U.S. patent application number 13/798434 was filed with the patent office on 2014-07-10 for ground cover mats with rectangular ends.
The applicant listed for this patent is MAXXIMAT, INC.. Invention is credited to Robert FOURNIER.
Application Number | 20140193196 13/798434 |
Document ID | / |
Family ID | 51059763 |
Filed Date | 2014-07-10 |
United States Patent
Application |
20140193196 |
Kind Code |
A1 |
FOURNIER; Robert |
July 10, 2014 |
GROUND COVER MATS WITH RECTANGULAR ENDS
Abstract
Reinforced ground cover mats are used to facilitate the passage
of heavy equipment and vehicles on wet or disturbed ground. The
ground cover mats are comprised of boards contained within a
peripheral metal frame having two substantially parallel opposing
end members that are I-beams, the upper and lower horizontal
flanges and vertical webs of which define an outer slot into which
a reinforcing member is inserted such that the reinforcing member
contacts the vertical web and upper and lower horizontal flanges.
Flanged caps may be attached to the ends of the reinforcing member
to retain a sling looped around the reinforcing member for pulling
the mat.
Inventors: |
FOURNIER; Robert; (Nisku,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MAXXIMAT, INC. |
Nisku |
|
CA |
|
|
Family ID: |
51059763 |
Appl. No.: |
13/798434 |
Filed: |
March 13, 2013 |
Current U.S.
Class: |
404/35 |
Current CPC
Class: |
E01C 9/083 20130101;
E01C 9/08 20130101 |
Class at
Publication: |
404/35 |
International
Class: |
E01C 9/08 20060101
E01C009/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 4, 2013 |
CA |
2800524 |
Claims
1. A ground cover mat comprising: (a) a quadrilateral frame
defining a lateral direction and a longitudinal direction, and
comprised of: (i) two substantially parallel opposing lateral
I-beam end members each comprising an I-beam comprising a vertical
web and upper and lower horizontal flanges connected to opposite
ends of the vertical web, said horizontal flanges forming inner and
outer slots; and (ii) two substantially parallel outside
longitudinal members, each having an inner channel; (b) two
opposing major surfaces formed from a plurality of elongate boards
retained within the frame, whereby said boards insert into, and are
retained by the inner slots of the end members or the inner channel
of the longitudinal members, or both; (c) a reinforcing member
having a rectangular cross-section, attached at each end of the
mat, whereby each reinforcing member directly inserts into, and is
retained by the outer slots of a different one of the I-beams, such
that the reinforcing member contacts the vertical web and upper and
lower horizontal flanges of that I-beam, and wherein the
rectangular cross-section is sized to fit fully, in the
longitudinal direction, within the outer slot of that I-beam.
2. The mat of claim 1 wherein the reinforcing member comprises a
hollow structural section.
3. The mat of claim 1 wherein the reinforcing members are longer
than the end members and project beyond each end of the end
members, and wherein each end of the reinforcing member has a
flanged cap extending beyond the width of the reinforcing
member.
4. The mat of claim 3 wherein the flanged cap is a rectangular
plate.
5. The mat of claim 1 wherein at least one of the horizontal
flanges forming the outer slot of each end member is bent at an
angle towards the opposing horizontal flange.
6. The mat of claim 5 wherein the lower horizontal flange is bent
upwards at an angle of about 35.degree..
7. A method of forming a ground cover mat comprising the steps of
(a) forming a quadrilateral frame defining a lateral direction and
a longitudinal direction, and comprised of: (i) two substantially
parallel opposing lateral I-beam end members each comprising an
I-beam comprising a vertical web and upper and lower horizontal
flanges connected to opposite ends of the vertical web, said
horizontal flanges forming inner and outer slots; and (ii) two
substantially parallel outside longitudinal members, each having an
inner channel; (b) forming two opposing major surfaces from a
plurality of elongate boards retained within the frame, whereby
said boards insert into, and are retained by the inner slots of the
end members or the inner channel of the longitudinal members, or
both; and (c) and reinforcing each end member with a reinforcing
member having a rectangular cross-section by inserting and
attaching the reinforcing member in the outer slot of one of the
I-beams, such that the reinforcing member contacts the vertical web
and upper and lower horizontal flanges of that I-beam, and wherein
the rectangular cross-section is sized to fit fully, in the
longitudinal direction, within the outer slot of that I-beam.
