FIELD OF THE INVENTION
This invention relates to modular floor mats, and more particularly to a system of modular floor mats capable of being connected in a variety of configurations for temporary roadways and flooring.
BACKGROUND
Modular flooring of various designs has been utilized for a significant period of time to provide a temporary walking or other rigid surface in areas where permanent flooring is either not necessary or prohibitively expensive. Modular flooring mats and systems are commonly used in industrial, construction and event applications to provide temporary roadways or flooring in outdoor or indoor environments. For example, these systems may be assembled on surfaces such as ice, grass, or artificial turf, as well as in industrial or construction areas. With respect to industrial or construction areas, temporary flooring may be utilized to provide walkways, driveways, parking areas or other rigid surfaces for the transport of materials, vehicles, storage or mounting of equipment, or simply as a walking, seating or standing surface for people. The modular nature of such flooring is utilized to adapt the flooring to the particular topographic or geographic needs of the particular site and to also allow for the efficient storage and transport of the modular flooring.
These temporary surfaces are commonly assembled from a plurality of modular floor mats connected to one another in adjacent and/or overlapping fashion. There are a wide variety of ways known to connect such floor mats in assembling a temporary surface, including fasteners such as cam locks and pins which rotate between locked and unlocked positions. Such fasteners extend through the mats through overlapping flanges on each edge of adjacent mats, where such flanges contain bores extending therethrough to accommodate the fasteners. Commonly, these bores will have one or more recessed ledges to accommodate the head or foot of the fasteners. Without a recessed ledge, the head or foot of a pin may project beyond the generally planar surface of the mat. For example, each flange may have a thickness equal to half of the thickness of the central portion of a mat and may extend in a co-planar fashion with either face of the mat. With these features, flanges may be arranged to create a substantially planar surface of uniform depth when the flange of one mat is placed in overlapping fashion over the flange of an adjacent mat-save for any tread features on either face of the mat. Tread is essential in industrial and construction applications so that vehicles and workers may comfortably and safely traverse the surface. However, in most modular floor mat systems, the configurations of the mats are limited to planar configurations which mimic a roadway, without any accommodation for alternate configurations which may allow mats to be placed in novel configurations or traverse terrain in a non-planar manner. This limitation is due in part to the interference of tread with the fastener-bore interaction.
A number of current modular flooring systems fail to address, or even contemplate, a solution to a user's desire to arrange mats in non-planar configurations.
U.S. Pat. No. 6,695,527 to Seaux et al. discloses mats interlocking at overlapping flanges. A pin is insertable through bores in said flanges, and recessed ledges are provided to allow the pin to sit below a generally planar work surface (i.e., a work surface having treads). Both the upper and lower surfaces of the mats may have treads, while the intermediate surface between flanges does not. Seaux et al. do not disclose any alternate configuration of the mats, or any structure which would allow for such configurations.
U.S. Pat. No. 9,068,584 to McDowell et al. discloses a locking-pin-and-mat assembly. It contemplates that the mats are “reversible” because they are “substantially identical.” However, McDowell et al. do not discuss mats having tread, which would interfere with the overlapping of mats and non-planar configurations.
Indeed, some in the industry have attempted to overlap mats having tread with the tread of one mat abutting an adjacent mat. This creates space between the mats and reduces the degree to which fasteners can engage both mats effectively, or in some cases even prevents fastening of adjacent mats. To overcome this, some in the field force the fasteners, by overtightening or applying pressure to the mats to artificially compress the space. This results in the fastener digging into the mat, damaging the mat and impairing its structural integrity.
U.S. Pat. No. 6,722,831 to Rogers et al. disclose a fastener made of a pin and rod extending therethrough with the foot of the fastener extending beyond the projected body of the pin when rotated to lock overlapping mats. The mats have an oblong-shaped recessed ledge on one surface to receive the pin and a larger, and a circular recessed ledge on the opposite surface to accommodate the movement of the foot, shown in FIG. 8 and FIG. 9 of the '831 patent. This requires a specific orientation for overlapping and connection of adjacent mats that limits the overall applications.
There remains a need for a modular flooring system capable of being assembled in novel configurations in applications where a non-planar mat configuration is preferred. Such a system that could safely accommodate tread in overlapping fashion would also be preferred but has yet to be successfully solved.
SUMMARY
As shown in FIGS. 1A and 1B, as well as the remaining accompanying drawings, the present invention is directed to a modular mat for a ground covering and system comprised of a plurality of such modular floor mats. Each of said modular floor mats have bores extending therethrough to receive fasteners, and the bores have recesses at each surface to accommodate the head or foot of the pin. Notably, these recesses have different depths, also referred herein as “offset spacing”, from one another which allow for multiple configurations of overlapping mats, including a tread-to-tread configuration, without damaging or deforming the mats when locking such mats together. Such damage or deformation may be caused by excessive spacing between each mat due to tread which is formed on any outer surface of the mats. Prior mat systems such as those discussed above disclose recesses in which fasteners can be placed, but none appear to disclose that these recesses are anything other than identically sized or spaced. The references described herein together fail to disclose offset recess spacing which may accommodate alternate mat configurations, such as configurations where either the treaded surfaces of flanges are secured together or a treaded flange surface and a non-treaded flange surface are secured together.
Mats are normally connected in a planar fashion, as shown in FIG. 2, wherein mats are placed adjacent to one another to form a level roadway. When assembling mats in a non-planar fashion, such as a stacked or stepped configuration, as described in greater detail herein, the portions of the flanges having tread may be facing each other, extending the length of the bore. The present invention accounts for this extended length when needed and allows for mats to still connect normally when connected in a planar configuration. As described in further detail herein, using mats without offset spacing in non-planar configurations would cause the foot of the pin core to dig into the recesses as the core is rotated to a locking position, as mentioned above.
Each modular mat of the present system comprises a first surface on one side and an opposite second surface on the other side, as shown in FIG. 1B. At least one of these first and second surfaces may have tread extending therefrom by a height represented by “f”. A plurality of bores are formed in and extend through each mat from the first surface to the second surface and are configured to receive a fastener therethrough. Each bore has recesses at each end thereof, between a central portion of the bore and each of the first and second surfaces. These recesses may either be a tread-surface recess with a depth represented by “tr” or a non-tread surface recess, which may also be referred to herein as a planar surface recess, with a depth represented by “nr”. These recesses are shown in FIGS. 3-4B. A tread surface recess will be formed at the end of a given bore which is adjacent to the first or second surface having tread thereon. A planar surface recess will be formed at the end of a given bore which is adjacent to the first or second surface having no tread thereon. The first and second surfaces of each mat may each independently have tread or no tread thereon. In any case, nr is not equal to tr in a system of mats.
Generally, nr is equal to the sum of tr and t. This equation may factor in a tolerance of 1/16 inches. In a preferred embodiment, nr is equal to 0.450 inches, tr is equal to 0.300 inches, and t is equal to 0.150 inches. In alternate embodiments, nr is equal to tr+t, tr is equal to 0.300 inches, and t is between 0.100 inches and 0.200 inches. This relationship may be expressed by: nr=tr+t. However, as mats are used, the tread may wear and become thinner such that the equation may become nr≤tr+t.
