Patent Application
20210108422
The present invention relates to a reusable lightweight panel mat system for the construction of equipment support surfaces and temporary walkways and roadways in areas having poor ground integrity characteristics. More particularly, the present invention relates to a reusable system of durable panel mats which are much lighter than wood or wood/steel mats which can be quickly and easily positioned in a single layer to form equipment support surfaces, walkways or roadways and which can thereafter be easily removed and stored until needed again.
While conventional wood mats provide useful service at a reasonable cost, the wood core can deteriorate over time due to moisture causing gradual rotting and degradation of the wood material. This causes the mat to be discarded, because unlike some of the other materials that are used on the upper and lower layers of the mat, the core cannot be replaced without essentially making an entirely new mat.
Reusable lightweight panel mat systems can be expensive to produce, rent, or purchase and although durable can be subject to damage from the operation of machines or equipment on its working surface. The cost, time, and effort to replace a mat due to damage can be expensive to the operator of the site that is using the panels. A single panel mat can also be heavy to life and move and if damages, may have usable aspects that may be wasted if replaced.
Thus, there is a need for improvement in these types of mat constructions both to provide longer service lives as well as to conserve natural resources and facilitate installation, and these needs are now satisfied by the panel mats of the present invention.
In accordance with principles of the invention, a lightweight universal panel mat made of plastic or elastomeric material and designed to be interlocked with additional panel mats of similar configurations is provided. The panel mat comprises a first section having an upper surface that forms a peripheral top surface of the panel mat and is relatively flat and provides a receptacle that is adapted to receive one or more removable panels; a second section having geometry that supports the first section; first, second, third and fourth sides forming a perimeter of the mat, wherein, the first and second sides are adjacent and each includes an upper structure that has an upper surface that extends the top surface of the mat and a lower surface that slopes downwardly towards the bottom surface of the mat and the third and fourth sides are adjacent and each includes a lower structure that has a lower surface that extends the bottom surface of the mat and an upper surface that slopes upwardly towards the top surface of the mat. Each upper and lower structure includes at least one opening passing therethrough. The downwardly sloped lower surface of the upper structure and the upwardly sloped upper surface of the lower structure are configured to allow for overlapping with respective lower and upper structures of other like mats when placed adjacent thereto for joining therewith by which the overlapped upper and lower structures form a generally flat continuous top and bottom surface of the overlapped mats and wherein the first and second sections are welded or bonded together to form a unitary panel mat.
In a preferred embodiment, the mat includes one or a plurality of removable panels with the first section forming a frame around the one or more removable panels.
In some embodiments, the first section comprises four sections that are attached together and form a frame that shapes sidewalls for the receptacle.
In some embodiments, the one or more panels are a plurality of removable panels that are locked to each other to thereby form a working surface and the panels are removable from the working structure to be replaced if damaged.
In some embodiments, the panels are removable panels of two different types that interengage. The sidewalls of the receptacle may include protrusions or recesses for joining with mating recesses or protrusions of the removable panels so that the panels can be locked to and secured to the sidewalls of the receptacle or to each other.
The panels preferably have a uniform configuration to facilitate removal and replacement of damaged panels. This can be a rectangular or square shape and a plurality of apertures that are configured to align with adjacent similarly configured panels. Alternatively, it can be an I- or Y-shape with protrusions and recesses for mating with adjacent similarly configured panels.
In some embodiments, the one or more panels comprises an array of removable panels wherein each removable panel comprises a cam that connects to an adjacent removable panel.
In some embodiments, each removable panel comprises a hook that engages a cam when locked.
In some embodiments, each removable panel comprises a protrusion that mates with an adjacent removable panel.
In some embodiments, the removable panels have a rectangular or square shape.
In some embodiments, the receptacle comprises sidewalls and a bottom surface that form an area that fits an array of the panels that are locked to each other to form a working a surface.
A support surface, deck, walkway or roadway comprising one or a plurality of the panel mats disclosed herein can be provided with the mats attached each other. These mats preferably include one or a plurality of panels that are removable when damaged and that are replaced by a like configured panel to extend the service life of the support surface, deck, walkway or roadway. The support surface, deck, walkway or roadway can be one that is constructed for temporary or permanent use.
