U.S. patent application number 15/661316 was filed with the patent office on 2018-02-01 for lightweight panel mat with interlocking elements.
The applicant listed for this patent is QUALITY MAT COMPANY. Invention is credited to Scott CALVERT, Don COUVILLON, Joe PENLAND, JR..
Application Number | 20180030666 15/661316 |
Document ID | / |
Family ID | 61011787 |
Filed Date | 2018-02-01 |
United States Patent
Application |
20180030666 |
Kind Code |
A1 |
PENLAND, JR.; Joe ; et
al. |
February 1, 2018 |
LIGHTWEIGHT PANEL MAT WITH INTERLOCKING ELEMENTS
Abstract
A lightweight universal panel mat made of plastic or elastomeric
material and having a first section that provides a relatively
flat, textured or structured top surface to facilitate movement
over the upper surface and a second section having geometry that
includes a plurality of cells having top surfaces that support the
first section. The panel mats also have first, second, third and
fourth sides that are configured with tabular extensions or
openings, slots or recesses configured and dimensioned to be able
to receive the tabular extensions. At least some of the tabs and
slots are configured to facilitate snap-locking. Thus, a plurality
of similarly configured panel mats can be connected by interlocking
of the tabs of one mat into the openings, slots or recesses of one
or more adjacent similarly configured mats.
Inventors: |
PENLAND, JR.; Joe;
(Beaumont, TX) ; CALVERT; Scott; (Beaumont,
TX) ; COUVILLON; Don; (Beaumont, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
QUALITY MAT COMPANY |
Beaumont |
TX |
US |
|
|
Family ID: |
61011787 |
Appl. No.: |
15/661316 |
Filed: |
July 27, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62368954 |
Jul 29, 2016 |
|
|
|
62402391 |
Sep 30, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E01C 5/20 20130101; E01C
2201/205 20130101; E01C 5/18 20130101; E01C 5/22 20130101; E01C
2201/12 20130101; E01C 2201/14 20130101; E01C 9/086 20130101; B66C
1/66 20130101 |
International
Class: |
E01C 9/08 20060101
E01C009/08; E01C 5/20 20060101 E01C005/20; E01C 5/18 20060101
E01C005/18 |
Claims
1. A lightweight universal panel mat made of plastic or elastomeric
material and designed to be interlocked with additional panel mats
of similar configurations, comprising: a first section having an
upper surface that forms a top surface of the panel mat and is
relatively flat, textured or structured to facilitate movement over
the upper surface; a second section having geometry that includes a
plurality of cells that are open or wherein some or all of the
cells have top surfaces with the geometry supporting the first
section and providing a plurality of open lower surfaces; first,
second, third and fourth sides wherein: the first side is
configured with a plurality of tabular extensions; the second side
is located adjacent the first side and is configured with a
plurality of tabular extensions; the third side is located opposite
the first side and is configured with openings that are
unobstructed and configured, dimensioned and arranged to receive
therein the plurality of first side tabular extensions; and the
fourth side is located opposite the second side and is configured
with slots or recesses that are configured, dimensioned and
arranged to receive therein the plurality of second side tabular
extensions, wherein the tabular extensions on the first side, the
second side or on both sides include either a protruding bump or
depression, and the openings, slots or recesses of the third or
fourth sides have an upper surface that includes a corresponding
depression or protruding bump that enables the respective tabular
extensions to be snap-lockingly engaged together; wherein the
tabular extensions and openings, slots or recesses are formed on
the first section, the second sections, or partially on each
section; wherein the upper surface of the first section is
generally rectangular of length L and width W where L and W each
may be any value between 1 foot and 12 feet; and wherein the first
and second sections are welded or bonded together to form a unitary
panel mat.
2. The panel mat of claim 1, wherein the first and second sections
are part of an integral component that is molded together, or the
tabular extensions, openings and slots or recesses are milled or
routered in a solid plastic or elastomeric component.
3. The panel mat of claim 1 further comprising metal wire, bar or
plate reinforcement located within the second section or between
the first and second sections.
4. The panel mat of claim 1 wherein the first side is configured
with at least three tabular extensions; the second side is
configured with at least three tabular extensions each having a
depression on an upper surface; the third side is located opposite
the first side and is configured with openings that are
unobstructed and configured, dimensioned and arranged to receive
therein the first plurality of tabular extensions; and the fourth
side is located opposite the second side and is configured with
spaced slots or recesses that are configured, dimensioned and
arranged to receive the second tabular extensions therein, wherein
the slots or recesses each have an upper surface that includes a
protruding bump configured and dimensioned to at least partially
engage a depression of the second tabular extension to provide
snap-locking of the bumps into the depressions; wherein the tabular
extensions and openings, slots or recesses are formed partially on
each section.
5. The panel mat of claim 1, wherein the first side is configured
with at least three tabular extensions, each having a protruding
bump on an upper portion thereof; the second side is configured
with at least three tabular extensions each having a protruding
bump on an upper portion thereof; the third side is located
opposite the first side and is configured with openings that are
unobstructed and configured, dimensioned and arranged to receive
therein the plurality of first side tabular extensions, with the
openings having an upper surface that includes a depression therein
that is configured and dimensioned to receive a protruding bump of
the first side tabular extensions; and the fourth side is located
opposite the second side and is configured with spaced slots or
recesses that are configured, dimensioned and arranged to receive
the plurality of second side tabular extensions therein, wherein
the slots or recesses each have an upper surface that includes a
depression therein that is configured and dimensioned to receive a
protruding bump of the second side tabular extensions.
6. The panel mat of claim 1, wherein the first side is configured
with at least two tabular extensions, each having at least two
protruding bumps on an upper portion thereof; the second side is
configured with at least two tabular extensions each having at
least two protruding bumps on an upper portion thereof; the third
side is located opposite the first side and is configured with
openings that are unobstructed and configured, dimensioned and
arranged to receive therein the first side tabular extensions, with
the openings having an upper surface that includes at least two
depressions therein that are configured and dimensioned to receive
the protruding bumps of the first side tabular extensions; and the
fourth side is located opposite the second side and is configured
with spaced slots or recesses that are configured, dimensioned and
arranged to receive therein the second side tabular extensions,
wherein the slots or recesses each have an upper surface that
includes at least two depressions therein that are configured and
dimensioned to receive the protruding bumps of the second side
tabular extensions.
7. The panel mat of claim 1, wherein each spaced slot or recess of
the fourth side of the panel has a lower surface that includes a
bridge or rail structure forming a lower entry of the slot or
recess for initial contact with the lower surface of a second side
tabular extension that is to be received therein.
8. The panel mat of claim 7, wherein the second side tabular
extensions are configured with an angled bottom portion that allows
the forward end of the second side tabular extensions to move away
from the upper portion of the slot or recess to allow detachment of
the second side tabular members from the slots or recesses.
9. The panel mat of claim 7, wherein the protruded bumps and
depressions are circular or oval in configuration and the
depression has a slightly larger circumference than the protruding
bumps, and wherein some or all of the openings, slots or recesses
includes either a cut out end portion, an open bottom, or an
opening adjacent and behind the bridge or rail structure to allow
mud, dirt or water to exit the opening, slot or recess and to
facilitate entry of the tabular members therein.
10. The panel mat of claim 1, wherein the upper surface of the
first section is a structured surface that includes a raised
pattern of spaced elements in a pattern, or channels that allow
water to drain from the mat, with the channels molded therein or
formed between a plurality of raised islands spaced by and closely
arranged, with the islands having a polygonal, circular, or
elliptical shape; and the lower surface of the second section is
structured and includes openings or channels to provide a secure
footing when the panel mat is placed on wet or muddy ground.
11. The panel mat of claim 10, wherein the structured lower surface
of the second section includes a plurality of cells having a
polygonal, circular or elliptical shape forming bottom openings in
the lower surface, wherein some or all of the cells have a top
surface that extends to and supports the upper surface of the first
section to strengthen the panel mat, and wherein some or all of the
cells have a flat bottom surface.
12. The panel mat of claim 1 further comprising a third section
located below and welded, molded, bonded, joined or sealed together
to the second section, the third section configured and dimensioned
to close off the plurality of bottom openings of the cells or when
applicable to receive flat bottom surfaces of some or all of the
cells, and form a bottom surface for the panel mat that is
relatively flat, textured or structured with the panel mat being
able to withstand point loads of between 300 and 500 psi and spread
loadings of 40,000 to 50,000 pounds per square foot.
13. The panel mat of claim 12, wherein the upper surface of the
first section is relatively flat and the third section is a
relatively flat plate, so that the bottom surface of the third
section is also relatively flat.
14. The panel mat of claim 1, which is either rectangular wherein
W=2 L or square wherein W=L, and wherein L is preferably 2.5, 3,
3.5, 4, 4.5, 5, 6, 7, or 8 feet and W is preferably 2.5, 3, 3.5, 4,
4.5, 5, 6, 7, 8, 9, 10, 12, 14 or 16, and when square has two or
three each of the first tabular members, second tabular members,
openings and slots or recesses or when rectangular has four or six
first tabular members, four or six openings, two or three second
tabular members and two or three slots or recesses.
