U.S. patent application number 14/623334 was filed with the patent office on 2016-08-18 for laminated mat with endcap.
The applicant listed for this patent is The Modern Group, Ltd.. Invention is credited to Orain Tubbs.
Application Number | 20160235234 14/623334 |
Document ID | / |
Family ID | 56621694 |
Filed Date | 2016-08-18 |
United States Patent
Application |
20160235234 |
Kind Code |
A1 |
Tubbs; Orain |
August 18, 2016 |
LAMINATED MAT WITH ENDCAP
Abstract
An improved laminated mat is disclosed and includes a plurality
of layers and end caps. The plurality of layers may be formed of
wood, synthetic materials, wood, metal, or a combination of such
materials. The end caps may form longitudinal edges of the
laminated mats, and may have an outer region having a thickness
equal to a total thickness of the plurality of layers. The outer
region of the end caps may provide improved performance of the
laminated by reducing wear and tear of the laminated mat. In an
additional aspect, the laminated may include attachment means
recessed within the plurality of layers, and may include a cover
plate that overlies the attachment means and is flush with a top
surface of the laminated mat.
Inventors: |
Tubbs; Orain; (Beaumont,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Modern Group, Ltd. |
Beaummont |
TX |
US |
|
|
Family ID: |
56621694 |
Appl. No.: |
14/623334 |
Filed: |
February 16, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E01C 9/086 20130101;
E04B 5/02 20130101 |
International
Class: |
A47G 27/02 20060101
A47G027/02 |
Claims
1. A laminated mat comprising: a plurality of layers, the plurality
of layers including at least a top layer and a bottom layer, the
top layer having a first thickness, a first width, and a first
length, and the bottom layer having a second thickness, a second
width, and a second length; and one or more end caps, wherein the
one or more end caps form longitudinal edges of the laminated mats,
and wherein the end caps have an outer region having a thickness
equal to a total thickness of the plurality of layers.
2. The laminated mat of claim 1, wherein the one or more end caps
include a channel sized to receive at least a portion of one of the
plurality of layers.
3. The laminated mat of claim 1, wherein the plurality of layers
includes an intermediate layer disposed between the top layer and
the bottom layer, and wherein each of the one or more end caps
includes a channel sized to receive a portion of the intermediate,
the portion of the intermediate layer extending beyond the top
layer and the bottom layer.
4. The laminated mat of claim 3, each of the plurality of layers
includes a plurality of boards, and wherein boards of adjacent
layers of the plurality of layers are disposed in a cross-hatched
manner with respect to each other.
5. The laminated mat of claim 1, wherein each of the one or more
end caps is formed as a single homogeneous piece.
6. The laminated mat of claim 1, further comprising one or more
attachment means.
7. The laminated mat of claim 6, wherein the one or more attachment
means are recessed within the plurality of layers such that the one
or more attachment means are substantially flush with a top surface
of the laminated mat.
8. The laminated mat of claim 6, further comprising one or more
cover plates.
9. The laminated mat of claim 8, wherein the one or more cover
plates are configured to be secured to one or more of the plurality
of layers.
10. The laminated mat of claim 9, wherein each of the one or more
cover plates is secured to one or more of the plurality of layers
in an orientation that overlies one of the one or more attachment
means, and wherein each of the one or more cover plates is seated
flush with a top surface of the laminated mat.
11. The laminated mat of claim 8, wherein each of the one or more
cover plates includes a member protruding perpendicular to a
surface of the one or more cover plates.
12. The laminated mat of claim 8, wherein each of the one or more
cover plates includes a member protruding from a surface of the one
or more cover plates, wherein the member is configured to be
inserted into an opening in one of the plurality of layers.
13. The laminated mat of claim 1, wherein the plurality of layers
are formed of wood.
14. The laminated mat of claim 1, wherein the plurality of layers
are formed of a synthetic material.
15. The laminated mat of claim 1, wherein the plurality of layers
are formed of wood, a synthetic material, or a combination
thereof.