Each mat typically includes an array of removable panels locked to each other and positioned in the receptacle of each panel mat. Also, the second section can include cells under the first section in an area that forms a frame for the removable panels.
The invention also provides a method of extending the service life of a support surface, deck, walkway or roadway which comprises constructing the support surface, deck, walkway or roadway with a plurality of mats disclosed herein; and replacing any of the removable panels that become damaged to allow continued use of the support surface, deck, walkway or roadway without having to replace an entire mat.
The invention is more fully appreciated upon a review of the appended drawing figures which illustrate the most preferred embodiments of the invention and wherein:
Certain terms that are used herein are defined hereinbelow to assist in the understanding of the invention.
The terms “substantially” and “relatively” are used for their ordinary meanings to indicate that the dimensions or configurations are not precise or exact. A skilled artisan can readily determine what tolerances are acceptable to provide a surface that is considered to be flat based upon the size of the panel mats and the type of service that the panel mats are expected to provide. Typically, the terms “substantially” or “relatively” will mean that a surface can vary by as much as an inch or two although in the more preferred embodiments the variance is less than 1 inch.
Additionally, all dimensions recited herein are approximate and can vary by as much as 10% to in some case 25%. In some situations, the term “about” is used to indicate this tolerance. And when the term “about” is used before reciting a range, it is understood that the term is applicable to each recited value in the range. Often, the craftsmanship and engineering procedures that are followed in construction of these mats minimize these tolerances as much as possible or industrially practical.
The present invention relates to improvements to panel mats related to adapted the panel mats to receive “sub panels” that form a working surface of the panel mat. The sub panels, which are generally referred to as removable panels are assembled in a receptacle or recess in the panel mat to from the surface area. The removable panels are connected to each other using mechanical attachments. The removable panels fit together to form a continuous surface subject to small seams where the removable panels abut. If an individual removable panel is damaged (e.g., due to on-the-job use) the damaged removable panel can be removed and replaced without the need to remove or replace other removable panels or the panel mat. The removable panels are adapted to have a mechanism that permits an individual removable mat to be disconnected from adjacent mats and removed from the panel mat. Removable in this context means a panel that has mechanical connectors that can be locked into place and unlocked for removal by hand or a mechanical tool. The following discussion first discussed the structure of panel mats and is followed by a discussion of panel mats having removable panels.
A rectangular panel mat can for example be square or rectangular and be made of plastic or elastomeric material. The panel mat can be made of first and second sections (for two layer mats) or with an additional third section (for three layer mats) which are part of an integral component that is molded to have the desired configuration and features. Typically, the first and second sections are molded together in one operation while the third section is later joined to the mat formed from the first and second sections. Alternatively, a two layer mat can be made from a solid integral plastic or elastomeric component wherein the tabular extensions, openings and slots or recesses are milled or routered into the component top provide the configurations and features. The third section can then be added to the formed mat. Preferably, however, the first and second sections are separately molded and then combined in the desired configurations disclosed herein. To form the panel, the molded first and second sections may be joined together by welding, an adhesive, molding, bonding, or by joining via an interlocking structure. Having each section heated and joined together in a press is another and more preferred joining option. The panel mat is configured to have a receptacle formed by a recess on the top of the panel mat. The receptacle is configured to receive removable panels that can be tiled together and are adapted to fit the shape and height of the receptacle. The receptacle can be formed by forming a first section to have a recess. By way of another example, the receptacle can be formed by providing four side pieces that are arranged to form a frame. The receptacle can have a bottom for receiving the removable panels (forming a bottom support) that is provided by forming the first section to have a recess and walls that form the frame or for example by the second section (and for example having the first section having walls that form the side walls of the receptacle).