15. The panel mat of claim 1 wherein the first section at the third
and fourth sides of the panel mat is configured to include a lip
portion that covers edges of the respective first and second sides
of adjacently connected similarly configured panel mats and
provides channels that assist in allowing drainage of water from
the top surface of the panel mat.
16. The panel mat of claim 1 wherein each side includes multiple
tabular members and the multiple openings with between 2 and 8
tabular members and openings being provided on each side of the
mat.
17. The panel mat of claim 1 further comprising one, two, three or
four lifting elements that are affixed to the mat to allow lifting
and installation or reclamation of the mat, with the lifting
element including (a) a ring or U or D shaped member that is
movable between first and second positions, wherein the first
position is one where the member resides below the surface of the
mat and the second position is an operative position where the ring
or U or D shaped member is exposed for engagement with lifting
equipment, and (b) a structure that secures the ring or U or D
shaped member to the mat.
18. A temporary support surface, deck, walkway or roadway
comprising a plurality of connected panel mats according to claim 1
with the first side tabular extensions of a first mat engaging the
third side openings of one or more adjacent similarly configured
panel mats and with the second side tubular extensions of the first
mat engaging the slots or recesses of the fourth side of one or
more adjacent similarly configured panel mats.
19. The invention of claim 18 wherein the mats can be joined
together in a manner that provides a staggered configuration that
avoids generating long straight seams between rows of joined
mats.
20. The temporary invention of claim 19 wherein the tabular members
and openings are arranged on the sides of the mat in a
configuration that allows the mats to be joined in an offset manner
so that the ends of the mat are not aligned when installed.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. application Nos.
62/368,954 filed Jul. 29, 2016 and 62/402,391 filed Sep. 30, 2016,
the entire content of each of which is expressly incorporated
herein by reference thereto.
BACKGROUND
[0002] The present invention relates to a reusable lightweight
panel mat system for the construction of equipment support surfaces
and temporary walkways and roadways in areas having poor ground
integrity characteristics. More particularly, the present invention
relates to a reusable system of durable panel mats which are much
lighter than wood or wood/steel mats which can be quickly and
easily positioned in a single layer to form equipment support
surfaces, walkways or roadways and which can thereafter be easily
removed and stored until needed again.
[0003] While conventional wood mats provide useful service at a
reasonable cost, the wood core can deteriorate over time due to
moisture causing gradual rotting and degradation of the wood
material. This causes the mat to be discarded, because unlike some
of the other materials that are used on the upper and lower layers
of the mat, the core cannot be replaced without essentially making
an entirely new mat.
[0004] Also, wood mats generally require heavy equipment for
installation due their weight and bulk. Accordingly, alternatives
to wood mats are needed for alternatives for wood mats that need to
possess the necessary physical properties to be able to withstand
harsh outdoor conditions as well as to support equipment. And of
course cost is a factor in determining the selection of alternate
materials, as it is not cost-effective to provide a mat that is
multiple times more expensive than one that can be made of
wood.
[0005] Thus, there is a need for improvement in these types of mat
constructions both to provide longer service lives as well as to
conserve natural resources and facilitate installation, and these
needs are now satisfied by the panel mats of the present
invention.
SUMMARY OF THE INVENTION
[0006] The invention now provides a lightweight universal panel mat
made of plastic or elastomeric material and designed to be
interlocked with additional panel mats of similar configurations.
These panel mats have a first section having an upper surface that
forms a top surface of the panel mat and is relatively flat,
textured or structured to facilitate movement over the upper
surface and a second section having geometry that includes a
plurality of cells that are open or wherein some or all of the
cells have flat top surfaces with the geometry supporting the first
section and providing a plurality of open lower surfaces. These
panel mats also include first, second, third and fourth sides
wherein: the first side is configured with a plurality of tabular
extensions; the second side is located adjacent the first side and
is configured with a plurality of tabular extensions; the third
side is located opposite the first side and is configured with
openings that are unobstructed and configured, dimensioned and
arranged to receive therein the plurality of first side tabular
extensions; and the fourth side is located opposite the second side
and is configured with slots or recesses that are configured,
dimensioned and arranged to receive therein the plurality of second
side tabular extensions.
[0007] The tabular extensions on the first side, the second side or
on both sides preferably include either a protruding bump or
depression, and the openings, slots or recesses of the third or
fourth sides have an upper surface that includes a corresponding
depression or protruding bump that enables the respective tabular
extensions to be snap-lockingly engaged together. Also, the tabular
extensions and openings, slots or recesses can be formed on the
first section, the second sections, or partially on each section.
The upper surface of the first section is generally rectangular of
length L and width W where L and W each may be any value between 1
foot and 16 feet; and the first and second sections are welded or
bonded together to form a unitary panel mat.
[0008] The first and second sections may be parts of an integral
component that is molded together or the tabular extensions,
openings and slots or recesses can be milled or routered in a solid
plastic or elastomeric component. If desired, these panel mats may
include metal wire, bar or plate reinforcement located within the
second section or between the first and second sections. Typical
metals for such use would be steel, stainless steel or
aluminum.
[0009] In one embodiment, the first side is configured with at
least three tabular extensions; the second side is configured with
at least three tabular extensions each having a depression on an
upper surface; the third side is located opposite the first side
and is configured with openings that are unobstructed and
configured, dimensioned and arranged to receive therein the first
plurality of tabular extensions; and the fourth side is located
opposite the second side and is configured with spaced slots or
recesses that are configured, dimensioned and arranged to receive
the second tabular extensions therein, wherein the slots or
recesses each have an upper surface that includes a protruding bump
configured and dimensioned to at least partially engage a
depression of the second tabular extension to provide snap-locking
of the bumps into the depressions; wherein the tabular extensions
and openings, slots or recesses are formed partially on each
section.
[0010] In another embodiment, the first side is configured with at
least three tabular extensions, each having a protruding bump on an
upper portion thereof; the second side is configured with at least
three tabular extensions each having a protruding bump on an upper
portion thereof; the third side is located opposite the first side
and is configured with openings that are unobstructed and
configured, dimensioned and arranged to receive therein the
plurality of first side tabular extensions, with the openings
having an upper surface that includes a depression therein that is
configured and dimensioned to receive a protruding bump of the
first side tabular extensions; and the fourth side is located
opposite the second side and is configured with spaced slots or
recesses that are configured, dimensioned and arranged to receive
the plurality of second side tabular extensions therein, wherein
the slots or recesses each have an upper surface that includes a
depression therein that is configured and dimensioned to receive a
protruding bump of the second side tabular extensions.
[0011] In yet another embodiment, the first side is configured with
at least two tabular extensions, each having at least two
protruding bumps on an upper portion thereof; the second side is
configured with at least two tabular extensions each having at
least two protruding bumps on an upper portion thereof; the third
side is located opposite the first side and is configured with
openings that are unobstructed and configured, dimensioned and
arranged to receive therein the first side tabular extensions, with
the openings having an upper surface that includes at least two
depressions therein that are configured and dimensioned to receive
the protruding bumps of the first side tabular extensions; and the
fourth side is located opposite the second side and is configured
with spaced slots or recesses that are configured, dimensioned and
arranged to receive therein the second side tabular extensions,
wherein the slots or recesses each have an upper surface that
includes at least two depressions therein that are configured and
dimensioned to receive the protruding bumps of the second side
tabular extensions.
[0012] Generally, the first and second sections are separate
components having peripheral boundaries configured to contact each
other for attachment, and the sections are welded, molded, bonded,
joined or sealed together where the peripheral boundaries contact
each other to prevent water from entering into and between the
sections. This also protects any internal steel reinforcement from
rusting.
[0013] Preferably, each slot or recess of the fourth side of the
panel has a lower surface that includes a bridge or rail structure
forming a lower entry of the slot or recess for initial contact
with the lower surface of a second side tabular extension that is
to be received therein. Similarly, the second side tabular
extensions are configured with an angled bottom portion that allows
the forward end of the second side tabular extensions to move away
from the upper portion of the slot or recess to allow detachment of
the second side tabular members from the slots or recesses.
[0014] Typically, the protruded bumps and depressions are circular
or oval in configuration and the depression has a slightly larger
circumference than the protruding bumps. Also, some or all of the
openings, slots or recesses include either a cut out end portion,
an open bottom or an opening adjacent and behind the bridge or rail
structure to allow dirt or water to exit the opening, slot or
recess and to facilitate entry of the tabular members therein.
[0015] In one configuration, the upper surface of the first section
is a structured surface that includes a raised pattern of spaced
elements in a pattern, such as a herringbone or spaced longitudinal
line pattern, or channels that allow water to drain from the mat.