8. The method of claim 7 wherein each reinforcing member comprises
a hollow structural section comprising steel.
9. The mat of claim 1 wherein the rectangular cross-section is
further sized to be substantially co-terminal, in the longitudinal
direction, with the horizontal flange of that I-beam when inserted
in the outer slot of that I-beam.
10. The method of claim 7 wherein the rectangular cross-section is
further sized to be substantially co-terminal, in the longitudinal
direction, with the horizontal flange of that I-beam when inserted
in the outer slot of that I-beam.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of Canadian
Patent Application No. 2,800,524 filed on Jan. 4, 2013 entitled
Ground Cover Mats With Rectangular Ends, the contents of which are
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to improved ground cover
mats.
BACKGROUND OF THE INVENTION
[0003] In the oil and gas industry, it is sometimes necessary to
provide ground cover mats with sufficient strength to support heavy
equipment and transport trucks over wet or disturbed ground.
[0004] Several prior art ground cover mats exist; however, they
sometimes lack sufficient reinforcement to withstand the pressure
of heavy equipment and transport trucks, and are expensive to
produce. What is needed is an improved ground cover mat which is
simple and relatively inexpensive and has sufficient strength and
durability to support heavy equipment.
[0005] Further, ground cover mats tend to be extremely heavy and
lengthy, making the mats difficult to store, lift, transport,
assemble or disassemble. Since a series of mats are generally
required to construct a temporary road, an improved ground cover
mat which is easy to handle is desirable.
[0006] There have been attempts in the prior art to solve such
problems. For example, U.S. Pat. No. 4,462,712 issued Jul. 31, 1984
to Penland, Sr. describes an interlocking mat assembly comprising
assemblies of two-ply laminated mats which interlock and are
secured together by nailing a top layer of planks over the
interlocked mats. However, this mat assembly is particularly labor
intensive.
[0007] Canadian Patent No. 1,285,166 issued Jun. 25, 1991 to Pouyer
describes a temporary road which includes a plurality of sets, each
defined by upper and lower matrices with the upper matrices
comprising boards and the lower matrices comprising cross-support
members for supporting the boards. The road is constructed by
interlocking series of sets in a superimposed assembly,
necessitating significant redundancy of effort in assembly and
disassembly.
[0008] U.S. Pat. No. 6,695,527 issued Feb. 24, 2004 to Seaux et al.
describes interlocking mats constructed of two mirror half pieces
which are joined together to form a complete single mat containing
an internal cellular structure. Traction promoting elements in the
form of raised strips extending outward from the planar surfaces of
the mats and aligned with the internal cell forming walls are
provided to improve traction and to absorb heavy loading from
vehicles and equipment. However, Seaux et al. indicates that when a
large number of the raised strips are not specifically positioned
in such a manner, the relatively thin outer skin defining the
roughly planar surfaces of the mats can become easily deformed by
such direct loading.
[0009] U.S. Pat. Nos. 4,600,336 and 5,087,149 issued Jul. 15, 1986
and Feb. 11, 1992 respectively, to Waller describe mat systems
having individual mats with alternating offset extensions and
recesses along the edges. These systems are disadvantageous in that
the offset extensions are comprised of individual planks which may
be subject to warping or splintering when exposed to heavy loads.
Further, the offset extensions need to be nailed in place to be
secured within the recess of an adjacent mat. An extra plank is
secured over the exposed nailed joints of adjacent mats to
interlock the mat assemblies together as a roadway, which
significantly increases material and labor requirements.