16. The laminated mat of claim 1, wherein the bottom layer includes
one or more metal channels.
17. A method for forming a laminated mat, the method comprising:
providing a first plurality of boards; disposing the first
plurality of boards adjacent to one another along a first axis;
providing a second plurality of boards; disposing the second
plurality of boards adjacent to one another along a second axis
that is perpendicular to the first axis; providing a third
plurality of boards; disposing the third plurality of boards
adjacent to one another along the first axis; providing end caps
along longitudinal edges of the laminated mat; and attaching the
first plurality of boards, the second plurality of boards, the
third plurality of boards, and the end caps to form the laminated
mat.
18. The method of claim 17, further comprising disposing one or
more metal channels between select ones of the third plurality of
boards.
19. The method of claim 17, wherein the end caps include a channel,
and wherein the method includes disposing one or more of the second
plurality of boards within the channel.
20. The method of claim 19, wherein the method includes: providing
one or more attachment means; securing the one or more attachment
means to at least one board selected from among the first plurality
of boards, the second plurality of boards, and the third plurality
of boards; and providing a cover plate for each of the one or more
attachment means; and securing each cover plate in an orientation
that overlies one of the one or more attachment means and is flush
with a top surface of the laminated mat.
Description
TECHNICAL FIELD
[0001] The present disclosure is generally related to laminated
mats, and more specifically to systems and methods for providing
endcaps for laminated mats.
BACKGROUND
[0002] Laminated mats are in broad use in many industries. However,
presently available laminated mats have several deficiencies that
affect their performance and reduce their useful life. For example,
many laminated mats are constructed from layers of wood, such as an
untreated wood. During use, wooden laminated mats come in contact
with the ground and moisture, which may cause the wooden laminated
mats to begin deteriorating or rotting. Typically, the
deterioration or rotting of wooden laminated mats begins at the
edge, where the layers of the wooden laminated mat are directly
exposed to the moisture. As the edges rot, the layers of the
laminated mat may begin to separate, which may increase the rate at
which the wooden laminated mat rots. Further, the separation of the
layers may cause the wooden laminated mats to warp, creating an
uneven surface, which may introduce tripping hazards to persons
working in areas where such wooden laminated mats are present.
Additionally, the rotting of the wooden laminated mat may
significantly decrease their useful lifespan. For example, the
useful life of wooden laminated mats is often less than 1 year, and
may be significantly shorter (e.g., 6 months) due to the
deficiencies described above. Thus, replacing the wooden laminated
mats once or twice a year imposes significant costs to industries
(e.g., the oil and gas industry) where such laminated mats may be
deployed.
[0003] In addition to deficiencies (e.g., rotting) caused by
weather elements (e.g., moisture, extreme heat, etc.), wear from
continued use and/or damage from heavy equipment used in the field
can cause individual pieces of wood used to construct the wooden
laminated mats to disintegrate and fall from the mats over time.
This disintegration causes loss of compression and torque of the
bolts and/or nails holding the mat together, which may cause the
wooden laminated mat to be no longer useable or to lose its
structural integrity. Additionally, the wear from continued use
and/or damage from heavy equipment may increase the likelihood that
rot occurs, and may increase the rate at which the layers of the
wooden laminated mat separate. This may also cause the useable life
of the wooden laminated mat to decrease.
[0004] Another type of mat may be referred to as a synthetic mat.
While synthetic mats generally do not have the same rotting
problems as wood mats, synthetic mats are not in wide use due to
various disadvantages. For example, in the event that there is rain
at a location where the synthetic mats are deployed, water tends to
stay on top of the laminated synthetic mats, thereby causing
slippery conditions. Synthetic mats also tend to be more labor
intensive to deploy. Moreover, synthetic mats generally have
continuous top surface and a hollow core. Because of this, if the
mat is ever pierced, water fills into the core and causes the
synthetic mat to be much heavier, which creates difficulties in
transporting and deploying the mats. Further, if the synthetic mats
are utilized in a cold environment, water expansion in the
presences of freezing conditions further damages the mats. Another
disadvantage of synthetic mats is that because they generally
comprise one large piece of surface material, they generally are
not repairable in a cost-effective manner in the event that the mat
is damaged.