These can be molded into the surface of the top section. The
channels can easily be achieved by including a plurality of raised
islands spaced by and closely arranged near each other to form the
channels, with the islands having a polygonal, circular, or
elliptical shape. Additionally, the lower surface of the second
section can be structured and can include openings or channels to
provide a secure footing when the panel mat is placed on wet or
muddy ground. These structured lower surface of the second section
preferably includes a plurality of cells having a polygonal,
circular or elliptical shape forming bottom openings in the lower
surface, wherein some or all of the cells have a top surface that
extends to and supports the upper surface of the first section to
strengthen the panel mat, and wherein some or all of the cells have
a flat bottom surface.
[0016] And the upper surface of the first section may be a
structured surface that includes channels that allow water to drain
from the mat and a plurality of raised islands spaced by and
closely arranged near each other to form the channels, with the
islands having a polygonal, circular, or elliptical shape; and
wherein the lower surface of the second section is structured and
includes a plurality of cells having a polygonal, circular or
elliptical shape to provide a secure footing when the panel mat is
placed on wet or muddy ground, wherein the cells have a top surface
that extends to and supports the upper surface of the first
section. The panel mats can be designed with the first section
including, at the third and fourth sides of the panel mat, a lip
portion that covers edges of the respective first and second sides
of adjacently connected similarly configured panel mats and
provides channels that assist in allowing drainage of water from
the top surface of the panel mat.
[0017] For any of the embodiments described herein, a preferred
embodiment of the invention provides a third section located below
and welded, molded, bonded, joined or sealed together to the second
section, with the third section configured and dimensioned to close
off the plurality of openings of the cells or when applicable to
receive flat bottom surfaces of some or all of the cells, and form
a bottom surface for the panel mat that is relatively flat,
textured or structured. This further strengthens the mat without
adding significant weight as it allows the cells to provide better
resiliency and compression properties to the panel mat.
[0018] It is also possible for the upper surface of the first
section to relatively flat and when the third section is a
relatively flat plate, the bottom surface of the third section is
also relatively flat. This type of construction is ideal for
placement of the panel mats for temporarily protecting gym flooring
or athletic fields from events such as graduations, concerts, of
other large gatherings. It is also very helpful to evenly
distribute any loads on the mats and prevents any edges of the open
cells from cutting into soft surfaces such as grass or filling up
with much or dirt.
[0019] Alternatively, when the top surface of the first section is
structured, the bottom surface of the third section can be
structured in a similar fashion to provide better engagement with
the ground or to allow the mats to be used with either side facing
upwards and away from the ground.
[0020] The panel mats of the invention are typically rectangular
wherein W=2 L or square wherein W=L, and wherein L is preferably
2.5, 3, 3.5, 4, 4.5, 5, 6, 7, or 8 feet and W is preferably 2.5, 3,
3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 14 or 16 feet. When the panel
mat is square, it includes two or three each of the first tabular
members, second tabular members, openings and slots or recesses or
and when rectangular it includes four or six first tabular members,
four or six openings, two or three second tabular members and two
or three slots or recesses. These panel mats generally weigh
between about 10 and 125 pounds making them easily movable manually
by one or two workers without the use for heavy equipment. These
panel mats are able to withstand point loads of between 300 and 500
psi and spread loadings of 40,000 to 50,000 pounds per square
foot.
[0021] Each side of the panel mats advantageously includes multiple
tabular members and multiple openings. Typically, between 2 and 8
tabular members and openings are provided on the first and second
sides of the mat but in some designs those numbers of members and
openings can be provided on each side of the mat for more secure
connection between conjoined mats.
[0022] The panel mats of the invention may also include one, two,
three or four lifting elements that are affixed to the mats to
allow lifting and installation or reclamation. These lifting
elements include (a) a ring or U or D shaped member that is movable
between first and second positions, wherein the first position is
one where the member resides below the surface of the mat and the
second position is an operative position where the ring or U- or
D-shaped member is exposed for engagement with lifting equipment,
and (b) a structure that secures the ring or U- or D-shaped member
to the mat. Preferably, the structure that secures the ring or U-
or D-shaped member to the mat includes a plate that engages the
surface of the mat opposite the surface from which the member
extends, and a post that extends through the mat for engagement
with the ring or U- or D-shaped member either directly or through a
connecting element.
[0023] Thus, the mats of the present invention can be assembled to
easily provide a temporary support surface, deck, walkway or
roadway using a plurality of connected panel mats as disclosed
herein. Generally, the first side tabular extensions of a first mat
engage the third side openings of one or more adjacent similarly
configured panel mats and the second side tubular extensions of the
first mat engage the slots or recesses of the fourth side of one or
more adjacent similarly configured panel mats. The mats can be
joined together in a manner that allows the ends to be aligned or
not. A staggered configuration is generally preferable as it avoids
generating long seams between rows of joined mats where the seam
can separate more easily during use of the temporary flooring.
Therefore, it is preferred that the tabular members and openings
are arranged on the sides of the mat in a configuration that allows
the mats to be joined in an offset or staggered manner so that the
ends of the mat are not aligned when installed.
[0024] The installation of the panel mats can proceed by a number
of ways depending upon what is desired. For a smaller installation,
smaller size mats that are easily lifted and installed by one or
two workers are preferable, while the larger size mats facilitate a
faster construction because more area is covered by each mat. The
lifting elements assist in allowing these larger mats to be lifted
and installed or reclaimed by equipment. And often, combinations of
the different mats would be utilized so that the temporary flooring
best covers the entire space to be protected by the mats.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0025] The invention is more fully appreciated upon a review of the
appended drawing figures which illustrate the most preferred
embodiments of the invention and wherein:
[0026] FIG. 1 is a perspective view of a panel mat according to the
present invention showing the top surface of the first section;
[0027] FIG. 2 is a perspective view of the mat of FIG. 1 showing a
lower surface of the second section;
[0028] FIG. 3 is an exploded view of the mat of FIG. 1;
[0029] FIG. 4 is an exploded view of the mat of FIG. 2;
[0030] FIG. 5 is an illustration of five mats that are
interconnected with the light areas illustrating the top surfaces
of the connected mats and the dark areas illustrating the bottom
surfaces of the connected mats;
[0031] FIG. 6 is a cross-sectional detail of the snap-locking
engagement of the male members and depressions of adjacently
connected mats;
[0032] FIG. 7 is a cross-sectional detail of the mat to show a lip
portion that forms with an adjacently connected mat a channel for
removal of water;
[0033] FIG. 8 is a perspective view of another panel mat according
to the present invention, showing the top surface thereof;
[0034] FIG. 9 is a perspective view of the panel mat of FIG. 8
showing the bottom surface thereof;
[0035] FIG. 10 is an exploded view of the panel mat of FIG. 8
looking down from the top surface;
[0036] FIG. 11 is an exploded view of the panel mat of FIG. 9
looking up from the bottom surface;
[0037] FIGS. 12A to 12C are cross-sectional views of the panel mat
of FIG. 8 with FIG. 12A showing a cross section across the entire
panel mat, FIG. 12B illustrating a cross-section of the extension
tab and FIG. 12C illustrating a cross-sectional view of the tab
receiving opening;
[0038] FIGS. 13A and 13B illustrate the joining of three panel mats
according to FIG. 8, with FIG. 13A showing the joined panel mats
from a top view thereof and FIG. 13B showing the joined mats from a
bottom view thereof;
[0039] FIG. 14 is a perspective view of yet another panel mat
according to the present invention when viewed from the top surface
thereof;
[0040] FIG. 15 is a perspective view of the panel mat of FIG. 14
when viewed from the bottom surface thereof;
[0041] FIG. 16 is an exploded view of the panel mat of FIG. 14;
[0042] FIG. 17 is a detail view of the interlocking of four panel
mats according to FIG. 14;
[0043] FIG. 18 illustrates a mat that has a structured upper
surface in the form of a herringbone pattern;
[0044] FIG. 19 illustrates the bottom surface of a mat that has
linear channels provided therein;
[0045] FIG. 20 illustrates a mat having four lifting elements;
[0046] FIGS. 21A and 21B illustrate the mat of FIG. 20 with the
lifting elements in an operative position in FIG. 21A and in a
retracted position in FIG. 21B;
[0047] FIG. 22 illustrates a particular construction for the
lifting element shown in FIG. 20;
[0048] FIG. 23 illustrates the bottom surface of the mat of FIG.
20; and
[0049] FIGS. 24A, 24B and 24C illustrates an alternative
construction for a lifting element wherein FIG. 24A illustrates how
the lifting element is inserted into the mat, while FIG. 24B
illustrates the ring of the lifting element in an operative
position and FIG. 24C illustrates the ring pivoted for placement in
the retracted position in the mat.
DETAILED DESCRIPTION OF THE INVENTION
[0050] Certain terms that are used herein are defined hereinbelow
to assist in the understanding of the invention.