The mats can have various sizes in a square of rectangular configuration typically ranging from 1′×1′ to 16′×16′ with rectangular sizes typically ranging from 1′×2′, 2′×6′, 3′×8′, 4′×8′, 4′×10′, 6′×9′, 6′×12′, 8′×12′, 8′×16″ and even 12′×16′. Larger sizes can be provided for certain specialty applications if desired. For manual installation, a square panel mat can have a 42″ side configuration as this facilitates molding of the first and second sections and results in a lightweight panel mat. The sections are typically molded to a thickness of between about 1/16″ to ⅕″ depending upon the plastic or elastomeric material that is used to make the panel. The panels themselves are slightly smaller than the overall size of the mat as they are configured and dimensioned to be received in the receptacle. The 42 inch square panel can have one or more replaceable panels as desired and would have a weight of approximately 40 pounds when molded from upper and lower halves of high density polyethylene each having a skin thickness of 0.2 inches. The preferred mats have sizes of 2.5′×2.5′, 3′×3′, 3.5′×3.5′ or 4′×4′ as these are relatively easy to be moved because they would have a weight of about 100 pounds or less so that they can be lifted and installed by manual labor rather than heavy equipment. The larger size panels are heavier but the temporary or permanent flooring can be installed more quickly given the greater area that these mats cover.
Rectangular mats can be used wherein the length dimension is double the size of the width dimension. Thus, along the length of one mat, two additional similarly configured mats would be joined thereto whereas the width dimension would be joined to half of the length of an adjacent mat. And if desired, combinations of square and rectangular mats can be joined together to form any particular shape decking or temporary roadway or walkway. As an example, a 42 inch square panel mat can also be joined to a rectangular panel mat that is 42″×7′ long. And if desired, rectangular or square mats can be made. The only limitation is the way that these mats are shipped with widths up to about 8 feet being preferred so that the mats can be shipped by conventional tractor trailers.
The thickness of the panel mats should be between about 1 and 3″ and typically between 1.5″ to 1.75″ thick. The mats (including the mats that use removable panels) are constructed to withstand repeated traffic from shop forklifts carrying loads, semi-truck and trailer travel, and stage point loads all while being rigid enough to protect the surface from damage and prevent any rutting of the subgrade. Point loads of between 300 and 500 psi are provided as point loadings while spread loadings of 40,000 to 50,000 pounds per square foot are provided. Particularly preferred materials for these panel mats are HDPE or Polypropylene. The panel mat should not have any external fasteners as the tabs and openings, slots or recesses are incorporated into the mat structure itself to facilitate interlocking during installation.
The panel mats and removable mats can be molded of many different materials, including any conventional polymeric or copolymeric thermoplastic materials, thermosetting materials, or even fiberboard materials made of recycled plastic or polymeric materials from used carpets, plastic packaging and the like. Mixtures or combined blends of plastic materials may also be used. The panels may also be made of elastomeric materials which can be thermosets (requiring vulcanization) or thermoplastic.
A wide range of thermoplastic or polymeric materials can be used for the sections of the panel mats and removable mats of this invention. These materials would be molded or cast to the desired size and thickness of the mat. Useful materials include:
It is also possible to utilize fiberboard as the elongated members or sheets that form the core structure. The fiberboard material is made of recycled plastic or polymeric materials from used carpets, plastic packaging, rice hulls and the like. They can be provided in the desired sizes for use as the core structure of the mats of this invention. They can be combined with other plastic materials as is generally known. In addition to being environmentally resistant due to their plastic content, these fiberboard/recycled materials are environmentally friendly by allowing recycling of used plastics or polymeric materials.
The top and bottom sections may also be made of an elastomeric material. The elastomers are usually thermosets (requiring vulcanization) but may also be thermoplastic. Typical elastomers include:
Unsaturated rubbers that can be cured by sulfur vulcanization—these are preferred from a strength and hardness standpoint:
The elastomeric, thermoplastic or thermosetting materials disclosed herein can also be provided with conventional fillers to increase weight and hardness. They also can be reinforced with particulates, fibers such as glass, fabric or metal screening or scrim to reduce elongation and provide greater rigidity.