[0005] Another type of mat is a laminated synthetic mat. While
laminated synthetic mats are not as susceptible to rot as wooden
laminated mats, laminated synthetic mats remain susceptible to
separation of the layers under normal wear and tear. Such a
separation reduces the useful life of the laminated synthetic mats.
For example, forklifts are often used to transport the mats (e.g.,
both laminated synthetic mats and wooden laminated mats) to a
location where the mats are to be deployed or stored. If the
forklift operator inadvertently catches the edge of the mats with
the forks of the forklift, the forks may slide between the layers
of the laminated mats, damaging the areas immediately surround the
impact zone and separating the layers of the laminated mat.
BRIEF SUMMARY
[0006] Systems, apparatuses and methods which provide for an
improved laminated mat comprised of synthetic material, wood, or
other materials are provided for herein. Such mats may include a
plurality of inventive features. For example, in some embodiments
the laminated mat may include one or more end caps configured to
reduce the likelihood that layers of the laminated mat are
separated during movement, use, and transport, and may reduce the
wear and tear of the laminated mate, and may increase the useful
life of the laminated mat.
[0007] In an additional or alternative embodiment, the laminated
mat may comprise a cover plate that may reduce a likelihood that
persons working in areas where the laminated mat may be deployed
are injured. For example the laminated mat may include attachment
means that may be recessed with respect to the top surface of the
mat. Such attachments means may present a potential hazard that
persons working in the area of the laminated may trip on. The cover
plate may overlie the attachment means and substantially fill the
recessed area where the attachment means is located, and may be
seated flush with the top surface of the laminated mat, thereby
eliminating the potential tripping hazard.
[0008] The foregoing has outlined rather broadly the features and
technical advantages of the present disclosure in order that the
detailed description of the invention that follows may be better
understood. Additional features and advantages of the embodiments
will be described hereinafter which form the subject of the claims
of the present disclosure. It should be appreciated by those
skilled in the art that the conception and specific embodiment
disclosed may be readily utilized as a basis for modifying or
designing other structures for carrying out the same purposes of
the present invention. It should also be realized by those skilled
in the art that such equivalent constructions do not depart from
the spirit and scope of the invention as set forth in the appended
claims. The novel features which are believed to be characteristic
of the present disclosure, both as to its organization and method
of operation, together with further objects and advantages will be
better understood from the following description when considered in
connection with the accompanying figures. It is to be expressly
understood, however, that each of the figures is provided for the
purpose of illustration and description only and is not intended as
a definition of the limits of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a more complete understanding of the present invention,
reference is now made to the following descriptions taken in
conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a perspective view of a laminated mat in
accordance with an embodiment of the present application;
[0011] FIG. 2 is an expanded perspective view of a laminated mat in
accordance with an embodiment of the present application;
[0012] FIG. 3A illustrates a cross-sectional view of a laminated
mat in accordance with an embodiment of the present
application;
[0013] FIG. 3B illustrates a perspective view of an end cap for a
laminated mat in accordance with an embodiment of the present
application;
[0014] FIG. 3C illustrates a cross-sectional view of an end cap for
a laminated mat in accordance with an embodiment of the present
application;
[0015] FIG. 4A illustrates a cover plate for a laminated mat in
accordance with an embodiment of the present application;
[0016] FIG. 4B illustrates a perspective view of a cover plate for
a laminated mat in accordance with an embodiment of the present
application;
[0017] FIG. 4C illustrates a profile view of a cover plate for a
laminated mat in accordance with an embodiment of the present
application;
[0018] FIG. 4D illustrates a top view of a cover plate for a
laminated mat in accordance with an embodiment of the present
application; and
[0019] FIG. 5 is a flow chart of a method for creating or using a
laminated mat in accordance with an embodiment of the present
application.