[0010] Canadian Patent No. 2,348,328 issued Oct. 22, 2002 to
Stasiewich et al describes a road mat including, at both of its
ends, couplings having retaining lips which engage complimentary
retaining lips of adjacent mats to prevent separation when weight
applied by a vehicle to one road mat is transferred to an adjacent
road mat. Canadian Patent No. 2,364,968 issued Jun. 22, 2004 to
Stasiewich et al describes a road mat having end and side
interlocks to secure adjacent mats. However, there is no provision
in either patent of details regarding attachment of the retaining
lips to the mat ends, or the use of any reinforcing structural
support.
[0011] The present invention addresses the above shortcomings of
the prior art, meeting the need for an improved ground cover mat
which has sufficient strength to support heavy equipment, provides
easy handling, and is simple and relatively inexpensive.
SUMMARY OF THE INVENTION
[0012] The present invention is directed to ground cover mats. In
one aspect of the invention, the invention comprises a ground cover
mat comprising: [0013] (a) a quadrilateral frame comprised of:
[0014] (i) two substantially parallel opposing I-beam end members
each comprising an I-beam comprising a vertical web and upper and
lower horizontal flanges connected to opposite ends of the vertical
web, said horizontal flanges forming inner and outer slots; and
[0015] (ii) two substantially parallel outside longitudinal
members, each having an inner channel; [0016] (b) two opposing
major surfaces formed from a plurality of elongate boards retained
within the frame, whereby said boards insert into, and are retained
by the inner slots of the end members or the inner channel of the
longitudinal members, or both; [0017] (c) a reinforcing member
having a rectangular cross-section, attached at each end of the
mat, whereby each reinforcing member directly inserts into, and is
retained by the outer slots of the I-beams, such that the
reinforcing member contacts the vertical web and upper and lower
horizontal flanges.
[0018] In another aspect, the invention comprises a method of
forming a ground cover mat comprising the steps of [0019] (a)
forming a quadrilateral frame comprised of: [0020] (i) two
substantially parallel opposing I-beam end members each comprising
an I-beam comprising a vertical web and upper and lower horizontal
flanges connected to opposite ends of the vertical web, said
horizontal flanges forming inner and outer slots; and [0021] (ii)
two substantially parallel outside longitudinal members, each
having an inner channel; [0022] (b) forming two opposing major
surfaces from a plurality of elongate boards retained within the
frame, whereby said boards insert into, and are retained by the
inner slots of the end members or the inner channel of the
longitudinal members, or both; [0023] (c) and reinforcing each end
member with a reinforcing member having a rectangular cross-section
by inserting and attaching the reinforcing member in the outer slot
of the I-beams, such that the reinforcing member contacts the
vertical web and upper and lower horizontal flanges.
[0024] In one embodiment, the reinforcing member comprises a hollow
structural section comprising steel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will now be described by way of an exemplary
embodiment with reference to the accompanying simplified,
diagrammatic, not-to-scale drawings.
[0026] FIG. 1 is a diagrammatic representation of a mat of one
embodiment of the present invention.
[0027] FIG. 2 is a cross-sectional view of the end assembly of a
mat of one embodiment of the present invention in FIG. 1 along line
Ia-Ia.
[0028] FIG. 3 is a detail perspective view of the end assembly of a
mat of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention provides for reinforced ground cover
mats. When describing the present invention, all terms not defined
herein have their common art-recognized meanings. To the extent
that the following description is of a specific embodiment or a
particular use of the invention, it is intended to be illustrative
only, and not limiting of the claimed invention. The following
description is intended to cover all alternatives, modifications
and equivalents that are included in the spirit and scope of the
invention, as defined in the appended claims.
[0030] The invention will now be described having regard to the
accompanying Figures. The mat (10) is comprised of a quadrilateral
frame (12), and planar surfaces formed from a plurality of elongate
boards (14). A suitable mat is described in Applicant's co-owned
U.S. Pat. No. 7,934,885, the entire contents of which are
incorporated herein by reference, where permitted.