Regarding the configuration of the panels, the sections are separately molded with peripheral boundaries that are configured to match each other. The first and second sections can be blow-molded or compression molded to the desired sizes. Then, the sections are joined together where the boundaries are in contact by welding, adhesives, heating, or interlocking connections or combinations thereof. It is desirable for the sections to be joined together to form a waterproof structure so that any openings existing between the sections do not fill up with dirt or water during use. Typically, the first and second sections are sealed by welding or adhesives at a peripheral seam. To facilitate an adhesive or weld the joint, the peripheral boundaries can be provided with a minimum flange detailed to provide additional surface area for sealing. The third section can then be joined to the other two to forma three ply mat. As noted, the third section provides additional compression and strength to the panel mat by holding the cells in position where they cannot move laterally.
The first section and removable panels can be configured with an appropriate top surface that may be relatively flat, textured or structured to facilitate movement over the panel mat. While a completely smooth top surface may be used, it is preferred that the top surface at least include some texture or channels that facilitate the drainage of moisture and provide a more secure footing for movement across the panels. The channels can be formed by texturing or spaced raised islands or other structures that are provided in the top surface. The top surface (first section and/or removable panel) can also include raised or embossed patterns or designs that indicate the supplier or owner of the mats. When a flat or relatively flat surface is provided for the top surface, grit or particles can be included to assist in providing better traction when the surface becomes wet. The panels are configured to be oriented with the top section (including removable panels) being the surface which is traversed by personal or equipment while the lower portion of the second section faces the ground.
The bottom surface of the panel mats may also configured with a flat, textured or structured surface. Preferably, the bottom surface is textured, structured or is provided with openings so that the panel mat can be securely placed on wet or muddy ground. For the latter feature, the bottom surface can be provided with closed holes that are of essentially the same configuration as the islands of the top section and that are sufficient tall to extend to the islands to provide further support to the upper surface of the top section. If desired, the holes can be configured as wells or cups that have the same configuration as the islands so that the top surfaces of the holes or cups fit into the islands. This provides reinforcement of the upper surface to movement or articles that contact that surface. If desired, the holes and islands can be joined together by welding, adhesives, bonding, heating or by snap-locking.
Alternatively, the first and second sections can be molded together as a single component. For this the top section is a plate or sheet that has a flat bottom surface so that it forms the upper portion and tops of the cells while the second section includes the cell sidewalls. The result is that the cells are closed at the top by the first section and the cell sidewalls provide the strength reinforcement of the top section. The first and second sections can be molded together to form the single component. The same result can be obtained by welding or adhering a top section plate that has a flat bottom to the upper ends of the cells of the second section. Of course the receptacle remains for receipt of the panels.
The third section can be provided as a flat plate if desired so that the bottom surface of the panel mat is relatively flat. Of course, the third section can also be provided with cells or can be in the form of a grating or other structure that has openings, channels or indentations. As the second section provides some of this, the third section is typically used to provide a flat bottom surface and to hold the cells of the second section in position between the first and third sections. And in some embodiments, the bottom surface can also include a textured surface or a raised or embossed patterns or designs that indicate the supplier or owner of the mats so that it appears the same as to top surface of the mat or to provide better gripping or more secure placement on the ground. Generally, the ground is prepared to be relatively flat to receive the bottom surfaces of the panel mats, but the panel mats can also be placed on a previously prepared flat cement or asphalt surface to provide temporary protection of such surfaces. Typically, however, the panel mats are placed on earth, grass, or similar terrain to provide better footing and support for personnel or light equipment traffic. The textured or structure bottom surface facilitate a more secure placement on gravel or wet or muddy ground.
An advantageous structure for the lower surface of the second section can be described as a honeycomb or open cell structure. The structures can be implemented in conjunction with removable panels if desired (e.g., by having them exist under the framing portion of the first section or inside the removable panels). The term “honeycomb structure” refers to a structure that has openings or open cells therein which extend to the bottom surface of the bottom section. The shape of the cells can be hexagonal, square, rectangular, or of another polygonal shape, or they can even be round or oval provided that the top surfaces or configurations of the cells match the configuration and arrangement of the islands of the top section. Some or all of the cells have a top surface which extend up to and into the islands through the lower surface of the top section. As noted, the top surfaces of these cells are joined to the lower surfaces of the islands by a press fit, snap-locking, adhesives or spot welding. The flat tops of the cells can also support a flat lower surface of the top section. With this construction, the strength of the panel can be further increased as each cell acts as a separate support for the upper surface of the top section.