DETAILED DESCRIPTION
[0020] Referring to FIGS. 1 and 2, a perspective view and an
expanded view of a laminated mat in accordance with an embodiment
of the present application is shown as a laminated mat 100. In an
embodiment, the laminated mat 100 may be constructed from wood. In
an additional or alternative embodiment, the laminated mat 100 may
be constructed from a synthetic material, such as rubber. In yet
another additional or alternative embodiment, the laminated mat 100
may be formed of both wood and synthetic materials. As shown in
FIGS. 1 and 2, the laminated mat 100 includes a plurality of
layers. For example, in an embodiment, the plurality of layers may
include a first layer 120, a second layer 130, and a third layer
140. In additional or alternative embodiments, the laminated mat
100 may include more than three layers or less than three layers.
In an embodiment, the third layer 140 may be a bottom layer of the
laminated mat 100 and the first layer 120 may be a top layer of the
laminated mat 100. During deployment of the laminated mat 100, the
third layer 140 may be in contact with the ground, and the layer
120 may be facing towards the sky (or a ceiling if deployed in a
covered environment), and the second layer 130 may be an
intermediate layer that is disposed between the first layer 120 and
the third layer 140, as shown in FIGS. 1 and 2. Additionally, as
shown in FIG. 1, the laminated mat 100 includes one or more
attachment means 150 that may be used to lift the laminated mat
100, such as during placement, storage, loading for transport, etc.
In an embodiment, the attachment means 150 may be a D-ring, as
described in more detail below. In an embodiment, the attachment
means 150 may be secured to the second layer 130 at a region 162,
and may reside within an opening 160 of the first layer 120, as
shown in FIG. 2. In an embodiment, the attachment means 150 may
reside within the opening 160 and be recessed from the top surface
of the first layer 120. By recessing the attachment means 150 from
the top surface of the first layer 120, cover plates may be secured
over the attachment means 150, as described in more detail below
with reference to FIGS. 4A-4D.
[0021] In an embodiment, the layers 120, 130, 140 of the laminated
mat 100 may be constructed from a plurality of individual boards,
as shown in FIGS. 1 and 2. Further, the individual boards of each
of the layers 120, 130, 140 may be in a cross-hatched orientation
with respect to an immediately adjacent layer. For example, as
shown in FIG. 2, the boards of the first layer 120 and the third
layer 140 are oriented parallel to a longitudinal axis 102 of the
laminated mat 100, while the boards of the second layer 130
oriented perpendicular to the longitudinal axis 102. Configuring
the boards of the layers 120, 130, 140 in a cross-hatched
orientation may increase the durability and strength of the
laminated mat 100. In an embodiment, the layers 120, 130, 140 may
be held together by bolts, as described with reference to FIG. 3.
The bolts may be countersunk into the laminated mat 100, such that
bolts are flush with, or slightly recessed from top surface of the
first layer 120.
[0022] In an additional or alternative embodiment, the layers 120,
130, 140 may each be formed as single continuous sheet, rather than
as a plurality of individual boards. For example, the first layer
120 may be formed from a first continuous sheet of material, the
second layer 130 may be formed from a second continuous sheet of
material, and the third layer 140 may be formed from a third
continuous sheet of material. The sheets may then be attached
(e.g., bolted, nailed, glued, etc.) to form the laminated mat
100.
[0023] It is noted that constructing the laminated mat 100 from
individual boards, rather than layers of sheets, may provide
advantages. For example, the individual boards may be spaced apart
to allow water to drain through the laminated mat 100, whereas the
continuous sheets may not allow water to drain through the
laminated mat 100. Thus, when single continuous sheets are used to
form the laminated mat 100, additional work may need to be
completed prior to deployment of the laminated mat 100, such as to
create slight gradient in the area where the laminated mats are to
be deployed so that the water will run off the top surface of the
layer 120. Further, by forming the laminated mat 100 from
individual boards, rather than continuous sheets, individual boards
of a particular layer of the laminated mat 100 may be replaced
without requiring replacement of the entire particular layer.