[0031] The quadrilateral frame (12) comprises two substantially
parallel opposing end members (18) and two substantially parallel
outside longitudinal members (20). Each end member (18) has an
inner slot (24) facing the opposing end member (18) and an outer
slot (26) facing away from the opposing end member (18). Each
longitudinal member (20) has a slot (not shown) facing the opposing
longitudinal member (20).
[0032] The elongate boards (14) are retained within the frame (12).
The plurality of boards (14) forms two opposing major surfaces
(28). The boards (14) insert into, and are retained by the inner
slots (24) of the end members (18). In FIG. 2, a board (14) is show
partially inserted into the inner slot of the end member (18). A
reinforcing member (16) is attached at each end of the mat (10) in
an orientation parallel to the end member (18). Each reinforcing
member (16) inserts into, and is retained by the outer slots (26)
of the end members (18).
[0033] In one embodiment, each board (14) has a substantially
rectangular cross-section and is disposed such that the vertical
dimension of the board (14) is larger than the horizontal
dimension, thus increasing the bending strength of the mat (10).
The boards may be glued together and staggered to increase the
strength of the mat. The boards (14) may be single 2.times.4 or
2.times.6 boards or may be constructed using wood layers bonded to
composite material layers.
[0034] In one embodiment, the board comprises at least one wood
layer bonded to at least one composite material layer. As used
herein, the term "composite" refers to any engineered material made
from two or more constituent materials with significantly different
physical or chemical properties and which remain separate and
distinct on a macroscopic level within the finished structure. In
one embodiment, the composite material layers may comprise
fiberglass; however, such other materials as are commonly used in
the art may also be employed for the boards (14).
[0035] The frame (12) is constructed from any suitable material
such as steel. In one embodiment, the frame (12) may comprises a
third longitudinal member comprising a mid rail (32) which is
connected at each end to the midpoint of each end member (18) in an
orientation that is substantially parallel to each longitudinal
member (20). In one embodiment, the mid rail (32) is an I-beam,
thereby having slots (34) facing the longitudinal members (20). The
boards (14) insert into, and are retained by the slots (34) on the
mid rail (32),
[0036] In one embodiment, a plurality of cross beam straps (36) are
arranged in an orientation that is substantially parallel to the
opposing end members (18). In one embodiment, each cross-beam strap
(36) comprises a flat metal bar, and is connected at one end to the
mid rail (32) and at the other end to a longitudinal member (20).
The cross beam strap (36) may be butt-welded to the longitudinal
members (20) and the mid rail (32), such that they are disposed on
top of the boards (14) and flush with the longitudinal members (20)
and mid rail (32). In an alternative embodiment, each cross-beam
strap (36) is lengthened slightly such that the ends overlap and
slide under the longitudinal member (20) channel on one side, and
either within the mid rail (32) I-beam channel on the other side
or, where there is no mid rail (rail), under the longitudinal
member (20) channel (20) on the other side. The strap (36) is then
lap welded to the longitudinal member (20) and the mid rail (32) or
the other longitudinal rail (20). A transverse groove having a
depth approximately equal to the thickness of the cross beam strap
(36) is cut into the boards (14) so that the strap (36) is
interface of the strap (36) is flush with the major surfaces (28)
formed by the boards (14). The cross beam straps (36) may be
aligned on either side of the mat, and held together by a pin (38)
which is welded in place.
[0037] As shown in FIG. 2, each end member (18) is an I-beam (38)
comprising a vertical web (40) and upper and lower horizontal
flanges (42, 44) connected to opposite ends of the vertical web
(40). The upper and lower horizontal flanges (42, 44) and vertical
web (40) form the inner and outer slots (24, 26). The upper and
lower horizontal flanges (42, 44) correspond to the top and bottom
horizontal portions of the letter "I" as viewed in cross section in
FIG. 2. As used herein, the terms "upper" and "lower" refer to the
I-beam when in the orientation shown for example in FIG. 2.