[0051] The terms "substantially" and "relatively" are used for
their ordinary meanings to indicate that the dimensions or
configurations are not precise or exact. A skilled artisan can
readily determine what tolerances are acceptable to provide a
surface that is considered to be flat based upon the size of the
panel mats and the type of service that the panel mats are expected
to provide. Typically, the terms "substantially" or "relatively"
will mean that a surface can vary by as much as an inch or two
although in the more preferred embodiments the variance is less
than 1 inch.
[0052] Additionally, all dimensions recited herein are approximate
and can vary by as much as .+-.10% to in some case .+-.25%. In some
situations, the term "about" is used to indicate this tolerance.
And when the term "about" is used before reciting a range, it is
understood that the term is applicable to each recited value in the
range. Often, the craftsmanship and engineering procedures that are
followed in construction of these mats minimize these tolerances as
much as possible or industrially practical.
[0053] The invention relates to a rectangular panel mat that is
preferably square and that is made of plastic or elastomeric
material. The panel mat can be made of first and second sections
(for two layer mats) or with an additional third section (for three
layer mats) which are part of an integral component that is molded
to have the desired configuration and features. Typically, the
first and second sections are molded together in one operation
while the third section is later joined to the mat formed from the
first and second sections. Alternatively, a two layer mat can be
made from a solid integral plastic or elastomeric component wherein
the tabular extensions, openings and slots or recesses are milled
or routered into the component top provide the configurations and
features. The third section can then be added to the formed mat.
Preferably, however, the first and second sections are separately
molded and then combined in the desired configurations disclosed
herein. To form the panel, the molded first and second sections may
be are joined together by welding, an adhesive, molding, bonding,
or by joining via an interlocking structure. Having each section
heated and joined together in a press is another and more preferred
joining option.
[0054] A typical panel mat has a 42'' square configuration as this
facilitates molding of the first and second sections and results in
a lightweight panel mat that can be easily installed manually. The
sections are typically molded to a thickness of between about
1/16'' to 1/5'' depending upon the plastic or elastomeric material
that is used to make the panel. The panels can range in size from
1'.times.1' to 16'.times.16'. They can be square of any size at or
it within those values and of any particular feet, inches or inch
fractions. Alternatively, the panels can be rectangular, e.g.,
1'.times.2', 2'.times.6', 3'.times.8', 4'.times.8', 4'.times.10',
6'.times.9', 6'.times.12', 8'.times.12', 8'.times.16'' and even
12'.times.16'. The 42 inch square panel would have a weight of
approximately 40 pounds when molded from upper and lower halves of
high density polyethylene each having a skin thickness of 0.2
inches. The preferred panels have sizes of 2.5'.times.2.5',
3'.times.3', 3.5'.times.3.5' or 4'.times.4' as these are relatively
easy to be moved because they would have a weight of about 100
pounds or less so that they can be lifted and installed by manual
labor rather than heavy equipment. The larger size panels are
heavier but the temporary flooring can be installed more quickly
given the greater area that these mats cover.
[0055] Also, rectangular mats can be used wherein the length
dimension is double the size of the width dimension. So for example
in the preferred embodiments, one side of the mat would have three
tabular extensions while the adjacent side would have six tabular
extensions. Thus, along the length of one mat, two additional
similarly configured mats would be joined thereto whereas the width
dimension would be joined to half of the length of an adjacent mat.
And if desired, combinations of square and rectangular mats can be
joined together to form any particular shape decking or temporary
roadway or walkway. As an example, a 42 inch square panel mat can
also be joined to a rectangular panel mat that is 42''.times.7'
long. And if desired, rectangular or square mats can be made. The
only limitation is the way that these mats are shipped with widths
up to about 8 feet being preferred so that the mats can be shipped
by conventional tractor trailers.
[0056] The larger size square or rectangular mats that weight more
than 100 pounds are provided with lifting elements as disclosed
herein. And while the lifting elements are very useful and possibly
necessary when provided on the larger, heavier mats, they also are
useful when applied to any size mats. For example, this would allow
multiple smaller mats to be lifted together by such elements to
expedite loading of the mats onto a truck or even for installation
or reclamation of such mats in connection with the forming or
breakdown of the temporary flooring.
[0057] As noted, the overall size (length, width) should be
maximized for loading the panel mats into standard ISO containers
and more importantly for concise packing into trucks, tractor
trailers or rail cars for shipping. Also the thickness of the panel
mats should be between about 1 and 3'' and typically between 1.5''
to 1.75'' thick. The mats are constructed to withstand repeated
traffic from shop forklifts carrying loads, semi-truck and trailer
travel, and stage point loads all while being rigid enough to
protect the surface from damage and prevent any rutting of the
subgrade. Point loads of between 300 and 500 psi are provided as
point loadings while spread loadings of 40,000 to 50,000 pounds per
square foot are provided. The highest loadings are achieved with
the three section constructions described herein and with the most
dense array of geometrical cells therein. Particularly preferred
materials for these panel mats are HDPE or Polypropylene. The panel
mat should not have any external fasteners as the tabs and
openings, slots or recesses are incorporated into the mat structure
itself to facilitate interlocking during installation.
[0058] When a third section is desired to seal off the cells, it
can be provided in the form of a plate or solid flat structure that
is bonded, adhered, welded or otherwise joined to the other
sections. It also can provide a relatively flat bottom surface for
the panel mat when desired, such as when the panel mats are to be
installed on a flat surface such as a floor.
[0059] The panel mats can be molded of many different materials,
including any conventional polymeric or copolymeric thermoplastic
materials, thermosetting materials, or even fiberboard materials
made of recycled plastic or polymeric materials from used carpets,
plastic packaging and the like. Mixtures or combined blends of
plastic materials may also be used. The panels may also be made of
elastomeric materials which can be thermosets (requiring
vulcanization) or thermoplastic.
[0060] A wide range of thermoplastic or polymeric materials can be
used for the sections of the panel mats of this invention. These
materials would be molded or cast to the desired size and thickness
of the mat. Useful materials include: [0061] Acrylonitrile
butadiene styrene (ABS) [0062] Acrylic (PMA) [0063] Celluloid
[0064] Cellulose acetate [0065] Cyclo olefin Copolymer (COC) [0066]
Ethylene-Vinyl Acetate (EVA) [0067] Ethylene vinyl alcohol (EVOH)
[0068] Fluoroplastics (PTFE, alongside with FEP, PFA, CTFE, ECTFE,
ETFE) [0069] lonomers [0070] Kydex, a trademarked acrylic/PVC alloy
[0071] Liquid Crystal Polymer (LCP) [0072] Polyacetal (POM or
Acetal) [0073] Polyacrylates (Acrylic) [0074] Polyacrylonitrile
(PAN or Acrylonitrile) [0075] Polyamide (PA or Nylon) [0076]
Polyamide-imide (PAI) [0077] Polyaryletherketone (PAEK or Ketone)
[0078] Polybutadiene (PBD) [0079] Polybutylene (PB) [0080]
Polybutylene terephthalate (PBT) [0081] Polycaprolactone (PCI)
[0082] Polychlorotrifluoroethylene (PCTFE) [0083] Polyethylene
terephthalate (PET) [0084] Polycyclohexylene dimethylene
terephthalate (PC (PC)T) [0085] Polycarbonate [0086]
Polyhydroxyalkanoates (PHAs) [0087] Polyketone (PK) [0088]
Polyethylene (PE) [0089] Polyetheretherketone (PEEK) [0090]
Polyetherketoneketone (PEKK) [0091] Polyetherimide (PEI) [0092]
Polyethersulfone (PES)--see Polysulfone [0093]
Polyethylenechlorinates (PEC) [0094] Polyimide (PI) [0095]
Polylactic acid (PLA) [0096] Polymethylpentene (PMP) [0097]
Polyphenylene oxide (PPO) [0098] Polyphenylene sulfide (PPS) [0099]
Polyphthalamide (PPA) [0100] Polypropylene (PP) [0101] Polystyrene
(PS) [0102] Polysulfone (PSU) [0103] Polytrimethylene terephthalate
(PTT) [0104] Polyurethane (PU) [0105] Polysulfone (PSU) [0106]
Polytrimethylene terephthalate (PTT) [0107] Polyvinyl chloride
(PVC) [0108] Polyvinylidene chloride (PVDC) [0109]
Styrene-acrylonitrile (SAN)
[0110] It is also possible to utilize fiberboard as the elongated
members or sheets that form the core structure. The fiberboard
material is made of recycled plastic or polymeric materials from
used carpets, plastic packaging, rice hulls and the like. They can
be provided in the desired sizes for use as the core structure of
the mats of this invention. They can be combined with other plastic
materials as is generally known. In addition to being
environmentally resistant due to their plastic content, these
fiberboard/recycled materials are environmentally friendly by
allowing recycling of used plastics or polymeric materials.