[0024] In an embodiment, the third layer 140 may include metal
channels 142, as shown in FIG. 4. The metal channels 142 may be
used to add strength to the laminated mat 100, and to prevent the
laminated mat 100 from warping. The metal channels 142 may be
configured such that the height of the legs of the metal channels
142 are flush with a lower surface of the third layer 140. In some
cases, the height of the legs may be slightly smaller such that the
metal channels 142 do not contact the ground. In an embodiment, the
metal channels 142 may extend along the length of the laminated mat
100 where attachment means 150 are located. Such a placement may
provide for additional strength to hold the weight of the laminated
mat 100 and any other load when the mat is being lifted using the
attachment means 150. While not shown, it is appreciated that the
metal channels 142 may be bolted with one or more of the layers
120, 130, 140.
[0025] Additionally, as shown in FIGS. 1 and 2, the laminated mat
100 includes end caps 110. The end caps 110 include a channel
configured to receive one or more of the layers 120, 130, 140 of
the laminated mat 100. In an embodiment, and as illustrated in
FIGS. 1 and 2, the end caps 110 may be positioned along the
longitudinal edges (e.g., the edges parallel to the longitudinal
axis 102) of the laminated mat 100. In an additional or alternative
embodiment, end caps 110 may be placed on all edges of the
laminated mat 100. It is noted, however, that the longitudinal
edges of the laminated mat 100 are high impact edges due to the way
the laminated mat 100 is oriented during use. For example, during
deployment and use, a plurality of laminated mats 100 may be placed
adjacent to one another along their respective longitudinal edges
to form a road upon which equipment (e.g., tractors, trucks, etc.)
may travel in a direction perpendicular to the longitudinal axis
102. Because direction of travel is perpendicular to the
longitudinal edges of the laminated mats, the longitudinal edges of
the laminate mat 100 experience more wear and more frequent high
impact from the heavy equipment that traverses the laminated mats.
This additional wear creates more strain between the layers 120,
130, 140 along the longitudinal edges than in other areas, such as
the edges perpendicular to the longitudinal axis 102. Thus, the
longitudinal edges of the laminated mat 100 are more likely to
break down or become damaged than the edges perpendicular to the
longitudinal axis 102. The end caps 110 may reduce the wear and
tear of the laminated mat 100 along the longitudinal edges.
[0026] For example, and referring to FIGS. 3A-3C, various views of
the laminated mat 100 and end caps 110 are shown in accordance with
an embodiment of the present application. In FIG. 3A, a
cross-sectional view of the laminated mat 100 in accordance with an
embodiment of the present application is shown. As explained above,
the end caps 110 may be configured to receive one or more of the
layers of the laminated mat 100. For example, in FIG. 3A, the
second layer 130 is shown extending into the channel of the end
caps 110. Further, the top surface of the first layer 120 and the
top surface of the end caps 110 may be substantially flush, and the
bottom surface of the third layer 130 and the bottom surface of the
end caps 110 may be substantially flush, as shown in FIG. 3A. In an
embodiment, the top surface of the first layer 120 and the top
surface of the end caps 110 may be textured to provide improved
grip for equipment and workers crossing the laminated mat 100,
which may be beneficial in some operational conditions, such as
when it is raining.
[0027] In additional or alternative embodiment, the channel of the
end caps 110 may receive more than 1 layer of the laminated mat
100. For example, if the laminated mat 100 included 4 layers, the
channel may be configured to receive the second and third layers
(e.g., the middle layers). As another example, if the laminated mat
100 included 5 layers, the channel may be configured to receive the
second and third layers (e.g., the middle layers). Further, the
channel may receive less than all of the middle layers in some
embodiments. For example, if the laminated mat included 4 layers,
the channel may only receive the second layer, or the third layer,
but not both, or may receive portions of the second and third
layers. In yet another additional or alternative embodiment, the
channel of the end caps 110 may receive only a portion of one or
more layers of the laminated mat 100. For example, if the laminated
mat 100 included two layers, the channel may receive a portion of
the two layers, such as by milling the two layers along the
longitudinal edges to form rabbets that are adjacent on each of the
layers (e.g., form a tongue) that may be inserted into the channel
while maintaining the top and bottom surfaces flush with the top
and bottom surfaces of the end cap 110. The end caps 110 may reduce
penetration of moisture between the layers 120, 130, 140. For
example, because an outermost edge of the laminated mat 100 may
correspond to the outer edge 310 of the end caps 110.