Typically, the honeycomb pattern of geometrical cells includes those that have a top surface having a perimeter of 3 to 12 inches. This includes round top surfaces of about 1″ to about 4″ diameter and square or rectangular trapezoids having side of about 1″ to about 4″. As noted, the tops of the cells can be open or some or all of them can be closed. The same is true of the bottoms of the cells, which again can be open or where some or all of the cells terminate in closed flat surfaces. Similar perimeters would be provided for other shapes (i.e., oval, pentagonal, hexagonal, octagonal, etc.). For greater compressive strengths, more dense (i.e., smaller size) cells may be provided. A skilled artisan can design the cell configuration for any particular compressive strength requirements based on the overall size of the mat and number of sections that are to be included.
The sidewalls of the cells are also configured to impart strength to the mat. These are typically provided at an angle with regard to the top or bottom surfaces of the mat rather than being perpendicular. Angles of between 45 and 75 degrees are preferred with 60 to 65 degrees being optimal.
The panel mats are carefully designed so that they can interlock with adjacent, similarly sized and configured panel mats to form a temporary surface or substrate upon which people or light equipment can be placed thereon or moved across much like a building floor. This interlocking is achieved by the unique design of the sides of the mat. As noted, the first and second sides each include an upper structure that has an upper surface that extends the top surface of the mat and a lower surface that slopes downwardly towards the bottom surface of the mat, while the third and fourth sides each include a lower structure that has a lower surface that extends the bottom surface of the mat and an upper surface that slopes upwardly towards the top surface of the mat. The downwardly sloped lower surface of the upper structure and the upwardly sloped upper surface of the lower structure are configured to allow for overlapping with respective lower and upper structures of other like mats when placed adjacent thereto for joining therewith by which the overlapped upper and lower structures form a generally flat continuous top and bottom surface of the overlapped mats.
The upper and lower structures of the mats also include a plurality of openings. The openings of the upper structures are provided with a lower portion that protrudes below the sloping side while the openings of the lower structures are configured to be slightly wider and recessed then the protruding portions of the upper structures. Alternatively, the upper structures can be provided with downwardly facing protrusions while the lower structures can be provided with recesses that receive the protrusions. These configurations allow the protruding portions of the upper structures to be received within the openings of the lower structures so that a secure connection can be made. In some embodiments, the components are configured to provide snap blocking of the upper layer into the lower layer. This can be done by providing a narrower rim around the upper edge of the lower opening or recess. Alternatively, the openings can be designed to receive a fastening or pinning member, such as a cam, which can be inserted and rotated to lock the upper structures to the lower structures. This provides the most secure connection between the mats that is the least resistant to separate or move apart when in use. Details of these configurations are described herein in connection with the appended drawings.
These panels are designed for quick and easy installation by one or two workers. To do this, a first mat is installed in a particular position with the lower structures exposed in the direction for addition of further mats. Thereafter, the upper structures of the additional mats are placed above the lower structures of the previously placed mat to connect the subsequent mats to the initially placed one. These operations are repeated until the entire temporary floor structure is completed. And the ends of the initially placed mats that have upper structures which are not in contact with lower structures of adjacent mats, a separate board or configured component can be placed beneath those sections for support to prevent breaking of upper structures. Alternatively, a certain number of the mats that are to be installed can be provided with only the lower structures on two sides and with opposite sides that are have the thickness of the entire mat. Similarly, on the last mats to be installed, the lower structure would not be receiving the upper structure of an additional mat. Again, a separate component can be added onto the lower structure to form the remaining upper surface of the mat, or certain mats can be provided only with upper structures on two sides and with the other two sides configured to have the thickness of the entire mat.