Each mat may further have a flange formed on and extending from at least one edge of the mat, as shown in FIG. 1A. Each flange is co-planar with one of the first surface and second surface and recessed from the other of the first surface and second surface. The flange co-planar with the first surface is referred to as the overhanging flange; the flange co-planar with the second surface is referred to as the underhanging flange. In embodiments including a flange, the plurality of bores extends through the flanges, from the co-planar surface through to the recessed surface. Each flange may be approximately half of the thickness of a mat, such that overlapped flanges of adjacent mats will create a planar surface of substantially uniform thickness.
As shown in FIGS. 5-9B, the system further includes a plurality of fasteners sized to be received in the bores. Each fastener has a head sized and dimensioned to be received and retained within each of the tread surface or planar surface recesses. The head is larger than the remainder of the fastener and wider than the bore so that the head cannot pass completely through the bore and so that the fastener may be in the correct vertical alignment when securing two adjacent and overlapping mats together. A foot opposite the head of the fastener is also sized and dimensioned to be received within each of the recesses, but may be in an unlocked configuration, where the fastener is inserted into the bore, and a locked configuration, where the foot has been adjusted such that the foot interacts with the recesses, the fastener cannot be removed from the bore, and the fastener is securing adjacent mats together; this is shown in FIGS. 10A-10B. Accordingly, each fastener has a length sufficient to extend through the bores of adjacent mats when mats are overlapped and the bores are aligned.
The mats overall may measure between 6 and 8 feet from end to end, preferably between 7 and 8 feet from end to end, and more preferably about 89.5625 inches from end to end. Mats may have a thickness of between 3 and 6 inches, preferably between 4 and 5 inches, and most preferably about 4 inches. These mats may be arranged in any configuration relative to one another, examples are shown in FIGS. 11-12. In a standard, planar configuration, as shown in FIGS. 13A-14E, a first mat and a second mat may be overlapped such that the planar surface recess of the first mat is adjacent to the planar surface recess of the second mat. A first mat and a second mat may also be overlapped such that the planar surface recess of the first or second mat is adjacent to the tread surface recess of the other mat (FIGS. 15A-17B) or such that the tread surface recess of the first mat is adjacent to the tread surface recess of the second mat (FIGS. 18A-20B). Each of these recess combinations may result in varying overall configurations of the mats.
Three such overall configurations of the mats are described herein: standard planar configurations, stacked configurations, and stepped configurations. In a planar configuration at least one of the mats is placed adjacent to another of the mats such that the mats together form a substantially planar surface. As shown in FIGS. 13A-14E and as discussed above, the planar surface recesses are adjacent in this configuration, and the mats together create a larger substantially planar surface. In a stacked configuration at least one of the mats is placed completely overlapping another of the mats such that a collective height of the stacked configuration is equal to a sum of the heights of the mats. As shown in FIGS. 18A-18E and 20A-20B, the stacked configuration features adjacent tread surface recesses. In a stepped configuration without flanges at least one of the mats is placed partially overlapping another of the mats such that a collective height of said stepped configuration at the point of overlap is equal to a sum of said heights of said mats.
Stepped configurations in mats having flanges can either be high stepped configurations (FIGS. 19A-19B) or low stepped configurations (FIGS. 16A-17B). A high stepped configuration comprises an underhanging flange of one mat being placed overlapping the overhanging flange of another of the mats. A low stepped configuration comprises either (i) the overhanging flange of one mat being placed overlapping the overhanging flange of another of the mats (FIGS. 16A-16B) or (ii) the underhanging flange of one mat being placed overlapping said underhanging flange of another of said mats (FIGS. 17A-17B).
The method of assembling the foregoing system comprises using a plurality of mats and fasteners, arranging the same in one or more of the foregoing configurations, as desired, and inserting fasteners into bores of the mats. Each fastener is in an unlocked position when placed in the adjacent and aligned bores of adjacent mats and is subsequently manipulated or transformed into a locked position when in place in those adjacent bores. When locked, the system of mats is able to provide a stable surface to be used by industrial, recreational, or other traffic. When the assembled mat system is no longer needed, a user may unlock each fastener, remove the fasteners from their respective bores, and disassemble the mats. The mats may then be reassembled or reconfigured as needed.
The modular mat and floor covering system, together with their particular features and advantages, will become more apparent from the following detailed description and with reference to the appended drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1A is a top plan view of a modular flooring mat of the present invention.
FIG. 1B is a cross-sectional elevation view of the modular flooring mat of FIG. 1A along line 1B-1B.
FIG. 2 is a top plan view of two of the modular flooring mats of FIG. 1A in a planar configuration.
FIG. 3 is a cross-sectional elevation detail view of a flange of the modular flooring mat of FIG. 1B.
FIG. 4A is a cross-sectional elevation view of a pin and modular floor mat assembly without flanges in a no-tread to tread configuration where the pin is unlocked.
FIG. 4B is a perspective view of the pin and modular floor mat assembly of FIG. 4A.
FIG. 5 is a perspective view of a pin assembly of the present invention, including the pin core and pin body.
FIG. 6A is a cross-sectional elevation view of the body of the pin assembly of FIG. 5.
FIG. 6B is a perspective view of the body of the pin assembly of FIG. 5.
FIG. 7 is a perspective view of a tool used in conjunction with the pin assembly of FIG. 5 to lock and unlock the pin assembly.
FIG. 8A is a front elevation view of the pin assembly of FIG. 5 in an unlocked position.
FIG. 8B is a side elevation view of the pin assembly of FIG. 8A.
FIG. 9A is a front elevation view of the pin assembly of FIG. 5 in a locked position.
FIG. 9B is a side elevation view of the pin assembly of FIG. 9A.
FIG. 10A is a top plan view of the pin assembly of FIG. 5 in a locked position within a pair of modular flooring mats of FIG. 1A.
FIG. 10B is a bottom plan view of the pin assembly of FIG. 10A.
FIG. 11 is a perspective view of the modular flooring mats of FIG. 1A arranged in a combination of planar and stacked configurations.
FIG. 12 is a perspective view of the modular flooring mats of FIG. 1A arranged in a combination of planar, high stepped, and stacked configurations.
FIG. 13A is a cross-sectional elevation detail view of the modular flooring mats of FIG. 1B arranged in a planar configuration.
FIG. 13B is a broader cross-sectional view of the modular flooring mats of FIG. 13A showing the central core portion of the mats.
FIG. 14A is a detail, cross-sectional elevation view of a pin and modular floor mat assembly in a first, or no-tread to no-tread, planar configuration where the pin is unlocked.
FIG. 14B is a perspective view of the pin and modular floor mat assembly of FIG. 14A.
FIG. 14C is a side elevation view of the pin and modular floor mat assembly of FIG. 14A.
FIG. 14D is a top plan view of the pin and modular floor mat assembly of FIG. 14A.
FIG. 14E is a bottom plan view of the pin and modular floor mat assembly of FIG. 14A.
FIG. 15A is a detail, cross-sectional elevation view of a pin and modular floor mat assembly in a second, or no-tread to tread, stepped configuration where the pin is unlocked.
FIG. 15B is a perspective view of the pin and modular floor mat assembly of FIG. 15A.
FIG. 15C is a side elevation view of the pin and modular floor mat assembly of FIG. 15A.
FIG. 15D is a top plan view of the pin and modular floor mat assembly of FIG. 15A.
FIG. 15E is a bottom plan view of the pin and modular floor mat assembly of FIG. 15A.