[0028] As can be seen in FIG. 3A, the longitudinal edges of the
laminated mat 100 may be the end caps 110. By forming the
longitudinal edges of the laminated mat 100 using the end caps 110,
an outer edge of the laminated mat 110 may not expose the layers
120, 130, 140 of the laminated mat 100. For example, and referring
to FIG. 3B, a perspective view of the end cap 110 is shown. As
shown in FIG. 3B, the end cap 110 includes a channel 300, an outer
edge 310, an upper portion 320, a lower portion 330, and an outer
region 340. During placement, the longitudinal edges of the
laminated mats 100 may be placed such that outer edges 310 of the
laminated mats 100 are placed adjacent to one another. As can be
seen in FIGS. 3A-3C, the outer edge 310 of the end cap 110 is
formed as a single piece, meaning that the layers 120, 130, 140 are
not exposed. Thus, the likelihood that equipment traversing the
laminated mat 100 catches one or more of the layers 120, 130, 140
and causes the one or more layers to separate may be reduced.
[0029] As shown in FIG. 3C, the channel 300 may have a thickness
302 and a depth 304. The thickness 302 may be sized to receive the
second layer 130 (or the boards that form the second layer 130).
For example, in an embodiment, the thickness 302 may be the same as
a thickness of the second layer 130. However, when the thickness
302 is the same as the thickness of the second layer 130, it may be
difficult to insert the second layer 130 into the channel 300 of
the end cap 110. Thus, in an additional or alternative embodiment,
the thickness 302 may be sized to be slightly larger than the
thickness of the second layer 130, which may make it easier to
assemble the laminated mat 100. Furthermore, in embodiments of
laminated mats comprising more than three layers, the thickness 302
may be sized to received one or more of the layers, and, in
embodiments comprising two layers, the thickness 302 may be sized
to receive the milled edges of the two layers, as described above.
The depth 304 of the channel 300 may vary depending a particular
configuration of the laminated mat 100. For example, a larger depth
302 may provide additional strength to the laminated mat 100. In an
embodiment, the depth 304 may be determined based on a desired
number of anchor points for securing the end cap 110 to the other
layer(s) of the laminated mat 100. For example, a larger depth 302
may provide additional points at which the end cap 110 may be
secured to the laminated mat 100.
[0030] As additionally shown in FIG. 3C, the upper portion 320 may
have a thickness 322, and the lower portion 330 may have a
thickness 332. In an embodiment, the thickness 322 may be the same
as, or substantially equal to a thickness of the first layer 120,
and the thickness 332 may be the same as, or substantially equal to
a thickness of the third layer 140. Further, the end cap 110 may
have an overall thickness 342. The overall thickness 342 of the end
cap 110 may be equal to, or substantially the same as the sum of
the thickness of the layers 120, 130, 140. Thus, when assembled,
the end cap 110 may be substantially flush with the upper surface
of the first layer 120 and the lower surface of the third layer
140. Because the longitudinal edges of the laminated mat 100 are
constructed as the end caps 110, the longitudinal edges are a
single homogeneous piece, which may be more resistant to wear and
tear, and may more easily withstand impact in high traffic/impact
areas, as is common to the longitudinal edges of the laminate mat
100.