The openings are aligned so that they can easily be connected together, either by the upper protrusion engaging the opening of the lower opening, with or without snap-locking, and without requiring a large amount of force to connect the structures together during installation or to disengage them when removing the installation. Alternatively, the holes can be configured to receive a fastening component that can be quickly placed therein and turned to lock the edges together.
The configuration of these mats as well as the various sizes that can be used, facilitates a relatively quick and efficient installation of a temporary flooring system. The smaller mats are easily lifted and installed by one or more workers without the use of any connecting hardware. The mats are designed such that each subsequent mat can be laid upon an installed mat with the sloping members in contact.
The openings can be configured so that those on the side of one mat can be received by or placed upon those on the corresponding side of another mat with the alignment tabs and slots assisting in the proper placement of one mat next to another. And when a very secure flooring is needed, the cams or other pinning elements can be used to connect the openings of those sides of the mats together in a locked position.
The configuration of the openings is designed and made either with cutouts or with a shorter or smaller dimension that does not extend to the full width of the mat such that the tabular members can be easily placed therein without binding. In addition, when larger panel mats are in use, the lifting elements allows those mats to be simply and easily transported into position. In fact, the flooring installation proceeds in a manner such that after the initial panels are in place, the equipment that is lifting the mats can then move over the previously installed mats such that the field or gymnasium surface is not damaged by the installation equipment.
As mentioned, the following description will first describe the general construction of panel mats followed by a description of the panel mat adapted to use and include removable panels in an area on the top surface of the panel mat.
Turning now to the drawings,
The opposite sides of the mat have the lower structures 120 that includes openings 125 and an upward sloping surface that is configured and dimension to conform precisely to the downward sloped surface of the upper structure.
And while these structures can have uniform descending or ascending flat surfaces, they are preferably made with different configurations such as undulations, or other irregular surfaces with the only requirement being that the upper structure and lower structure fit together to form a uniform thickness which is the same as that of the rest of the mat.
Joining technique for the first and second sections is to prepare them in a twin-sheeting operation. This operation, which is also known as twin sheet forming, combines the process disciplines of compression molding, blow molding, and vacuum forming to mold, laminate, and trim multiple layers of materials (substrates with cover stock) in a one step process. The twin sheet molding process forms two sheets of plastic simultaneously through the use of a separate mold on the top platen and a separate mold on the bottom platen. Once the plastic sheets have been vacuum formed, they remain in their respective molds. While both sheets still remain at their forming temperature, the two molds are brought together under high pressures and the two sheets are bonded together. The result is a single product with hollow areas requiring no secondary bonding operations.
Also illustrated in
The aligned holes 110, 125 are also illustrated. These can be configured as described herein where the holes on the first section 200 can include a lower protrusion that fits within the opening 110 of the second section 300. Alternatively, the second section 300 can have a raised periphery around the opening which fits into a recess in the bottom of the opening 125 of the first section 200. The main feature of these holes are that they are in alignment to allow interlocking and connection of one mat to an adjacent, similarly configured mat.
Additionally, a third section 400 in the form of a flat plate is later added to the support component if desired when the flat bottom surface 130 is desired for the mat.
The third section preferably is used to provide a flat bottom surface for the panel mat. It is possible for the third section to be configured so that it also extends beneath the tabular members to further reinforce those members and help them resist damage during installation when the tabular members are inserted into the openings, slots or recesses, as well as to protect against damage from impact if the panel mats were to be dropped in a way where the tabular members would engage the ground first and bear the force of the weight of the mat. This is typically used on flat or graded surfaces, such as those provide by cement, asphalt or clay.
The first 200 and second 300 sections are joined together in a first operation either by compression molding or by heating and pressing the sections together. These sections also can be joined by suitable adhesives or by welding. Third section 400 can then be optionally added in a second operation where it is welded to the second section 300 of the joined first 200 and second 300 sections. The bottom surface 130 of the mat is selected based on the intended use of the mats.