FIG. 16A is an exploded, cross-sectional elevation detail view of the modular flooring mats of FIG. 1A arranged in a first low stepped configuration.
FIG. 16B is a broader cross-sectional view of the modular flooring mats of FIG. 16A showing the central core portion of the mats.
FIG. 17A is an exploded, cross-sectional elevation detail view of the modular flooring mats of FIG. 1A arranged in a second low stepped configuration.
FIG. 17B is a broader cross-sectional view of the modular flooring mats of FIG. 17A showing the central core portion of the mats.
FIG. 18A is a detail, cross-sectional elevation view of a pin and modular floor mat assembly in a third, or tread to tread configuration, which may be stacked or stepped, where the pin is unlocked.
FIG. 18B is a perspective view of the pin and modular floor mat assembly of FIG. 18A.
FIG. 18C is a side elevation view of the pin and modular floor mat assembly of FIG. 18A.
FIG. 18D is a top plan view of the pin and modular floor mat assembly of FIG. 18A.
FIG. 18E is a bottom plan view of the pin and modular floor mat assembly of FIG. 18A.
FIG. 19A is an exploded, cross-sectional elevation detail view of the modular flooring mats of FIG. 16A arranged in a high stepped configuration.
FIG. 19B is a broader cross-sectional view of the modular flooring mats of FIG. 19A showing the central core portion of the mats.
FIG. 20A is an exploded, cross-sectional elevation detail view of the modular flooring mats of FIG. 16A arranged in a stacked configuration.
FIG. 20B is a broader cross-sectional view of the modular flooring mats of FIG. 20A showing the central core portion of the mats.
Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION
The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
It is understood that the present subject matter may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided for the purpose of illustration and not in a limiting sense. Indeed, the subject matter is intended to cover alternatives, modifications, and equivalents of these embodiments, which are included within the scope and spirit of the subject matter as defined by the appended claims and their equivalents. It will be clear to those of ordinary skill in the art that the present subject matter may be practiced without such specific details set forth herein order to provide a thorough understanding of the present subject matter.
Although the subject matter has been described in language specific to structural features, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. It is contemplated that any features of one foregoing embodiment may be interchanged with an element of any of the other embodiments or the equivalents thereof.
As shown throughout the Figures, and with particular reference to FIGS. 1A and 1B, the modular mat 110 of the present invention is comprised of a central core portion 112 and a flange 120 extending from at least one side thereof, preferably from two adjacent sides of the central core portion 112. The mat 110 may be of any suitable dimension for the building of a temporary floor covering system or roadway, as described further herein. In at least one embodiment, as in FIGS. 1A and 1B, the mats 110 may be substantially square in overall shape, and measure between 6 and 8 feet from end to end (including central core 112 and flange 120), preferably between 7 and 8 feet, more preferably 89.5625 inches on each side in at least one embodiment, and between 3 and 6 inches in depth or thickness, preferably between 4 and 5 inches in depth. In at least one other embodiment, the mat 110 may be substantially rectangular in overall shape, including a permanently attached series of two mats, which as shown in FIGS. 1A and 2 may be attached by a plurality of screws 152 inserted through corresponding aligned apertures 150 of the mats 110, which may measure between 6 and 9 feet in length (preferably between 7 and 8 feet), between 12 and 16 feet in width (preferably between 13 and 15 feet), and between 3 and 6 inches in depth or thickness (preferably between 4 and 5 inches). In a preferred embodiment, each mat 110 measures approximately 7.5 feet long by 14 feet wide with a depth of 4 inches, although it should be understood that any suitable dimensions may be used.
Modular floor mats 110 of the present invention may be constructed of any suitable material that can withstand the intended load for the floor or ground covering. “Floor” and “ground” may be used interchangeably herein. For instance, the mats 110 may be made of a plastic material, such as polypropylene, polyethylene, polystyrene, acrylonitrile butadiene styrene, and polyvinylchloride. In a preferred embodiment, the modular floor mats 110 are constructed of high-density polyethylene (HDPE) post-industrial recycled plastic, optionally reinforced with adhesives for added strength, flex and impact characteristics. This material is resistant to a wide range of temperatures. The material is also extremely strong and able to bear large loads as are common in construction and industrial areas. The material composition of the mats 110 may additionally include impact modifiers for added strength, UV resistant fillers to prevent degradation and delamination and anti-static additives. However, it should be understood that the modular floor mats 110 may be constructed of any suitable material having the strength and durability requirements necessary for their intended purpose. For example, the material is also suitable for providing load bearing for lighter loads as well, such as pedestrian foot traffic in both industrial and non-industrial settings.
Optionally, the mats 110 may further be formed of identical or mirrored flipped layers. Each of the layers has an inner surface and an outer surface, respectively. Each of these layers may be made of the same material as discussed above, preferably HDPE plastic, optionally reinforced with adhesives or other additives to provide the desired strength and flex characteristics. Each of the layers may be formed by molding, such as compression molding or injection molding, or an otherwise appropriate technique for forming given the particular material used. mirrored, identical, or substantially identical dual layers which, when affixed together, are staggered to provide a flange 120. Each opposing layer may further provide a treaded surface 130, having various surface patterns to improve traction of personnel, pedestrians, or vehicles traversing the mats 110. In other embodiments, the entire mat 110 may be extruded as one piece.
Each modular mat 110 has a first surface 116 on one side and a second surface 118 on the opposite side, as shown in FIG. 1B. With reference to FIGS. 1A and 1B, each modular mat 110 comprises a central core area 112, and a flange 120 extending outwardly from the central core area 112. The central core area 112 comprises the majority of the mat 110 and provides the usable surface of the mat 110, upon which equipment and personnel may travel. As such, the central core area 112 is the primary load-bearing portion of the mat 110. It may therefore be substantially planar, to facilitate the bearing of load and conveyance of people and equipment thereon. The central core area 112 shown in FIGS. 1A and 2 is generally square or rectangular in shape, however, it may be of any suitable shape, including hexagonal or other geometries, provided that the mats 110 are adapted for overlapping and/or interlocking with adjacent mats 110.
The flange 120 extends outwardly from at least one side of the central core area 112. In at least one embodiment, as shown in FIGS. 1A and 1B, the flange 120 extends from two adjacent sides of the central core area 112. In preferred embodiments, the flange 120 may be formed integrally with the central core area 112 so as to extend continuously therefrom. In other embodiments, the flange 120 may be securely affixed to the central core area 112, such as through welding, adhesion or other method of secure attachment. Whether affixed to or formed integrally therewith, the flange 120 extends from the central core area 112 continuous with either the first 116 or second 118 surface, and the intermediate surface 124 of each flange is recessed from the opposite surface 116, 118. The flange 120 has a thickness less than the thickness of the mat 110, preferably being half of the thickness of the mat 110.
The flange 120 extending from the central portion 112 of each mat 110 is referred to herein as a flange 120 regardless of the orientation of the mat. However, for purposes of clarity, the flanges 120 may be referred to as overhanging 120a and underhanging 120b flanges. It is to be understood that by flipping the orientation of each mat the overhanging 120a flange may become the underhanging 120b flange, and vice versa. As shown in FIG. 1B, overhanging flange 120a has a surface coextensive with the first surface 116 and an intermediate surface 124a recessed from the second surface 118. Underhanging flange 120b has a surface coextensive with the second surface 118 and an intermediate surface 124b recessed from the first surface 116. As the reference for these structures 120a, 120b may change with the orientation of the mat 110, “flange” as used herein may refer to either or both flanges 120a, 120b. Similarly, an intermediate surface 124 may refer to either or both of the intermediate surface 124a, 124b.