[0111] The top and bottom sections may also be made of an
elastomeric material. The elastomers are usually thermosets
(requiring vulcanization) but may also be thermoplastic. Typical
elastomers include:
[0112] Unsaturated rubbers that can be cured by sulfur
vulcanization--these are preferred from a strength and hardness
standpoint: [0113] Natural polyisoprene: cis-1,4-polyisoprene
natural rubber and trans-1,4 polyisoprene gutta-percha; [0114]
Synthetic polyisoprene; [0115] Polybutadiene; [0116] Chloroprene
rubber, i.e., polychloroprene; [0117] Butyl rubber (i.e., copolymer
of isobutylene and isoprene) including halogenated butyl rubbers
(chloro butyl rubber; bromo butyl rubber); [0118] Styrene-butadiene
Rubber (copolymer of styrene and butadiene); and [0119] Nitrile
rubber (copolymer of butadiene and acrylonitrile). [0120] Saturated
(i.e., non-vulcanizable) rubbers include: [0121] Ethylene propylene
rubber (EPM); [0122] Ethylene propylene diene rubber (EPDM); [0123]
Epichlorohydrin rubber; [0124] Polyacrylic rubber; [0125] Silicone
rubber; [0126] Fluorosilicone Rubber; [0127] Fluoroelastomers;
[0128] Perfluoroelastomers; [0129] Polyether block amides; and
[0130] Chlorosulfonated polyethylene.
[0131] The elastomeric, thermoplastic or thermosetting materials
disclosed herein can also be provided with conventional fillers to
increase weight and hardness. They also can be reinforced with
particulates, fibers such as glass, fabric or metal screening or
scrim to reduce elongation and provide greater rigidity.
[0132] Regarding the configuration of the panels, the sections are
separately molded with peripheral boundaries that are configured to
match each other. The first and second sections can be blow-molded
or compression molded to the desired sizes. Then, the sections are
joined together where the boundaries are in contact by welding,
adhesives, heating, or interlocking connections or combinations
thereof. It is desirable for the sections to be joined together to
form a waterproof structure so that any openings existing between
the sections do not fill up with mud, dirt or water during use.
Typically, the first and second sections are sealed by welding or
adhesives at a peripheral seam. To facilitate an adhesive or weld
the joint, the peripheral boundaries can be provided with a minimum
flange detailed to provide additional surface area for sealing. The
third section can then be joined to the other two to form a three
ply mat. As noted, the third section provides additional
compression and strength to the panel mat by holding the cells in
position where they cannot move laterally.
[0133] The first section can be configured with an appropriate top
surface that may be relatively flat, textured or structured to
facilitate movement over the panel mat. While a completely smooth
top surface may be used, it is preferred that the top surface at
least include some texture or channels that facilitate the drainage
of moisture and provide a more secure footing for movement across
the panels. The channels can be formed by texturing or spaced
raised islands or other structures that are provided in the top
surface. The top surface can also include raised or embossed
patterns or designs that indicate the supplier or owner of the
mats. When a flat or relatively flat surface is provided for the
top surface, grit or particles can be included to assist in
providing better traction when the surface becomes wet. The panels
are configured to be oriented with the top section being the
surface which is traversed by personal or equipment while the lower
portion of the second section faces the ground.
[0134] The bottom surface of the panel mats may also configured
with a flat, textured or structured surface. Preferably, the bottom
surface is textured, structured or is provided with openings so
that the panel mat can be securely placed on wet or muddy ground.
For the latter feature, the bottom surface can be provided with
closed holes that are of essentially the same configuration as the
islands of the top section and that are sufficient tall to extend
to the islands to provide further support to the upper surface of
the top section. If desired, the holes can be configured as cells
or cups that have the same configuration as the islands so that the
top surfaces of the holes or cups fit into the islands. This
provides reinforcement of the upper surface to movement or articles
that contact that surface, If desired, the holes and islands can be
joined together by welding, adhesives, bonding, heating or by
snap-locking.
[0135] The third section can be provided as a flat plate if desired
so that the bottom surface of the panel mat is relatively flat. Of
course, the third section can also be provided with cells or can be
in the form of a grating or other structure that has openings,
channels or indentations. As the second section provides some of
this the third section is typically used to provide a flat bottom
surface and to hold the cells of the second section in position
between the first and third sections. And in some embodiments, the
bottom surface can also include a textured surface or a raised or
embossed patterns or designs that indicate the supplier or owner of
the mats so that it appears the same as to top surface of the mat
or to provide better gripping or more secure placement on the
ground.
[0136] Generally, the ground is prepared to be relatively flat to
receive the bottom surfaces of the panel mats, but the panel mats
can also be placed on a previously prepared flat cement or asphalt
surface to provide temporary protection of such surfaces.
Typically, however, the panel mats are placed on earth, grass, or
similar terrain to provide better footing and support for personnel
or light equipment traffic. The textured or structure bottom
surface facilitate a more secure placement on gravel or wet or
muddy ground.
[0137] One advantageous structure for the upper surface of the
first section is one that includes raised circular or polygonal
islands, or combinations thereof, with the islands spaced and
arranged closely together near each other. This forms channels
between and around the islands that are typically between 0.25 and
1 inch wide. When polygonal islands are used, the spacing can be
somewhat uniform but it also can be random. The islands can be
oriented along a horizontal or vertical direction if desired. The
only restrictions would be that the islands not be too high (more
than 1 inch tall) or spaced too far apart (more than 2 inches) so
that a person's foot can get caught or twisted between the islands.
A preferred hexagonal structure is illustrated in the drawings, but
other structures that include squares, rectangles, triangles,
octagons, pentagons or other shapes including circles or ovals can
be used. A surface texture that mimics spaced boards or tire thread
designs are also suitable.
[0138] An advantageous structure for the lower surface of the
second section can be described as a honeycomb or open cell
structure. The term "honeycomb structure" refers to a structure
that has openings or open cells therein which extend to the bottom
surface of the bottom section. The shape of the cells can be
hexagonal, square, rectangular, or of another polygonal shape, or
they can even be round or oval provided that the top surfaces or
configurations of the cells match the configuration and arrangement
of the islands of the top section. Some or all of the cells have a
top surface which extend up to and into the islands through the
lower surface of the top section. As noted, the top surfaces of
these cells are joined to the lower surfaces of the islands by a
press fit, snap-locking, adhesives or spot welding. The flat tops
of the cells can also support a flat lower surface of the top
section. With this construction, the strength of the panel can be
further increased as each cell acts as a separate support for the
upper surface of the top section.
[0139] Typically, the honeycomb pattern of geometrical cells
includes those that have a top surface having a perimeter of 3 to
12 inches. This includes round top surfaces of about 1'' to about
4'' diameter and square or rectangular trapezoids having side of
about 1'' to about 4''. As noted, the tops of the cells can be open
or some or all of them can be closed. The same is true of the
bottoms of the cells, which again can be open or where some or all
of the cells terminate in closed flat surfaces. Similar perimeters
would be provided for other shapes (i.e., oval, pentagonal,
hexagonal, octagonal, etc.). For greater compressive strengths,
more dense (i.e., smaller size) cells may be provided. A skilled
artisan can design the cell configuration for any particular
compressive strength requirements based on the overall size of the
mat and number of sections that are to be included.
[0140] The sidewalls of the cells are also configured to impart
strength to the mat. These are typically provided at an angles with
regard to the top or bottom surfaces of the mat rather than being
perpendicular. Angles of between 45 and 90 degrees are preferred
with 60 to 89 degrees being optimal.
[0141] The cells can be spaced apart or can be placed with at least
part of their sidewalls in contact. The number of cells and their
spacing and arrangement can vary but a skilled artisan can easily
determine any optimum arrangements based on the anticipated loading
that will be applied to the mats. It is also possible to have some,
typically half, of the cells face upward and others, again
typically half, facing downward. This allows half of the cells to
include flat surfaces facing the first section and half of the
cells to have flat bottom surfaces facing the third section. The
flat surfaces can be placed within recesses in the top and/or
bottom plates or the can support a flat surface of the top and/or
bottom plates that face the cells. Of course, other arrangements
are possible including from 10% to all of the cells having flat top
surfaces, as well as from 10% to all of the cells having flat
bottom surfaces. The half and half arrangement provides better
support for the upper and lower surfaces of the mat when the first
and third sections are provided as plates.
[0142] The panel mats are carefully designed so that they can
interlock with adjacent, similarly sized and configured panel mats
to form a temporary surface or substrate upon which people or light
equipment can be placed thereon or moved across much like the a
building floor. This interlocking is achieved by a unique design of
tabular members and corresponding recesses. A first side of the
panel has spaced tabular members arranged along that side. These
tabular members can have a trapezoidal, rectangular, square, half
oval or half round shape. For example on a square 42 inch panel,
three tabular members would be provided, typically on 1 foot
centers. More or less tabular members can be included depending
upon the actual dimensions of the panel mat and the size of the
tabular members. One preferred arrangement disclosed herein
includes two tabular members on each side of a square panel mat and
more can be used on the longitudinal sides of the mat when it is
rectangular rather than square. For example, a 42'' by 84''
rectangular mat could 4 to 6 tabular members on the longitudinal
sides and 2 to 3 tabular members on the shorter sides. For larger
mats, as many as 8 to 12 tabular members per side can be used. The
tabular members can also be formed on either the top or bottom
section of the panel mat on a first side thereof, or with a portion
of each tabular member part provided on each section. Preferably
each section provides about 25 to 75% of the tabular member, with
typically about 50% formed on each section. When about half of the
tabular member is provided on each section, the halves can be
joined together the welding or adhesive used to provide the seal at
the periphery boundary of the panel mat.