And while the cells are a preferred embodiment, it is also possible to configure the second section 300 with other structures that can support the first section 200 and upper surface 105 of the mat. Such other structures can include rod or bar members that are preferably rectangular and that are placed between and adhered to the first section 200 and second section 300 whether in the form of parallel spaced members or in the form of intersecting members that form a grid or grating-like structure that contacts the bottom of top surface 105 for support. The particular internal configuration between the first and second sections can be selected based on the anticipated weight and forces that the upper surface 105 of the mat will experience in use. And the formation of spacing between the bars or rods whether they are interconnected or not provide the equivalent of the cells of the current embodiment, with the top surfaces of the bars or rods providing the necessary support for the upper surface 105 of the mat. In embodiments having a receptacle for removable panels the panel mat can be adapted to include members outside of the area for the receptacle.
The mat 500 may have a flat upper surface 105 although it is possible to configure that surface with channels or other irregularities for water removal. For use indoors or in areas that are shielded from the elements (e.g., under a tent), a flat top surface is acceptable.
To provide a bottom flat surface 130 for the mat, third section 400 is provided as a separate flat plate. This plate 400 may be bonded to the lower side of the second section by welding, adhesives or by applying heat and pressure to the components in a mold. Third section 400 includes cut outs so that the openings of the upper and lower structures are not blocked.
As noted, although not necessarily preferred for certain embodiments, the panel mats can be formed of first and second sections that are obtained from a single piece of plastic or elastomeric material that is cut, drilled, milled or routered to the desired shape and configuration. For example, a solid sheet or molded plastic or rubber can be configured with the taps, slots, openings, and surface features described herein. While this is more expensive, the costs for setting up the machining equipment would be amortized across the large number of mats that would be produced with these features. This can be used to form the first and second sections of the mat while when a flat or closed bottom surface is desired, this would be achieved by the addition of a third section of a flat plate.
And as noted, the channels that are linear or random lines or grooves on the top and bottom surfaces of the panel mat allow water to drain from the top surface while also allowing the bottom surface of the mat to be more securely placed on wet or muddy ground. And the bottom surface may include openings as shown herein for the second to partially receive gravel or other prepared ground surfaces to again more securely anchor the panel mat in place. It also can be flat by the addition of a third section.
The mats can also be joined to form a temporary flooring installation that is continuous or discontinuous, i.e., one that leaves certain openings between joined mats. This allows the mats to be placed around trees, light towers or other obstacles that exist in the area that is to be provided with a temporary flooring of joined mats. In particular, it is relatively easy to leave openings such as by simply omitting one or more mats to provide open space in the floor structure. This can serve a number of purposes, such as allowing the floor structure to be installed around a column, pole, post or other upstanding structure, as well as to leave open space for a light tower, camera tower, and video screen support or speaker support tower. Furthermore, in the event that a mat is damaged after installation, it can be unlocked, disconnected and removed for replacement by another similarly sized and configured mat without having to remove all further mats that are connected together in the installation. Similarly, with use of the removable panels, in the event that a removable panel is damaged after installation, it can be unlocked, disconnected and removed for replacement by another removable panel without having to remove all further mats or panels that are connected together in the installation.
The top patterns or structures that are applied to the mats (and panels) also provide the capability to change out the center section to customize the mat with any particular design for a purchaser of the mat. This enables the costumer to advertise its company name or logo as well as to indicate the user or manufacturer of the mat. And furthermore, it is possible to add wraps, fabrics or coatings of a particular logo onto the upper surfaces of the mat. The logo can be applied to each mat or portions of a logo can be applied to different mats such that when they are connected, a much larger logo is made to provide enhanced visibility.
With reference now to
With reference now to
With reference now to
With reference now to
To replace a damaged panel mat, the frame closest to the damaged mat must first be removed. Then, panels are removed from the removed frame area to the location where the damaged mat is located. Thereafter, the damaged mat is removed and replaced with a new panel mat. Finally, the remaining mats and frame are reinstalled to provide a renewed overall mat. This can be done in the field or back at the factory where the mats were initially made. Either way, most of the mat is re-used with only one or a small number of the panel mats becoming damaged to the point where replacement is needed.