In a preferred embodiment, the flange 120 and central core area 112 are formed of the same material, such as described above for the mats 110, such as, but not limited to, a high-density polyethylene (HDPE) plastic. The flange 120 is disposed along at least one edge of the mat 110. With reference to FIGS. 1A and 1B, the flange 120 is disposed along two adjacent edges of the mat 110. The flange 120 is configured and positioned to provide an area for an adjacent mat 110 to overlap and join the first mat 110, as will be discussed in greater detail hereinafter. As can be appreciated from FIG. 3, the flange 120 portion of the mat 110 may further be structured to taper or reduce in height as it extends away from the central core area 112. In other words, in some embodiments the flange 120 has a sloped incline such that it is thicker where the flange 120 meets the central core area 112 and becomes rounded at the end of the flange 120 extending farthest away from the central core area 112. Such geometry facilitates the overlapping and interconnection of adjacent mats 110 in various configurations to form a flooring system 100. For example, the rounded edge of the flange 120 is shaped so that either edge may directly abut the central core area 112 when in a non-planar configuration.
A single mat 110 of the present invention has a central core area 112, flange(s) 120 which extend therefrom, and first and second surfaces 116, 118. As used herein, the first surface 116 refers to the continuous surface extending from the central core portion 112 to the flange 120a, not including the intermediate surface 124a of such flange 120a. As used herein, the second surface 118 refers to the continuous surface extending from the central core portion 112 to the flange 120b, not including the intermediate surface 124b of such flange 120b.
The first and second surfaces 116, 118 are disposed for contacting and engaging elements such as walking or vehicular traffic, which may further include heavy loads of equipment, materials, or may simply involve a high degree of traffic. Accordingly, the first and second surfaces 116, 118 include a plurality of traction elements, or treads 130, to increase the friction on the surface and permit the vehicle and/or pedestrian greater purchase on the surface. The treads 130 therefore increase the safety of the mat 110. The treads 130 generally extend outward from one or both of the first and second surfaces 116, 118 sufficiently to provide additional friction to the surface, but not so far as to be an impediment to motion across the surface. The treads 130 may also be recesses in the first and second surfaces 116, 118, or a combination of extensions and recesses. They may be disposed in any orientation and configuration along the first and second surfaces 116, 118.
It should also be understood that one or more of the modular floor mats 110 may be provided with one or more sloped side edges to permit wheeled vehicles, such as wheelchairs or construction vehicles, to gain access to the modular flooring system 100. Such sloped side edge may contain one or more receiver pins or other features which mate with the features of the adjacent mats 110, including the flanges 120 thereof.
In a preferred embodiment, the mat 110 includes different grades of tread 130 for creating different amounts or types of friction, which may be particularly suited for a specific kind of traffic. These different grades of tread 130 may be located on the same surface of the mat 110. Alternatively, each first and second surface 116, 118 of the mats 110 may have different grades of tread 130 so that the same mat 110 may be used in multiple environments. In a preferred embodiment, the tread 130 is disposed on the first and/or second surface 116, 118 of the mat 110. This tread 130 extends to the edges of the planar surface of the mats 110, including the portion of the flange 120 continuous with such central portion 112, but without extending on to the intermediate surfaces 124. Therefore, the intermediate surface 124 at the recessed portion of the flange 120 is a non-tread surface 124 of the mat 110. Non-tread surfaces of a mat 110 may be referred to herein as planar surfaces, however, a planar surface should not be interpreted to have no texture or be completely homogenous; a planar surface as used herein is a surface 116, 118, 124 not having tread 130 extending therefrom. In a planar configuration, this intermediate surface 124 is hidden between the flanges 120 of adjacent mats 110.
For instance, each first and/or second surface 116, 118 includes a plurality of industrial grade treads 130. These industrial grade treads 130 are raised portions of the first and/or second surface 116, 118 and are of a size and shape appropriate to support the heavy weight loads of industrial applications, such as construction vehicles and equipment, as well as engage large tires or other traction elements during inclement weather or submersion in water or mud. The number and distribution of the industrial grade treads 130 may vary according to a particular contemplated weight load. Generally, the heavier the weight intended to be supported on mats 110, the larger in size and dimension and/or number of the industrial grade treads 130 present on the outer surface 118. Such treads 130 may rise between 0.10 and 0.20 inches above the surface 116, 118 of the mat 110, preferably rising 0.150 inches above the surface 116, 118 of the mat 110.
In an alternate embodiment, each first and/or second surface 116, 118 includes a plurality of pedestrian grade treads 130. These pedestrian grade treads 130 are preferably raised portions of the first and/or second surface 116, 118, and are of a size, shape and configuration to support people walking, running, dancing, or otherwise moving or standing on the first and/or second surface 116, 118 of the mat 110. It is contemplated that the pedestrian grade treads 130 may include raised portions or recesses in the first and/or second surface 116, 118. The pedestrian grade treads 130 are preferably raised areas of the first and/or second surface 116, 118, but may not comprise as high of an elevation as the industrial grade treads 130 on the opposing side of the mat 110. Moreover, the pedestrian grade treads 130 may include a substantially planar top surface to facilitate easier walking or standing by people, as compared to the industrial grade treads 130, which need not necessarily have a planar top surface. Such treads 130 may rise between 0.10 and 0.20 inches above the surface 116, 118 of the mat 110, preferably rising 0.150 inches above the surface 116, 118 of the mat 110.
Each mat 110 includes at least one bore 140 integrally formed therein. The bore(s) 140 may be located anywhere on the mat 110, though preferably they are located at or near the periphery of the mat 110. The bore(s) 140 extend through the mat 110, such as from the first surface 116 to the second surface 118 when extending through the central core area 112 of the mat 110. In preferred embodiments, the bore(s) 140 is located at the flange 120 and extends through the entire flange 120, as shown in FIG. 3, from the first or second surface 116, 118 to the intermediate surface 124. Regardless of its location on the mat 110, the bore 140 extends through the entirety of the thickness of the mat 110 at that location and defines a space in its center. Preferably, each mat 110 includes a plurality of bores 140. Each bore 140 comprises a central portion 142 and two recesses 144, 146, as described in further detail herein. Each bore 140 is correspondingly shaped and configured to matingly engage and receive a corresponding pin 200 for attachment purposes, as described in greater detail hereinafter. In at least one embodiment, as shown throughout the Figures, the bore 140 has an oblong shape with a first dimension, a second dimension transverse to the first dimension along a surface plane, the first dimension being longer than the second dimension, and a third dimension extending through the thickness of the mat perpendicular to the surface plane, each such dimension is structured to receive a pin body 210 in the central portion 142 thereof and restrain the pin body 210 from rotational motion as rotational force is applied to a pin core 220 within the body 210, as described in greater detail hereinafter. It should be appreciated, however, that the bore 140 may be of any configuration or shape as is appropriate for securing a fastener 200 therein.