[0143] The opposite side of the panel mats from the first tabular
members would be configured with corresponding openings configured
and dimensioned to receive the tabular members. The opening can be
a full opening into which the tabular member extends, or it can be
a slot formed between the top and bottom sections. In an
alternative and preferred embodiment, the openings are made in the
lower half of the panel while the upper half of the panel provides
a continuous surface above the opening. This arrangement
facilitates cleanout of the openings if mud or other debris is
caught in them. Neither the first tabular members nor the openings
include any means for joining or connecting the first tabular
members to the openings in any temporary or permanent way. This
allows the tabular members to simply slide into and out of the
openings for a smooth and fast installation or removal of the panel
mats.
[0144] An arrangement of additional or second tabular members is
provided on a second side of the panel mat that is adjacent to the
first side that includes the first tabular members. These second
tabular members include a central depression on a top surface
thereof. The depression may be a cell that may be cylindrical,
oval, rectangular or square with rounded edge openings. These
additional tabular members also preferably include a bottom surface
that is angled so that the forwardmost end of the tabular member is
located at a higher position than the rearwardmost end. This
configuration facilitates interlocking and disengagement of the
tabular members.
[0145] The opposite side of the panel from the additional tabular
members includes slots or recesses that are configured and
dimensioned to receive the additional tabular members therein. An
opening is provided on the lower surface of the slot or recess to
allow for drainage of water, dirt, rocks or other debris that may
enter therein. The opening is located sufficiently inwardly from
the end of the slot so that a bridge or rail structure is provided
at the entry for initial contact with the lower surface of the
additional tabular members and for providing support to the tabular
member when it is present in the slot or recess. The upper surface
of the slot or recess includes a male member for interlocking with
the depression of the additional tabular member of an adjacent
panel. These male members are configured and dimensioned to only
partially engage the apertures of the additional tabular members to
receive only part of the male members to provide a snap-locking
connection between the slots or recesses with the additional
tabular members of an adjacent panel when installing the panels on
a properly graded or flat surface. The depression is configured
with a rounded opening to facilitate movement of the male member
into and out of the depression to facilitate installation and
subsequent withdrawal of the tabular member from the slot or
recess. The angled bottom portion of the additional tabular members
assists in the removal of the male member from the depression as it
allows the forward ends of the tabular member to move away from the
male members when the opposite end of the panel mat is lifted for
detachment of the interlocked male members and apertures during
removal of the panel mats.
[0146] The tabular members can instead include a protruding bump on
an upper surface while the openings, slots or recesses include an
upper surface that includes a depression for facilitating a
snap-locking engagement of the bumps and depressions. Of course, a
skilled artisan would readily recognize that the reverse
arrangement is also acceptable, namely that the tabular members can
include the recesses while the upper surfaces of the openings slots
or recesses includes the bumps or other male member protrusions.
Combinations can also be made with bumps and/or depressions
provided on the tabular members and the corresponding engageable
depressions and/or bumps on the openings, slots or recesses.
[0147] The openings or recesses are configured to be shorter or
smaller than the width of the mat. This facilitates the insertion
of the tabular members into the recesses or openings. And the bumps
and other interlocking structures can be provided on only one of
the sides or on both sides as desired. Usually, providing the
interlocking structure on the tabular members on one side of the
mat is sufficient to achieve good interlocking when the temporary
flooring is installed. Alternatively, each opening or recess should
also have a portion of the cut out so that there is enough room for
the tabular member end to slide in easily without binding.
Preferably, this allows the tabular members to be inserted at a 45
degree angle.
[0148] For even greater connection of the mats, each side of the
mat can include multiple tabular members, from 2 to as many as 8 to
12 tabular members being possible, with openings for receiving the
provided number of such members arranged between the tabular
members. The larger mats would include at least 8 tabular members
on two sides. When a rectangular panel is to be made, the longer
side would be provided with additional tabs and matching openings
or slots or recesses as applicable. As noted as many as 8 to 12
tabular members can be included. This can be done with either the
smooth tabular members or the additional tabular members that
include the bumps or depressions.
[0149] These panels are designed for quick and easy installation by
one or two workers. The snap-locking feature of the additional
tabular members avoids the use of bolting, adding pins or
complicated joining configuration which take time and effort
resulting in much higher labor costs to install and remove the
panels. And the openings or recesses are designed to easily receive
the bumps and depressions of the tabular members to allow
snap-locking without requiring a large amount of force to lock them
together during installation or to disengage them when removing the
installation.
[0150] The configuration of these mats as well as the various sizes
that can be used, facilitates a relatively quick and efficient
installation of a temporary flooring system. The smaller mats are
easily lifted and installed by one or more workers without the use
of any connecting hardware. The mats are designed such that the
tabular members can easily slide into the openings of an adjacent
mat when the additional mat to be installed is held at
approximately a 45 degree angle. This enables the tabular members
to be smoothly and easily received in the slots or recesses for a
quick snap locking of the mats.
[0151] The configuration of the openings are designed and made
either with cutouts or with a shorter or smaller dimension that
does not extend to the full width of the mat such that the tabular
members can be easily placed therein without binding. In addition
when larger panel mats are in use, the lifting elements allows
those mats to be simply and easily transported into position. In
fact, the flooring installation proceeds in a manner such that
after the initial panels are in place, the equipment that is
lifting the mats can then move over the previously installed mats
such that the field or gymnasium surface is not damaged by the
insulation equipment.
[0152] Turning now to the drawings, FIG. 1 shows a square panel mat
100 that has three tabular members or tabs 105 on the first side
110 thereof, and three additional tabular members or tabs 115 on
the second side 120 thereof. The additional tabs 115 have a
depression 125 in the form of an oval opening that has rounded
edges and that extends into the tab, the function of which will be
described with respect to FIG. 6. The upper surface of panel mat
100 also includes a plurality of raised hexagonal islands 160 which
are spaced to provide channels therebetween which allow water to
drain from the mat.
[0153] The panel mat 100 also has three openings 130 located on
side 135 and three slots or slot-like recesses 140 located on side
145. Slots 140 also include a male member 150 which extends into
the slot, the function of which is also explained with regard to
the description of FIG. 5.
[0154] FIG. 2 illustrates the bottom surface of panel mat 100
wherein the same element numbers are used to describe the same
components or features shown in FIG. 1. Additionally, the lower
surface of panel mat 100 includes a plurality of hexagonal shaped
holes 155.
[0155] FIG. 3 more clearly shows that the panel mat 100 of FIG. 1
is initially molded in two sections, a top section 200 and a bottom
section 300. The top section 200 includes the upper portions 205 of
tabs 105 and upper portions 215 of additional tabs 115. The upper
portions 205, 215 of the tabs are integrally formed with the top
section 200. The top section 200 also has a peripheral boundary 225
which is located at the end of the downward facing edges 220 that
are provided as well as below the sides of tab portions 205, 215.
The bottom section 300 includes the lower portions 305 of the first
tabs 105 as well as lower portions 315 of the additional tabs 115
with both portions integrally formed with the bottom section 300.
Bottom section 300 also has upwardly extending edges 320 the ends
of which form peripheral boundary 325. Peripheral boundary 325 also
includes the ends of the tab portions 305, 315.
[0156] When the top and bottom sections of the mat are placed upon
each other, the peripheral boundaries 225, 325 come into contact
with each other and can be joined together by welding or an
adhesive. This allows the spaces between the sections to be sealed
from the entry of water, dirt or debris.
[0157] FIG. 3 also illustrates the holes 155 on the bottom surface
of the bottom section to show how they are molded into the panel
mat. These holes, which in this figure appear as hexagonal cups
355, have top surfaces 360 that fit beneath and contact the lower
surfaces of islands 160 of the top section 200. Bottom section 300
also shows the bridge or rail structure 370 and adjacent openings
375 that allow dirt or debris that enters into slots 140 to exit
rather than to remain in the panel mat.
[0158] FIG. 4 shows the bottom surface of the bottom section 300 of
the panel mat 100 with greater detail of the internal surface of
the top section 200. The same numerals used in FIG. 3 are used in
FIG. 4 to designate the same components. The internal surface of
the top section shows the back sides 260 of the raised islands.
Also shown is the bottom of depression 125 which as shown is an
oval cell or cup, and male member 150. These features are more
clearly shown in FIG. 6.
[0159] FIG. 5 illustrates a number of connected mats wherein the
lighter colors show the upper surfaces of the panel mats and the
darker colors illustrate the bottom portions of the panel mats. The
first tabs 105 of one panel mat are received in the openings 130 of
an adjacent panel mat. Similarly, the additional tabs 115 are
received in slots 140 of an adjacent panel mat. The details of
these interlocking connections are illustrated in FIGS. 6 and
7.