[0031] Furthermore, and as illustrated in FIG. 3C, the outer region
340 of the end cap 110 may have a width 344. The width 344 of the
outer region 340 may be configured to reduce or minimize impact
from forks of a forklift. For example, the end cap 110 may be
formed of rubber, and the width 344 of the outer region 340 may be
sufficient to withstand impact from forks of a forklift without
allowing the forks to penetrate to the layer(s) within the channel
300 or the remaining portions of the laminated mat 100. For
example, as the forks penetrate the outer region 340, the forks may
penetrate into the outer region, but due to the softness (or
elasticity) of the outer region 340, the forks may eventually begin
to push the laminated mat 100, rather than continue to penetrate
through the laminated mat 100 and separate one or more of the
layers 120, 130, 140. In an embodiment, the outer region 340 of the
end cap 110 may include a strip of metal extending from the lower
surface of the end cap 110 toward the upper surface of the end cap
110, where the strip of metal may engage the forks if they
penetrate the end cap 110 to a threshold depth, and may prevent the
forks from penetrating further into the end cap 110, so as to
protect the portion of the second layer 130 inserted into the
channel, and the remaining layers of the laminated mat 100.
[0032] Referring to FIGS. 4A-4D, various views of a cover plate for
a laminated mat in accordance with an embodiment of the present
application are shown as a cover plate 400. FIG. 4A illustrates the
cover plate 400 as installed on the laminated mat 100 of FIGS.
1-3C. As shown in FIG. 4A, the cover plate 400 includes a first
opening 410 and a second opening 420. The first opening 410 may be
dimensioned to allow a retention member of the attachment means 150
to protrude through the first opening 410. It is noted that the
attachment means 150, and the retaining member in particular, may
be flush with the top surface of the first layer 120 when
installed. As shown in FIG. 4A, the cover plate 400 may be secured
to the laminated mat 100 using a screw 422 that is inserted through
the second opening 420. The screw 422 may be recessed from, or may
be flush with the top surface of the first layer 120
[0033] By using the cover plate 400 in conjunction with the
laminated mat 100, work place injuries caused by workers tripping
while walking through a work site where the laminated mat 100 is
deployed. For example, as explained above, the attachment means 150
may be recessed within the first layer 120 of the laminated mat 100
by securing the attachment means 150 to the second layer 130 (e.g.,
at a region 162 of FIG. 2) such that the attachment means 150
resides substantially within an opening (e.g., the opening 160 of
FIG. 2) of the first layer 120 of the laminated mat 100. When the
cover plate 400 is not used, the attachment means 150 and the
opening in which the attachment means 150 resides may pose a
hazard, whereby workers may step into the opening or on the
attachment means 150 and trip or twist their ankle. Thus, the cover
plate 400 may reduce the likelihood that workers trip or are
injured while walking across the laminated mat 100.
[0034] FIG. 4B illustrates a perspective view of the cover plate
400 of FIG. 4A. As shown in FIG. 4B, the cover plate 400 may
include a member 402. In an embodiment, the member 402 may be
perpendicular to the cover plate 400, and may project downward from
the cover plate 400 towards the attachment means 150. In such an
embodiment, the member 402 may be configured to maintain the top
surface of the cover plate 400 in a substantially parallel
orientation with respect to the first layer 120 of the laminated
mat 100 so as to prevent the cover plate 400 from resting at an
angle when secured to the laminated mat 100. This may prevent the
cover plate 400 from being lower on the edge of the cover plate 400
opposite the first opening 420, which would pose a risk of
workplace injury by workers tripping on the edge of the first layer
120 proximate the lowered edge of the cover plate 400. In an
additional or alternative embodiment, the member 402 may be a latch
configured to be inserted into an opening (not shown) in the
attachment means 150 or the laminated mat 100. For example, instead
of being substantially planar, as shown in FIG. 4B, the member 402
may include a curved or angled portion that may be inserted into an
opening in the laminated mat 100 or the attachment means 150, where
the opening is configured to receive at least a portion of the
member 402 and to prevent the edge of cover plate 400 proximate the
member 402 from lifting up. Thus, when the cover plate 400 is
secured to the mat 100, the member 402 may need to be inserted into
the opening of the laminated mat 100 or the attachment means 150
prior to securing the screw 422 to the laminated mat 100.