It should be understood that an alternate embodiment of the present invention without flanges 120, bores 140 may be formed in the central portion 112 of the mat 110 or other configurable material. As shown in FIGS. 4A and 4B, such bores extend from the first surface 116 of the mat through to the second surface 118 of the mat, having recesses 144, 146 on each side. In this alternate embodiment, a pin assembly 200 may extend through bores 140 aligned between adjacent stacked mats 110, joining adjacent mats 110 together. The present invention may assist in joining a set of mats 110 or any other configurable or constructable material which have tread 130 or other surface features on at least one of the first and second surface 116, 118 thereof.
As shown in FIG. 3, recesses 144, 146 are formed at each end of the bore 140 between the central portion 142 of the bore 140 and the first and/or second surface 116, 118. Recesses 144, 146 are sized to form a ledge upon which the lip 214 of the pin 200 sits and within which the foot 226 of the pin 200 may be rotated into a locking position. The interaction of the lip 214 and recess 144, 146 prevents the pin 200 from passing entirely through the bore 140, so that it may be locked or unlocked by a user, and remain in place securing adjacent mats 110 when locked. Each recess may be a tread-surface recess 144 or a non-tread surface recess 146, depending on whether the surface 116, 118, 124 adjacent to the recess 144, 146 has tread extending therefrom. Tread-surface recesses 144 have a shallower depth than the depth of non-tread surface recesses 146, as the tread-surface recess 144 accounts for the depth of the tread when the mats 110 are configured in a tread-to-tread or no-tread-to-tread arrangements. Generally, in at least one embodiment and with reference to
FIG. 3, the depth of the non-tread surface recesses 146 (“nr”) is equal to the depth of the tread-surface recess 144 (“tr”) plus the depth of the tread 130 (“r”). Expressed as an equation:
Accordingly, in a preferred embodiment, nr is equal to 0.450 inch, tr is equal to 0.300 inch, and t is equal to 0.150 inch. The mats 110 should allow for some variation in these measurements to account for field tread wear. For example, nr and tr may have a tolerance of one-sixteenth of an inch, or approximately 0.0625 inch.
In practice, the above equation may require adjustment as follows:
While nr and tr are unaffected by use of these mats 110 in the field, t may decline over time as the depth of the tread wears down due to use, misuse, weather, or other conditions. As a result of this wear and the resulting decrease in t, a mat 110 will have a nr which is greater than the combination of tr and the, now diminished, tread depth, t.
However, each of the foregoing equations may be altered depending on the geometry of the tread 130. For example, where the tread 130 has a substantially flat surface to accommodate pedestrians, as shown throughout the drawings, this equation may hold true. Where the tread 130 becomes tapered as it extends away from the mat 110 surface, it may not be necessary to accommodate the entire depth of the tread 110, as the most distant portion of the tread 130 may warp when compressed by an adjacent mat 110. Accordingly, in such embodiments non-tread surface recesses 146 (“nr”) may be less than or equal to the depth of the tread-surface recess 144 (“tr”) plus the depth of the tread 130 (“t”):
Though it should be understood, as noted above, that this equation may require adjustment as the mats 110 are used. Where tread 130 of different depths is present on a mat 110, t may be equal to the greatest depth of tread 130, the average depth of tread 130, or other calculation to consider the various depths, as required by the circumstances. Further, the above equations may slightly vary depending on such circumstances. Such circumstances may include the material from which the tread 130 is formed, the geometry of the tread 130, the weight of the mats 110, the application of the mats 110, or other relevant considerations.
In a preferred embodiment, the fastener 200 is a pin 200, which may be of any suitable size and shape to perform the functions described herein. The pin 200 consists of a pin body 210 and a pin core 220 extending through the body 210. The pin may be a cam locking pin, as shown in the Figures, although it should be appreciated that other locking pins 220 having different configurations may be used as corresponds to and matingly fits within the particular bore 140 integrally formed in the mats 110.
The pin body 210 has an oval-shaped form, as shown in FIGS. 5-6B, terminating in a head 212 at one end. The pin body 210 defines a channel 217 formed in its center, extending from a top surface 213 of the pin body 210 to a bottom surface 215 of the pin body 210, the channel 217 being correspondingly shaped to receive and movably retain the pin core 220 in the channel 217. The channel 217 having a recess at the top surface 213, with the diameter of the recess being greater than the diameter of the rest of the length of the channel 217 and sized to receive and retain the head 222 of the pin core 220 therein. A lip 214 extends outward from the circumference of the head 212 and prevents the pin assembly 200 from falling through a bore 140 as the dimensions of the lip 214 are greater than the diameter of the central portion 142 of the bore 140 but smaller than the diameter of the recesses 144, 146 of the mats 110. Accordingly, the lip 214 of the pin assembly 200 sits within a recess 144, 146, below the surface 116, 118, 124 of the mat 110. The head 210 may be slightly rounded at its top surface 213 to protrude away from the lip 214 not farther than the tread 130 extending from the mat 110. As shown in FIG. 6B, indicators may be formed on the top surface 213 which aid a user in determining whether the pin assembly 200 is in a locked or unlocked position.
In a preferred embodiment, the pin body 210 is dimensioned to span almost the depth of two flanges 120, such that the head 212 and foot 226 may each occupy the recesses 144, 146 at each respective end of the bore 140. The pin body 210 may measure between 3.5 and 4.5 inches across, preferably 3.91 inches, and between 1 and 2.5 inches deep, preferably 1.96 inches; the lip 214 may extend from the body 210 to measure between 4 and 5 inches across, preferably 4.32 inches, and between 2.5 and 3.5 inches deep, preferably 2.98 inches; with a recess for the pin core 220 measuring between 1 and 2 inches in diameter, preferably 1.625 inches. These are but a few non-limiting examples.
The pin body 210 may be constructed of plastic, such as the same HDPE plastic used in the mat 110. The pin core 220 may be made of high-grade metal, such as aluminum, or other material that is suitable for engaging the pin body 210 and the material of the mat 110. In a preferred embodiment, and as shown in FIG. 5, the pin body 210 is overmolded onto the core 220 and is made of 25% glass-filled polyoxymethylene, also known as POM or acetal. The overmolding of the pin body 210 onto the pin core 220 takes place through an injection molding process wherein the pin body 210 is formed in a mold containing the formed pin core 220 such that the plastic of the pin body is in contact with the pin core 220 in the mold and the pin core 220 defines the channel 217 of the pin body 210 extending from the top surface 213 to the bottom surface 215.
The pin core 220 may be constructed of metal, such as high-strength aluminum alloy, plastic, or other suitable material. The pin core 220 includes a head 222 having a recess 224 formed therein, a foot 226 opposite from the head 222, and a length extending between the head 222 and foot 226. As shown in FIGS. 5 and 7, recess 224 is formed within the head 212 of the pin core 220 and is correspondingly shaped to receive and retain at least a portion of a tool 102 therein, such as but not limited to a hex bit of a t-bar 102. The size of the bit will depend on the size of the pin core 220. For instance, in at least one embodiment, the t-bar 102 has a ⅝″ hex bit, though larger and smaller sizes are also contemplated. On the other end of the pin core 220, and with reference to FIGS. 8A-8B and 9A-9B, the foot 226 of the pin core 220 may have a flared base, tapered to gradually form a frictional fit with the mats 110. In a preferred embodiment, this flared base consists of ramps 227 on either end of the foot 226 which have a 15° incline, though other angles or degrees of incline are contemplated. The ramps 227 may have an incline ranging between a maximum of 25° and minimum of 10°.
