA28 10 % EVA28
Example 8 60 % HDPE 95 % HDPE 0,25 :
0,5 : 0,25
40 % EVA28 5 % EVA28
_
Example 9 70 % HDPE / /
30 % EVA18
Example 10 60 % HDPE / /
40 % EVA18
Example 11 60 % HDPE 100 % HDPE 0,15 :
0,7 : 0,15
40 % EVA28
Example 12 30 % HDPE 100 % HDPE 0,15 :
0,7 : 0,15
70 % EVA18
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Date recue/Date received 2023-05-15
20
Example 13 30 % HDPE 100 % HDPE 0,3 : 0,7: 0
70 % EVA18
Example 14 30 % HDPE 1000/0 HDPE 0,2 : 0,8: 0
70 % EVA18
In examples 12 and 13, a two-layer structure is provided, namely a layer
structure of the
form AB. A spunbonded layer comprising polypropylene is arranged, in
particular lami-
nated, on the layer B.
HDPE is provided as the thermoplastic further plastic material and also as the
material for
the comparative examples not according to the invention. The copolymer
comprising eth-
ylene and vinyl acetate is formed as ethylene-vinyl acetate and has a vinyl
acetate content
of at least substantially 28% based on the copolymer of ethylene and vinyl
acetate. This
material is referred to as "EVA28". Another copolymer comprising ethylene and
vinyl ace-
tate is formed as ethylene-vinyl acetate and has a vinyl acetate content of at
least substan-
tially 18% based on the copolymer of ethylene and vinyl acetate. This material
is referred
to as "EVA18". When the copolymer of ethylene and vinyl acetate is added to
the thermo-
plastic material, it is envisaged that it is admixed with the thermoplastic
material prior to
extrusion of the carrier web. Extrusion is performed with both the
thermoplastic resin ma-
terial and the copolymer of ethylene and vinyl acetate.
The above-mentioned design examples have been examined with regard to
different crite-
ria. The adhesive tensile strength has been determined according to DIN EN
12004-
02:2017-05. Furthermore, the modulus of elasticity has been determined to
determine the
flexibility. In addition, the decoupling properties have been investigated
when using the
decoupling membrane as a decoupling underlay for a tile covering. Furthermore,
the adhe-
sion to the tile adhesive of the decoupling membrane has been determined. The
water
tightness has also been determined.
The results table shown below relates the experimental results relative to
each other. The
following results can be achieved:
unsatisfactory result
= -- unsatisfactory result
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Date recue/Date received 2023-05-15
21
= o: satisfactory result
= +: good result
= ++: very good result
The table below illustrates the results:
Adhesive Adhesion to Water-
Example tensile Flexibility the tile adhe-
Decoupling
strength sive density
Comparison example o o - ++ o
0
Example 1 o + +/++ ++ +/++
Example 2 + ++ ++ ++ ++
Example 3 ++ ++ ++ ++ +
Example 4 + o/+ + ++ +
Example 5 ++ + ++ ++ ++
Example 6 ++ + ++ ++ ++
Example 7 + + +/++ ++ +/++
Example 8 ++ +/++ ++ ++ ++
Example 9 o o 0 ++ +
Example 10 o + + ++ +/++
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Date recue/Date received 2023-05-15
22
Example 11 ++ +/++ ++ ++ +/++
Example 12 ++ +/++ ++ ++ ++
Example 13 ++ ++ ++ +/++
Example 14 ++ +/++ ++ ++ ++
The above results illustrate that by adding the copolymer containing ethylene
and vinyl
acetate to the material of the carrier web according to the invention, both
the adhesive
tensile strength and the flexibility (by reducing the modulus of elasticity)
can be improved.
Even with increasing amounts of the copolymer containing ethylene and vinyl
acetate
(EVA28) only in the outer layers (layer A), very good adhesive tensile
strengths can be
achieved. Even up to 50% of the copolymer containing ethylene and vinyl
acetate (EVA28)
or even up to 70% of the copolymer containing ethylene and vinyl acetate
(EVA18) can be
added to the outer layer A without the decoupling web becoming too soft.
Furthermore, even better flexibility results are obtained if the central layer
B sandwiched
between the outer layers A also contains the copolymer comprising ethylene and
vinyl ac-
etate.
Alternatively, very good results are also achieved if, in a two-layer
structure (AB), only the
outer layer A contains the copolymer comprising ethylene and vinyl acetate.
Ultimately, the water resistance remains virtually unaffected by the addition
of the copol-
ymer containing ethylene and vinyl acetate.
In addition to the adhesive tensile strength, the addition of the copolymer
comprising eth-
ylene and vinyl acetate can also improve the adhesion to the tile adhesive and
the decou-
pling properties. This results in an improved application and use of the
decoupling sheet
according to the invention.
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Date recue/Date received 2023-05-15
23
Reference List:
1 Decoupling web
2 Surface covering structure
3 Carrier web
4 Carrier web plane
5 Nubs
6 Layer structure
7 Layer thickness
8 Nonwoven layer
9 Distance
10 Nub end faces
11 Nub plane
12 Undercut
13 Tile adhesive
14 Tile
15 Nub interior
16 Side wall
17 Underground
18 Projection
A Layer
B Layer
C Layer
L Longitudinal direction
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Date recue/Date received 2023-05-15