[0160] FIG. 6 shows that the additional tab 115 is formed by
joining upper section 215 to lower section 315 at the point where
the peripheral boundaries 225, 325 meet. Depression 125 is shown in
position after having received male member 150 to provide
snap-locking of one panel mat to another. FIG. 6 also shows the
angled bottom portion 380 of additional tab 115 which is provided
to disengage the interlocking of male member 15 in depression 125.
This is achieved by lifting the opposite end of the panel mat
upward so that the sloped bottom portion 380 moves downward in
order to minimize engagement of male member 150 with depression
125. This along with the curved upper portions of the depression
125 allow the male member to slip out of the depression to
disengage the snap-lock connection.
[0161] FIG. 7 illustrates tab 105 and it's insertion into opening
130. Tabular member 105 is also made by joining upper portion 205
to lower portion 305 at the peripheral boundaries 225, 325. As
there is no interlocking of tab 105 into opening 130, the alignment
and interconnection of the panel mats are achieved by configuring
opening 130 to be of the same shape as but just slightly greater
size than tab 105 so that simply sliding the tab 105 into slot 130
provides a tight fit.
[0162] FIG. 6 also illustrates the lip portion 180 that is provided
on the top section 200 along one edge thereof. This contacts the
end portion of the adjacent panel mat to provide a longitudinal
channel 185 that allows water to drain from between the connected
panel mats. Similarly in FIG. 7, lip portion 190 that is provided
on the top section 200 along one edge thereof to engage the end of
an adjacent panel mat to form a similar longitudinal channel 195
that performs the same function of allowing water to drain from
between the connected panel mats.
[0163] FIGS. 3, 6 and 7 also illustrate the angled sidewalls of the
cells that provide additional strength to support the upper surface
of the first section as well as to provide compression resistance
to the mat. While it is possible to use 90 degree cell wall angles,
these are harder to mold into the second section and are not
preferred for that reason. Instead, an angled sidewall, one that is
fully or at least partially angled with respect to the upper and
lower mat surfaces, provides greater rebound to the mat after the
applied forces are removed. It also allows the cells to slightly
compress but as each cell is adjacent another cell, the expansion
is limited by the expansion of the adjacent cells. This provides
good compression resistance to the mat. And a noted herein, the use
of the bottom third section joined to the second section provides
additional support for the cells and even more compression strength
to the mat.
For the second section, a number of different structures can be
used to provide support for the upper surface and the first
section. In one embodiment, a grid or grating structure can be used
where the cells are defined by the openings of the structure, with
the cell walls forming polygons or being round or oval in shape
with the walls preferably oriented perpendicular to the first
section flat bottom surface. Alternatively, the walls can be
oriented at an angle to the first section flat bottom surface, with
that angle measuring between 45 and 90 degrees and preferably
between 60 and 70.degree. with respect to the first section flat
bottom surface. The perpendicular orientation provides the greatest
compressive strength to the mat while the angled walls provide
other benefits with regard to greater cell openings on the bottom
sides of the cells and easier manufacture especially to facilitate
removal from the mold that forms the cells. It is also contemplated
that some or all of the cells could be closed or have flat top
surfaces that would contact and support the first section flat
bottom surface that is positioned on top of the cells.
[0164] The cell structure also provides a plurality of open bottom
ends of the cells that face away from the first section. Having
these cells remain open facilitates installation of the mats on
grass surfaces wherein the entire grass surface is not contacted by
the mat but only by the perimeters of the open cells. This
minimizes damage to the grass during use of the mats. Additionally,
the mats can be made of transparent or translucent plastic material
so that sunlight can pass through the mats and contact the grass.
This facilitates grass growth and health to again reduce damage
from coverage by the mats.
[0165] In some cases, it is desirable for some or all of the
bottoms of the cells to have a closed bottom surface. This is
desired know when the third section plate is to be included in the
mat structure as the closed bottom surfaces of the cells supports
the third section plate. A good compromise of open and close cells
would be 50:50 for both the top and bottom portions of the second
section.
[0166] It is also desirable to provide a draft angle for the
sidewalls of the cells as noted above. In this regard, the top
portions of the cells would be smaller than the openings on the
bottom of the cells. This structure which is referred to above as
angled sidewalls prevents bending and twisting and of the mat when
subjected to load bearing forces. And while an angle of 90.degree.
is preferred from a strength standpoint, when the second section is
molded, that angle can provide difficulty in removing the second
section from the mold. Thus, a slightly lesser angle should be used
to provide a draft angle that assists in removal of the molded
second section from the mold. This can be in the range of
89.degree. to 85.degree.. As noted herein, other angles of as low
as 45.degree. can be used if desired for any particular mat
configuration or temporary surface installation.
[0167] FIGS. 8-11 illustrate another panel mat 400 in accordance
with the present invention this panel mat includes a first side
that has three tabular extensions 405 each with a round protruding
bump or disk 410. The second side of the mat is similarly
configured with tab extensions 415 and round protruding discs 420
as shown. The mat has a flat upper surface 425 although it is
possible to configure that surface with channels or other
irregularities for water removal. For use indoors or in areas that
are shielded from the elements (e.g., under a tent), a flat top
surface is acceptable.
[0168] The opposite sides of the panel mat from tabular members are
configured to receive such members. A third side of the mat
includes three openings 430 each of which includes a central
depression 435 which is configured, positioned and dimensioned to
receive the circular bumps or disks 410 from a similarly configured
panel mat to provide a snap-locking connection therebetween. To
facilitate a smooth and easy connection, the depressions have a
slightly greater circumference then the circular bumps or disks so
that they can be received easily therein. In a preferred
embodiment, the sidewall of the bumps is slightly angled so that it
creates a tighter connection as it enters into the depression, but
an extremely tight or nearly permanent connection is not desired,
as the mats are generally used as a temporary flooring which needs
to be disengaged and removed after a certain period of use. And
preferably, the top surface of the bump or disc contacts the base
of the depression to provide further support of that portion of the
panel mat.
[0169] The fourth side of the panel mat includes similarly
configured openings 440 with an additional feature of a floor or
bridge element 445 which helps secure the tabular members 415 in
the recess with the circular disk 420 in snap-locking engagement
with the depression 455 that is present in the upper surface of the
slot or recess 430. This depression 455 is best shown in FIG.
10.
[0170] FIGS. 10 and 11 also illustrate the three individual
sections 460, 470, 480 which are joined together to form the panel
mat 400. First or top section 460 includes part of the tabular
members 410, 415 and the flat surface 425 that forms the top
surface of the panel mat. Section 460 is relatively flat although
it does include circumferential lip that provides a general recess
beneath the top surface to receive the top surfaces of the
geometric structures 475 that are present in the second section
470. These geometric structures 475 are generally cylindrical or
trapezoidal in shape and have flat heads that contact and bond to
the lower surface of section 460.
[0171] Second section 470 include also includes tabular members 485
and circular protruding discs 490 which are configured to be
received within the back side of disks 420 of the first section
460, the back side acting as a depression, so that the tabular
members can snap-lock the tabular portions 415,485 together. A
similar structure is provided for the tabular members 405,495 so
that they can also snap-lock together. And the disks of the tabular
members 485, 495 of the second section are designed so that they
fit within the depressions of the tabular members 405, 415 of the
top section 460. The sidewalls of these disks or bumps 490 can be
angled to provide an easy entry into the depression followed by a
more secure joint. This is of importance because the second section
is adhered to, welded to, or otherwise bonded to the first section
to provide an integral panel mat component of the two sections that
can be used as is or that can be provided with the third section
480. While a press-fit is acceptable, the disc and recess are
configured so that the top surface of the disc is seated in the
bottom surface of the recess to provide further support to the
tabular member.
[0172] Yet another way to join sections 460, 470 together would be
to heat the sections and press them together in a mold so that the
top surfaces of the geometrical elements 475 bond to the bottom
surface of section 460. Similarly, the top surfaces of bumps 490 of
tabular members 485 can bond to the recesses behind bumps 420 of
tabular members 415. The same is true for the joining of tabular
members 495 and 405. The resulting structure is an integrally
joined together and cannot be easily separated.
[0173] A most preferred joining technique for the first and second
sections is to prepare them in a twin-sheeting operation. This
operation, which is also known as twin sheet forming, combines the
process disciplines of compression molding, blow molding, and
vacuum forming to mold, laminate, and trim multiple layers of
materials (substrates with cover stock) in a one step process. The
twin sheet molding process forms two sheets of plastic
simultaneously through the use of a separate mold on the top platen
and a separate mold on the bottom platen. Once the plastic sheets
have been vacuum formed, they remain in their respective molds.
While both sheets still remain at their forming temperature, the
two molds are brought together under high pressures and the two
sheets are bonded together. The result is a single product with
hollow areas requiring no secondary bonding operations.