As described further herein, the pin core 220 has a frictional fit with the overmolded pin body 210. As shown in FIG. 7, the tool 102 may be inserted into the recess 224 formed in the head 222 of the pin core 220 and rotated to apply sufficient torque to overcome the frictional fit of the of the pin core 220 and pin body 210 and rotate the core 220 with respect to the pin body 210. The foot 226 contacts the underside of the mats 110, including contact at the ramp(s) 227, at the recesses 144, 146 of each mat 110. During rotation of the pin core 220, the foot 226 applies compressive forces against the mats 110 by the foot 226 engagement with the recess 144, 146. The lowest portion of the ramp 227 incline may first contact a recess 144, 146 upon initial rotation of the pin core 220. As the rotation continues, the incline of the ramp 227 applies increasingly compressive forces on the recesses 144, 146. Each recess 144, 146, being integral with the mats 110, passes these compressive forces onto each mat 110, bringing the adjacent mats 110 closed together. As shown in the locked position of FIGS. 10A and 10B, the ramp 227 of the foot 226 is fully engaged with the recess 146 when locked, and each flange 120 has been brought closer together by this interaction.
The pin 200 is inserted into the bore 140 in an unlocked position. FIGS. 5 and 6B show a foot axis 228 and pin body axis 216, respectively; the axes extending across the length of each of the foot and body. As shown in FIGS. 8A and 8B, the length 226 of the foot 226 is in registry with the length 216 of the pin body 210 such that both components may fit within the bore 140. As shown in FIG. 8, a tool 102 may be inserted into the recess 224 in the pin core 220 and rotated, providing rotational force to the pin core 220 against the pin body 210 sufficient to overcome the frictional force holding the pin core 220 in place, thus moving the pin 200 from an unlocked to a locked position by turning the tool 102 90°. The locked position is shown in FIGS. 9A-10B and is defined when the length 228 of the foot 226 and length 216 of the pin body 210 are not in registry, that is, in any arrangement between 0° and including 90°. Preferably, the length 228 of the foot 226 and the length 216 of the pin body 210 are perpendicular when in the locked position.
To lock the pin 200, force is applied to the pin core 220 sufficient to overcome the threshold level of friction between the pin body 210 and pin core 220 and selectively move the core 220 relative to the pin body 210. In at least one embodiment, this force is applied by inserting a hex key or other suitable tool 102 into the recess 224 at the head 222 of the core 220 and applying rotational force or torque to the tool 102. Once sufficient force is applied to overcome the threshold level, the frictional grip of the pin body 210 on the core 220 is released and the core 220 rotates relative to the pin body 210. The core 220 rotates as the pin body 210 is held stationary by its contact and tight corresponding fit against the central portion 142 of the bore 140. In some embodiments, the pin body 210, which is made of a more resilient material than the pin core 220, temporarily bends or deflects to allow the core 220 to move out of frictional engagement and rotate relative to the body 210. Once the core 220 has slipped out of frictional engagement with the body 210, the body 210 resumes its original shape. In a preferred embodiment, where the body 210 is formed or overmolded onto the rounded core 220, the frictional engagement between these components is at least sufficient to maintain the relative position of the body 210 and core 220 until force is applied by a user.
In the embodiment described above, the applied force may be rotational force. It is also contemplated that non-rotational force may be used in other embodiments, such as but not limited to linear force in at least one direction. In addition, though it is described that the force is applied to the recess 224 or pin core 220, it is also contemplated that in other embodiments the force may be applied to the other parts of the pin assembly 200 as necessary to lock or unlock any given fastener 200 used in conjunction with the mat system 100 presented herein.
The pin 200 may be rotated until a locked position is achieved. There may be any number of locked positions, such as one for each discrete formation in the pattern at the interface between the outer surface of the core 220 and the inner surface pin body 210. The locked positions may be dictated by the number of rotations of the hex key or other tool 102 used to apply force to the pin 200. For instance, in at least one embodiment, the locked positions may be defined by a number of rotations or fractions of a rotation of a hex key or similar tool 102, such as a quarter of a turn, half a turn, an entire turn, or multiple turns. In at least one embodiment, as little as a quarter of a turn on a hex key or similar tool 102 is needed to navigate from an unlocked to a locked position. In other embodiments, the locked position(s) may be dictated by the geometric configuration of the outer surface of the pin core 220 and the corresponding inner surface of the pin body 210, such that each successive angle or structural element causes frictional engagement between the pin core 220 and pin body 210 to be reestablished following the release of a prior frictional engagement when rotation of the pin core 220 brings the next successive structural elements into contacting engagement.
Regardless of how achieved, the locked position(s) may be defined when the length 228 of the foot 226 of the pin core 220 and the length 216 of the pin body 210 deviate from one another, such as when they become misaligned or no longer parallel. They may be disposed at any angle relative to one another in a locked position. In at least one embodiment, a locked position may be defined by the length 228 of the foot 226 of the pin core 220 and the length 216 of the pin body 210 being substantially perpendicular to one another as shown in FIGS. 9A-10B. This may provide an optimal secure fit of two adjacent floor mats 110. The locked position may also occur when the foot 226 of the pin core 220 has been sufficiently rotated such that maximum compressive forces are applied to the mats 110 by the interaction of ramps 227 of the foot 226 and the recess 144, 146 of the bore 140.
In a preferred embodiment, the frictional engagement that holds the pin 200 in the locked position is between the components of the pin 200 themselves—that is, between the pin core 220 and pin body 210—rather than with the mat 110, as is the case with some existing fasteners. Because of this internal frictional fit, when vehicles or pedestrian traffic shake or rattle the mats 110 joined together and locked with these pins 200, the vibrations imparted on the pin 200 do not shake or rattle the pin 200 loose from the locked position. Rather, the frictional fit between the pin body 210 and core 220 holds the pin 200 in place in the locked position. The amount, intensity or frequency of vibrations from traffic or other use of the mats do not rise to the threshold level of friction necessary to overcome the frictional fit between the pin body 210 and core 220, and therefore the body 210 holds the core 220 in place.
The present invention also contemplates an improvement to floor covering systems 100 composed of a contiguous placement of the above-described mats 110. In such placement, there are no significant gaps between the modular floor mats 110 which create a substantially planar surface to cover a desired subsurface. The present system 100 is additionally configurable into non-planar arrangements. By stacking mats 110 or placing mats 110 in a step or stacked configuration, various arrangements of mats 110 are possible, as described in greater detail below.
Generally, as shown in FIGS. 1A-2, 10, and 11, the floor covering system 100 of the present invention includes a plurality of mats 110 disposed in adjoining, overlapping and interlocking fashion. The system 100 is extendable in multiple directions to accommodate a desired topographic plan. Such topographic plan is typically directed towards the conveyance or support of equipment, vehicles, personnel and the like and is adapted to conform to the topographic or geographic features of the substrate surface, such as grass, dirt, artificial turf or the like. When connected in a floor covering system 100, the mats 110 of the present invention provide distribution of weight over a larger surface area, thus allowing heavy equipment to traverse varying ground conditions. The floor covering system 100 further comprises a being joined by a pin assembly 200 in the bore 140, as discussed in greater detail herein.