[0035] FIG. 4C illustrates a profile view of the cover plate 400.
As shown in FIG. 4C, the attachment means 150 may reside below the
cover plate 400 when secured to the laminated mat 100. FIG. 4D
illustrates a top view of the cover plate 400. In addition to
reducing the likelihood of work place injuries, the cover plate 400
may also protect the attachment means 150 from damage caused by
machinery (e.g., trucks, tractor treads, etc.) that may traverse
the laminated mat 100. Thus, using cover plates, such as the cover
plate 400, may improve the laminated mat 100 by reducing the
likelihood of injury and by reducing wear and tear on the
attachment means 150.
[0036] Referring to FIG. 5, a flow chart of an exemplary embodiment
of a method for creating or using a laminated mat is shown as a
method 500. At 510, the method 500 includes providing a first
plurality of boards (e.g., the plurality of boards comprising the
first layer 120 of FIGS. 1 and 2), and, at 520, the method 500
includes disposing the first plurality of boards adjacent to one
another along a first axis (e.g., the longitudinal axis 102 of
FIGS. 1 and 2). At 530, the method 500 includes providing a second
plurality of boards (e.g., the plurality of boards comprising the
second layer 130 of FIGS. 1 and 2), and, at 540, the method 500
includes disposing the second plurality of boards adjacent to one
another along a second axis that is perpendicular to the first axis
(e.g., an axis perpendicular to the longitudinal axis 102 of FIGS.
1 and 2). At 550, the method 500 includes providing a third
plurality of boards (e.g., the plurality of boards comprising the
third layer 140 of FIGS. 1 and 2), and, at 560, the method 500
includes disposing the third plurality of boards adjacent to one
another along the first axis (e.g., the longitudinal axis 102 of
FIGS. 1 and 2). At 570, the method 500 includes providing end caps
(e.g., the end caps 110 of FIGS. 1-3C) along longitudinal edges of
the laminated mat, and, at 580, attaching the first plurality of
boards, the second plurality of boards, the third plurality of
boards, and the end caps to form the laminated mat. The end caps
may include a channel (e.g., the channel 300 of FIG. 3.
[0037] In an embodiment, the method 500 may include additional
steps (not shown in FIG. 5). For example, the method 500 may
include disposing one or more of the second plurality of boards
within the channel, as described above. As another example, the
method 500 may include disposing one or more metal channels (e.g.,
the metal channels 142 of FIG. 2) between select ones of the third
plurality of boards. As yet another example, the method 500 may
include providing one or more attachment means, securing the one or
more attachment means to at least one board selected from among the
first plurality of boards, the second plurality of boards, and the
third plurality of boards, providing a cover plate for each of the
one or more attachment means, and securing each cover plate in an
orientation that overlies one of the one or more attachment means
and is flush with a top surface of the laminated mat.
[0038] Laminated mats constructed according to the method 500 may
provide improved laminated mats. For example, because the laminated
mats include end caps along the longitudinal edges (e.g., high
impact, high traffic areas), the laminated mats may be more
resistant to wear and tear. Additionally, by providing cover plates
in some embodiments, a likelihood of injury to workers that are
working in areas where the laminated mats are deployed may be
reduced or eliminated.
[0039] Although the present invention and its advantages have been
described in detail, it should be understood that various changes,
substitutions and alterations can be made herein. without departing
from the spirit and scope of the invention as defined by the
appended claims. Moreover, the scope of the present application is
not intended to be limited to the particular embodiments of the
process, machine, manufacture, composition of matter, means,
methods and steps described in the specification. As one of
ordinary skill in the art will readily appreciate from the
disclosure of the present invention, processes, machines,
manufacture, compositions of matter, means, methods, or steps,
presently existing or later to be developed that perform
substantially the same function or achieve substantially the same
result as the corresponding embodiments described herein may be
utilized according to the present invention. Accordingly, the
appended claims are intended to include within their scope such
processes, machines, manufacture, compositions of matter, means,
methods, or steps.
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