Referring now to
Preferably, the removable panel comprises a plastics material moulding, with an internal frame of metal or some other sufficiently strong material embedded with that moulding. In this case, the internal frame may provide projecting tabs and receptors for the tabs of another like panel. Further, the internal frame may provide connection points for other components to be attached to the panel.
With reference now to
As shown in
The insert may be made of other materials besides metal. For example, it might be moulded from a hard plastics material, or could be a carbon or glass fibre reinforced plastics moulding.
The removable panels of
The panel mats themselves can be modified to fit any particular installation. A temporary floor installer would generally know how many mats are needed for a particular installation, as well as the width and length of the area to be protected by the temporary flooring, along with what types of openings may be needed to go around trees, poles, towers, etc. Thus, the installer can provide a kit with the requisite number and sizes of mats, adapters, half adapters, short adapters and side ramps and appropriate locking elements or cams so that the installer or purchaser would obtain everything needed for the installation. Generally, at least 3 cams are provided per mat to join the two upper structures to lower structures of an adjacent mat or to an adapter. One cam would be located in the corner opening of the mat, and one each would be located on the two adjacent sides. The lower structures on the other two sides of the mat are connected from the upper mat structure or side ramp that is placed above it, generally with two cams. Of course, more locking elements could be used depending upon the expected use of the temporary flooring system or to at least have a few spare locking elements in case some are damaged during installation. The kit could also include installation instructions showing how to start the laying and connecting of the mats.
The plastic and elastomeric materials disclosed herein generally have sufficient strength for many applications, but their strength and rigidity can be enhanced by reinforcing the material with appropriate fillers or other materials, such a glass fibers, other particular matter as is generally known in the art. The additional placement of a metal wire, bar, rod or plate into the mold that is used to prepare the sections or in between the sections before they are sealed together can provide further strengthening of the panel mats. Typical metals for such use would be steel, stainless steel or aluminum.
In some embodiments, the panel mats can be made translucent. When these panel mats are to be used outdoors and the mat materials are not sufficiently resistant to withstand long term exposure to sunlight, appropriate additives to improve the UV resistance of the material can be included.
The panel mats can be provided in different sizes, but generally, square mats or rectangular mats having longitudinal sides that are twice as long as the mat width are preferred. The thickness of the mat can vary depending upon the intended use of the mat. As noted herein, the thickness also determines the size of the side ramp angled portion. Also, the thickness is determined based on the thickness of each of the first, second and third sections. These can be varied as desired for the intended application, with thicker first and third sections and perpendicular cell walls in the second section being used for heavier load bearing installations.
The panel mats can be made with different materials and reinforcements for different applications. As the outer surfaces of the mats may be very similar in appearance, it is not readily observable as to which panel mat has a particular construction. For this reason, another aspect of the invention relates to the providing of each mat with identification means that indicates the material, reinforcement and construction of the panel mat. Thus, when a number of different panel mats are maintained in an inventory, the identification means enables operators to readily determine which mats have the particular materials and properties needed for a particular end use, so that the correct mats can be selected and provided to a jobsite for use by the customer. This would be necessary whether the mats are being purchased by the customer or whether the mats are being leased for use.
Therefore, in sum, it is to be realized that the optimum dimensional relationships for the parts of the invention can include variations and tolerances in size, materials, shape, form, function and use are deemed readily apparent and obvious to the skilled artisan, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the claims appended hereto.
Unless defined otherwise, all technical and scientific terms used herein have same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Also, as used herein and in the appended claims, the singular form “a”, “and”, and “the” include plural referents unless the context clearly dictates otherwise. All technical and scientific terms used herein have the same meaning.
The foregoing detailed description is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily be apparent to those having ordinary skill in the art, it is not desired to limit the invention to the exact constructions demonstrated. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 62/914,386, filed on Oct. 11, 2019, the entirety of which is expressly incorporated herein by reference thereto.
| Number | Date | Country | |
|---|---|---|---|
| 62914386 | Oct 2019 | US |