The floor covering system 100 is built by securing one modular mat 110 to an adjacent modular mat 110′. Adjacent mats 110, 110′ are disposed in at least partially overlapping fashion, for instance such that the flange 120 of one mat 110 overlaps a flange 120′ of an adjacent mat 110′, as shown in FIGS. 13A-B. The bores 140 integrally formed in the flanges 120, 120′ of mats 110, 110′ also overlap and correspond one to another, such that the bores 140 of one mat 110 align with the bores 140′ of the adjacent mat 110′. In the planar configuration shown in FIGS. 13A and 13B, this results in an overhanging 120a and underhanging 120b′ flanges overlapping to align the bores 140, 140′ in each flange 120a, 120b′. As shown in FIGS. 14A and 14B, a pin 200 is then inserted and extends through the bores 140, 140′ of each mat such that the head of the pin 212 is within a recess 144 of one mat 110, and the opposite pin foot 226 is within the recess 144′of an adjacent mat 110′.
Each mat 110 includes a plurality of bores 140, each configured to accept a pin 200. Therefore, the system 100 may include a plurality of pins 200. In a preferred embodiment, a plurality of bores 140 are formed along the flanges 120 of the mat 110, corresponding with the bores 140′ of adjacent mats 110′, and accommodate a plurality of corresponding pins 200, thereby providing a number of securing points along the mats 110. This provides stability to the floor covering system 100, restricting the movement of individual mats 110 as a load is moved across multiple mats 110.
The pin 200 may be rotated or turned, such as by using a key or tool 102, to move the pin 200 into a locked position, which is shown in FIGS. 8A-9B. In this locked position, the foot 226 of the pin core 220 now protrudes beyond the profile of the pin body 210 and engages with a recess 144 of the bore 140. Since the length of the foot 226 along the foot axis 228 is longer than the second dimension of the central part of the bore 140, the foot 226 extends beyond the central part of the bore 140 and to the perimeter of the recess 146 as shown in FIG. 9B. The ramps 227 of the foot 226 contact the walls of recess 144 and hold the pin core 220 against the mat 110. As the bore 140 conforms to the pin body 210 shape, the foot 226 in this locked position may now not pass back through the bore 140, thereby locking the pin 200 in place. FIGS. 9A and 9B show the bore 140 and pin 200 in the locked position from each side of the mat 110.
To join adjacent mats 110, 110′, the mats 110, 110′ are positioned next to and/or partially overlapping one another. The bores 140, 140′ of respective mats 110, 110′ are aligned with one another. A pin 200 is then inserted into the central portion 142 of each bore 140, 140′ by first inserting the foot 226 through the bore 140 opening and continuing to insert the pin 200 along the third dimension of first bore 140 then bore 140′. For insertion, the pin 200 is in the unlocked position shown in FIGS. 6A and 6B. In this unlocked position, the length of the pin foot 226 of the pin 200 is parallel to the length of the pin body and the length of the bore 140 opening. As shown in FIGS. 13A-14E, insertion progresses by inserting the pin assembly 200 into the bore 140 of an overhanging flange 120a then the bore 140′ of the underhanging flange 120b′. The pin 200 may be inserted until it is no longer capable of further movement into the bores 140, 140′, such as when the lip 214 extending from the head 212 is stopped by the narrower first and second dimensions (diameter) of the central portion 142 of the bore 140. The lip 214 may then rest on the recess 144, 146 of the bore 140 which it first entered. In this position, the foot 226, may be rotated beyond the profile of the pin body 210 and into the space adjacent to a recess 144′, 146′ of the other bore 140′.
When it is desired to disconnect the mats 110, 110′, the hex key or other tool 102 may again be inserted into the recess 224 at the head 222 of the pin core 220 and rotational force applied. Force may be applied in the same or opposite rotational or angular direction as was applied to move to a locked position, depending on the embodiment. In at least one embodiment, force is applied in the opposite direction from locking. Once sufficient force is applied to overcome the frictional force between the pin body 210 and core 220, the body 210 may temporarily deflect and permit the core 220 to move or rotate relative thereto. Overall movement of the pin body 210 relative to the core 220 stops when the applied force falls below the threshold level of the frictional force between the pin body 210 and core 220. This force may be repeatedly or continuously applied to each pin 200 in the system 100 until all pins 200 are once again in the unlocked position, at which point the pins 200 may be removed from the bores 140, 140′. The mats 110, 110′ are now no longer connected and can be separated for transportation, storage or reuse.
Consistent with the systems and methods described in greater detail herein, each of the mats 110, 110′ in the system 100 may be assembled in alternate configurations due to the offset spacing of the bore 140 recesses 144, 146 in which the height of recesses 144 and 146 differ from one another. For instance, as best shown in FIG. 3, and described herein above, tread recess 144 has a height of tr and non-tread recess 146 has a height of nr, where tr is greater than nr. In some embodiments, height nr is greater than height tr by the same height as that of the tread 130, t, where the height of the tread 130 is the distance the tread 130 projects or extends from the corresponding surface 116, 118. In other embodiments, the difference in heights tr and nr is the same as t. Tread 130 is present on the first and/or second surfaces 116, 118 of the mats 110, but does not extend to the intermediate, or non-tread, 124 portions of the flanges 120. In a standard planar configuration, the intermediate, or non-tread, surfaces 124, 124′ of adjacent flanges 120, 120′ abut and/or contact one another when overlapped in the standard planar configuration. However, the alternate configurations described herein are possible because of the differences in heights tr and nr of recesses 144, 146; the system 100 accommodates no-tread-to-no-tread, tread-to-no-tread, or tread-to-tread arrangements of mats 110 as a function of the differences in heights tr and nr. Because of the differences in heights tr and nr, the mats 110, 110′ may be aligned and overlapped in any combination or orientation-including non-planar configurations-and the pins 200 will still fit within the bores 140, 140′ and lock to join the mats 110, 110′ without digging into or damaging the mats 110, 110′.
For example, a no-tread-to-no-tread arrangement is shown in FIGS. 11, 13A-13B, and 14A-14E. Standard, planar configurations of mats 110, 110′ extending in a horizontal direction result in this arrangement, such as those shown in FIGS. 2 and 7. The mats 110, 110′ are overlapped such that non-tread surfaces 124, 124′ of flanges 120, 120′ on adjacent mats 110, 110′ contact and abut one another, and consequently non-tread surface recesses 146, 146′ of bores 140 on adjacent mats are adjacent. Tread surface recesses 144, 144′ are facing outward and accommodating the pin head 212 at one side and foot 226 on the other side. As shown in FIGS. 14A-14C, the head 212 and foot 226 extend beyond the bore 140, 140′ but are substantially co-extensive with the height of the tread 130. The head 212 and foot 226 may extend beyond or sit below the bore 140, 140′ only to the extent such projection or recession does not interfere with traffic flow or cause a tripping hazard. Extension beyond the bore 140, 140′, but not beyond the furthest surface of the tread 130, 130′ is permissible in this arrangement as it does not interfere with the tread 130, 130′ on the mat 110, 110′ surface. In some embodiments, the head 212 and foot 226 may not necessarily be co-extensive with the height of the tread 130, 130′ extending from each mat 110, 110′, but the pin 220 has sufficient height to extend through the third dimension of the bores 140, 140′ in tread-to-no-tread, or tread-to-tread configurations as well, but not extend beyond the bores 140, 140′ so far as to cause a tripping hazard or other impediment to the use of the system 100. In alternate embodiments, the head 212 sits slightly below the height of the tread 130, 130′.