However, the artisan will recognize that the I-beam can adopt any
particular orientation when in use.
[0038] The I-beam (38) is sized to accommodate the board (14) and
the reinforcing member (16) accordingly. The I-beam (38) has a
length which does not extend past the edges of the lateral members
(20) or the length of the reinforcing member (16). In one
embodiment, the width of the I-beam (38) is substantially identical
to the width of the board (14), as shown in FIG. 1. In one
embodiment, not shown, the board (14) may be notched to accommodate
the I-beam (38) when the width of the I-beam (38) is less than the
width of the board (14). The I-beam (38) may be formed of
structural steel or other suitable materials commonly used in the
art.
[0039] The I-beam (38) is positioned in an orientation
substantially parallel to the respective end member (18) and
perpendicular to the lateral members (20) so as to encase the
boards (14) on one side, and the tubular member (16) on the other
side. The boards (14) are compressed by the upper and lower
horizontal flanges (42, 44) of the I-beam (38). The I-beam (38) is
joined to the reinforcing member (16) by welding or other suitable
techniques commonly used in the art.
[0040] As shown in FIG. 3, the reinforcing members (16) are longer
than the end members (18) and project beyond each end of the end
members (18). In one embodiment, the reinforcing members (16)
terminate before the outside edge of each lateral member (20) so
that they do not impinge on adjacent mats. In one embodiment, the
reinforcing members (16) are constructed of hollow structural
sections, and have a rectangular cross-section profile. The
reinforcing members (16) may be conveniently be formed of
commercially available hollow structural sections or other suitable
materials commonly used in the art.
[0041] Each end of the reinforcing member (16) has a flanged cap
(46) extending beyond the width of the reinforcing member (16). In
one embodiment, the flanged cap (46) may cap the entirety of the
reinforcing member end (16) as shown in FIGS. 1 and 3. In one
embodiment, the flanged cap (46) is formed substantially in the
shape of a rectangle with rounded corners. The flanged cap (46) is
constructed of steel or other suitable materials commonly used in
the art, and are attached to each reinforcing member end (16) by
welding or other techniques commonly used in the art. In one
embodiment, the reinforcing member (16) is sized to fit fully
against the vertical web (40) and between the upper and lower
horizontal flanges (42, 44) of the I-beam (38), as shown in FIG.
2.
[0042] A recess (50) in the ends of each lateral member (20) is
provided for allowing access to the flange capped ends (48) of the
reinforcing members (16). It can be understood that to lift the
mat, a sling (not shown) is looped around the flange capped ends
(48) of each of the tubular members (16) and is then drawn
tight.
[0043] In one embodiment, at least one of the horizontal flanges
(42, 44) forming the outer slot (26) of each end member (18) is
bent at an angle towards the opposing horizontal flange (42, 44) to
contact the reinforcing member (16), thereby securing the
reinforcing member (16) between the horizontal flanges (42,
44).
[0044] The dimensions and mechanical properties of the end members
(18), reinforcing members (16) and flanged caps (46) may vary
according to the size and construction of the mat, and its intended
application. In an exemplary configuration, as shown in FIG. 3, the
end member (18) is approximately 84-inches long, with the I-beam
(38) having a total depth of approximately 6-inches, horizontal
flanges (42, 44) approximately 6-inches wide and 0.26-inches thick,
and a web approximately 0.23-inches thick. The angle, .alpha.,
between the horizontal and the bent arm of the lower flange (44)
may be approximately 35.degree.. The reinforcing member (16) is
about 96-inches long, and has a hollow structural section
approximately 4-inches in height, 3-inches in width and 0.25-inch
in wall thickness. The flanged cap (46) is approximately 3.5-inches
in height, 5-inches and width, and 0.375-inches in thickness. The
end member (18) and the flanged caps (46) are made of structural
steel having a yield strength at least approximately 300 MPa, and
the reinforcing member is made of structural steel having a yield
strength of at least approximately 345 MPa.
* * * * *