A tread-to-no-tread arrangement is shown in FIGS. 15A-15E. Stepped configurations of mats 110, 110′ result in this arrangement, such as depicted in FIG. 12, where the system 100 can be built in a combination of vertical and horizontal directions relative to the ground to gradually create increases in elevation from the ground. In such configurations, the flanges 120, 120′ of adjacent mats 110, 110′ are overlapped such that a tread surface 122′ from one mat 110′ and non-tread surface 124 from another mat 110 face one another, such that their respective recesses 144′, 146 of the bores 140, 140′ on adjacent mats are adjacent. This can be done with either the tread surface 122′ facing up, as illustrated in FIGS. 16A and 16B, or tread surface 122′ facing down, as illustrated in FIG. 17A-17B. When the pin 200 is placed through the bore 140, 140′ to connect the mats 110, 110′, as shown in FIGS. 15A-15C, the head 212 extends beyond the bore 140 to a distance that is maximally co-extensive with the height of the tread 130, or just beyond the tread, and the foot 226 extends beyond the bore 140′ to a distance that is maximally co-extensive with the non-tread surface recess 146′. This arrangement is possible due to the offset spacing of the recesses 144, 146, 144′, 146′ which accommodates what would otherwise be an increased depth of the arrangement, i.e., an increased collective third dimension depth of the bores 140, 140′ due to the tread 130′ intervening between the bores 140, 140′ adding height to the arrangement 100 which is not usually present in a standard, planar configuration. Because the tread-surface recesses 144, 144′ are shorter by the depth of the tread 130, 130′, as described in more detail herein, the tread 130′ intervening between the bores 140, 140′ in this arrangement is accommodated. Without such offset spacing, the lip 214 and foot 226 of the pin 200 would be forced to dig into each mat 110, 110′ as the pin is locked, as the pin does not have any mechanism to compensate for the change in the third dimension of the bores 140, 140′ resulting from the intervening tread 130′. A tread-to-tread arrangement is shown in FIGS. 18A-18E. Stacked configurations of mats 110, 110′ result in this arrangement in which the system 100 can be built in the vertical direction relative to the ground, as illustrated in FIG. 12. As best seen in FIGS. 18A and 18C, adjacent mats 110, 110′ are overlapped such that the tread surfaces 122, 122′ from flanges 120, 120′ of the adjacent mats 110, 110′ are disposed facing one another with the tread 130, 130′ of each contacting and abutting one another. Non-tread surfaces 124, 124′ face outward. The mats 110, 110′ are overlapped such that the flanges 120, 120′ of each overlap with the bores 140, 140′ of each aligning with one another, with the tread surface recesses 144, 144′ of the mats 110, 110′ facing one another and aligned with one another. The non-tread recesses 146, 146′ are facing outward. The mats 110, 110′ may be arranged with only the flanges 120, 120′ overlapping, as depicted in FIG. 19A and 19B, or with the flanges 120, 120′ and central areas 112, 122′ of the mats 110, 110′ overlapping one another respectively, as depicted in FIG. 20A and 20B, depending on the desired effect or constraints of the site. Regardless of which portions overlap in this configuration, and as shown in FIGS. 16A-16C, the pin head 212 and foot 226 are preferably substantially co-extensive with the ends of the non-tread surface recesses 146, 146′ but may extend slightly beyond the recesses 146, 146′. The combined height of the treads 130, 130′ between the bores 140 is most significant in this arrangement but is nevertheless accommodated by the offset spacing of the recesses 144, 146, 144′, 146′, as described herein above.
When used with respect to modular floor mats 110, these alternate configurations are referred to herein as stacked (FIGS. 20A and 20B), high stepped (FIGS. 19A and 19B), and first and second low stepped (FIGS. 16A-17B) configurations. The standard, planar configuration is shown in FIGS. 13A and 13B. These configurations are described with reference to FIGS. 16A-17B and 19A-20B and the overhanging 120a and underhanging 120a flanges 120 described herein. Whether a flange 120 is overhanging 120a or underhanging 120b is relative to the position of the mat 110 in relation to the surface to be covered by the system 100, as described in further detail herein. With reference to FIGS. 13A and 13B, a planar configuration involving an overhanging flange 120a being placed on top of an underhanging flange 120b′, is shown. This results in a no-tread-to-no-tread arrangement.
Stepped configurations are shown in FIGS. 16A-17B and 19A-19B. FIGS. 19A and 19B show a high stepped configuration, wherein the underhanging flange 120b′ of one mat 110′ is placed on top of the overhanging flange 120a of an adjacent mat 110. In a high stepped configuration, a tread-to-tread arrangement is formed. FIGS. 16A and 16B show a first low stepped configuration, wherein the overhanging flange 120a′ of one mat 110′ is placed on top of the overhanging flange 120a of an adjacent mat 110. FIGS. 17A and 17B show a second low stepped configuration, wherein the underhanging flange 120b of one mat 110 is placed on top of the underhanging flange 120b′ of an adjacent mat 110′. Each of the first and second low stepped configurations form a no-tread-to-tread arrangement. In each of the high, first low, and second low stepped configurations, the central portions 112, 112′ of the mats 110, 110′ are not placed on top of each other, only the flanges 120a, 120b′ are overlapping and interacting.
A stacked configuration is shown in FIGS. 20A and 20B and is similar to the high stepped configuration of FIGS. 19A and 19B. In a stacked configuration, the underhanging flange 120b of one mat 110 is placed on top of the overhanging flange 120a′ of an adjacent mat 110′. In a stacked configuration, the central portions 112, 112′ of the mats 110, 110′ are also placed on top of each other, such that the flanges 120b, 120a′ are interacting in addition to the remainder of the mats 110, 110′.
In any of the foregoing configurations, the unused overhanging 120a and underhanging 120b flanges of each mat 110 are available for connection with other adjacent mats 110′ to be connected in any of the configurations described herein, space permitting. For example, as shown in FIG. 11, two mats may be arranged in a planar configuration, but a third mat may be placed in a stacked configuration with one of the mats 110, connecting through the unused flanges 120′ of the adjacent mats 110′ in a planar configuration. Additionally, as shown in FIG. 12 stacked, stepped, and planar configurations may be intermixed to form ramp-like structures or other formations which may have utility in any given application.
With reference again to FIGS. 4A and 4B, alternate embodiments of the present invention 100 are contemplated wherein the offset spacing described herein exists between components 110 of any material which may be stacked or laid in series and which may have textured or treaded 130 surfaces on one or more surfaces, including, without limitation, the first and second surfaces 116, 118 thereof. In such embodiments, the components 110 may not necessarily require a flange. The components may be stackable or steppable shapes of any geometry, the surfaces 116, 118 of which may or may not have textured elements 130. Bores 140 formed within the central portions of the components may have offset recesses 144, 146, as described herein, at either end of the central portion 142 of the bore 140. The central portion 142 is shaped to conform to a fastener 200, specifically the fastener body 210, which may be a pin as described herein. The fastener may interact with the bore 140 and recesses 144, 146 in any fashion known in the art, including by interaction between receivers formed in the central portion 142 of the bore 140 and arms or other extensions of the fastener 200.
Since many modifications, variations and changes in detail can be made to the described preferred embodiments, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents. Now that the invention has been described,
Patent Application
20250019974