[0174] To provide a flat surface 450 for the mat, third section 480
is provided as a separate flat plate. This plate 450 may be bonded
to the lower side of the second section 470 by welding, adhesives
or by applying heat and pressure to the components in a mold. Third
section 480 includes openings 430 and bridge members 445 which
assist in allowing the tabular members to snap-lock with the
recesses 455 that are provided in the lower surface of the second
section 470.
[0175] FIGS. 12A-12C provide details of how the three sections are
joined together. The lower surface of the top section 460 is bonded
to the top surfaces of the geometric elements 475 of layer 470.
Between the geometric elements, a lower portion is provided that
provides another flat surface that is adhered or bound to the
inside surface of lower section 480. This is best shown in FIGS.
12B and 12C. FIG. 12B also shows the construction of the tabular
portion to illustrate how tabular portion 485 and disk 490 fit into
the back side of protruding disc 420 of tabular member 415. Again,
the top surface of bump or disk 490 is bonded to the lower surface
of the recess provided on the opposite side of bump 420. FIGS. 12B
and 12C also illustrate the use of partially angled sidewalls for
the cells of the second section. Preferably, at least 1/3 to 1/2 of
the cell height is provided as an angled portion wherein the angle
is between 45 and 75 degrees with respect to either the top or
bottom surfaces of the mat.
[0176] FIGS. 13A and B illustrate how the panel mats can be joined
together with FIG. 13A a showing a top view and FIG. 13B showing a
bottom view. It is preferred that the panel mats be joined in a
staggered configuration so that all of the joints do not align in
the temporary floor that is constructed. Also, FIGS. 13A and 13B
show two square panels bonded together before a third panel is
interlocked thereto in a staggered configuration. Another
embodiment of the invention relates to the use of a rectangular
panel and the two panels that are joined together in a linear way
as shown in FIGS. 13A and 13B could instead be configured as a
single rectangular panel mat. These larger rectangular panel mats
would be use for larger installations as the larger rectangular
size would facilitate a faster installation. The construction would
be the same as disclosed herein for the square panel mats that are
shown.
[0177] FIGS. 14-16 illustrate yet another panel mat 500 according
to the present invention. This panel mat 500 has two tabular
extensions on each side, one 505 in a relatively higher position
and the other 510 in a relatively lower position. These dual
tabular extensions are provided uniformly on each side of the panel
mat 500.
[0178] The lower tabular extensions 510 have on their upper surface
protruding discs or bumps 515 while the higher tabular extensions
505 have on their lower surfaces, depressions 520 which are
configured dimensioned and arranged to receive therein the bumps
515 of the lower tabular extensions 510. The upper surface of the
mat 525 as well as the lower surface of the mat 530 are shown as
being relatively flat, but as noted herein, a textured or
structured surface can also be provided when these mats are to be
used outdoors where they will experience rain, snow or other forms
of moisture.
[0179] FIG. 16 illustrates the three sections of panel mat 500,
namely upper section 540 middle section 550 and lower section 560.
As in the embodiment of FIGS. 8-11, the middle section 550 is
configured with the plurality of geometric elements, shown in FIG.
16 as flat-top trapezoidal elements 555 which are designed so that
their top surfaces contact the bottom surface of top section 540.
Also, the middle section 550 includes supporting structures for the
tabular extensions. As in the other embodiments, the top 540 and
middle 550 sections are joined together securely by molding,
welding, adhesives or by the application of heat and pressure while
in a press in order to securely attach the sections together.
Thereafter, the lower or third section 560 can be bonded to the
bottom of the second section to seal off all of the geometric
elements and form a flat bottom surface for the panel mat 500.
[0180] FIG. 17 illustrates how the panel mats can be joined
together with the relative positions of tabular members 505, 510,
protruding bumps 520, and mating depressions. As shown, the mat is
slightly skewed during installation so that the upper tabular
member 505 is slightly above tabular member 510 while the other
tabular member 510 is placed below tabular member 505 of an
adjacent mat. These tabular members slide easily together and
provide snap-locking of the mats together. Also the tabular members
are configured so that the joining line of the mats are not
straight thus providing greater stability of the installed
temporary flooring.
[0181] As noted, although not necessarily preferred for certain
embodiments, the panel mats can be formed of a single piece of
plastic or elastomeric material that is cut, drilled, milled or
routered to the desired shape and configuration. For example, a
solid sheet or molded plastic or rubber can be configured with the
taps, slots, openings, and surface features described herein. While
this is more expensive, the costs for setting up the machining
equipment would be amortized across the large number of mats that
would be produced with these features. This can be used to form the
first and second sections of the mat while when a flat or closed
bottom surface is desired, this would be achieved by the addition
of a third section of a flat plate.
[0182] And as noted, the channels that are linear or random lines
or grooves on the top and bottom surfaces of the panel mat allow
water to drain from the top surface while also allowing the bottom
surface of the mat to be more securely placed on wet or muddy
ground. And the bottom surface may include openings as shown herein
for the second to partially receive gravel or other prepared ground
surfaces to again more securely anchor the panel mat in place. It
also can be flat by the addition of a third section.
[0183] FIGS. 18 and 19 illustrate mats that have alternative
structured surfaces. FIG. 18 illustrates a mat 600 that includes an
upper surface in the first section 810 with a herringbone pattern
of raised elongated bumps 625. These bumps are molded into the
upper surface of the top section 610 of the mat in order to provide
resistance to slipping when operators or equipment move across the
mat. The herringbone pattern and elongated bumps 625 provide
sufficient open space between them to allow water to drain from the
mat in particularly when a worker steps on the mat or a tire or
other item moves across the mat when the mat is wet.
[0184] Alternatively, other designs can be used to provide a
structured surface on the mat. FIG. 19 illustrates a mat 700 that
has on the bottom of its third section 710 a plurality of linear
channels 725 which are molded into the bottom surface of that
section. These channels 725 assist in allowing moisture to drain
from the mat when the mat is placed on wet or muddy ground. It also
provides a more secure footing for the mat on such ground.
[0185] And while the panel mats of the present invention are shown
with tabs on one side and receiving openings or recesses on an
opposite side, it is also possible to include alternating tabs and
openings or recesses on any particular side of the mat. FIG. 20
illustrates a rectangular mat 800 that has six tabular members on
the shorter side and 810 members on the longer side. The opposite
sides to those would have six or eight openings, respectively, as
described hereinabove. Mat 800 also has multiple tabular members on
two sides and multiple holes on the other two sides. It is also
possible to include such multiple tabs and openings on each side of
the mat if desired. In such a configuration, the mats cannot be
joined with each mat in an end to end or side to side alignment
with an adjacent mat. Instead, these mats would be staggered so
that the tabular members can be received in the openings of an
adjacent mat. This results in a staggered joining of adjacent mats
which is advantageous because the final joined flooring structure
would not have aligned mats that would provide linear extended
joints across the entire flooring. Such an arrangement is preferred
because the mats would tend to remain connected and would resist
disengagement compared to mats that are aligned with complete
linear joints across the entire flooring installation.
[0186] When tabs are provided on two sides of the mat and openings
on the opposite two sides, it is preferred, however, that tabs and
openings or recesses be provided on opposite sides of the mat as
this facilitates a more rapid installation. For certain
installations, however, especially when larger size panel mats are
used, the provision of tabs and recesses on a particular side of
the mat assist in aligning multiple panel mats for installation.
This is of greater interest when rectangular rather than square
panel mats are used.
[0187] The mats can also be joined to form a temporary flooring
installation that is discontinuous, i.e., one that leaves certain
openings between joined mats. This allows the mats to be placed
around trees, light towers or other obstacles that exist in the
area that is to be provided with a temporary flooring of joined
mats. In particular, it is relatively easy to leave openings such
as by simply omitting one or more mats to provide open space in the
floor structure. This can serve a number of purposes, such as
allowing the floor structure to be installed around a column, pole,
post or other upstanding structure, as well as to leave open space
for a light tower, camera tower, video screen support or speaker
support tower. Furthermore, in the event that a mat is damaged
after installation, it can be unlocked, disconnected and removed
for replacement by another similarly sized and configured mat
without having to remove all further mats that are connected
together in the installation.
[0188] The third section preferably is used to provide a flat
bottom surface for the panel mat. It is possible for the third
section to be configures so that it also extends beneath the
tabular members to further reinforce those members and help them
resist damage during installation when the tabular members are
inserted into the openings, slots or recesses, as well as to
protect against damage from impact if the panel mats were to be
dropped in a way where the tabular members would engage the ground
first and bear the force of the weight of the mat. This is
typically used on flat or graded surfaces, such as those provide by
cement, asphalt or clay.
[0189] Of course, as noted herein, when the upper surface of the
first section is structured, the bottom surface of the third
section can be similarly structured in a similar manner or with a
different type of structure. FIGS. 18 and 19 illustrate a preferred
combination of different structures wherein FIG. 18 shows a
herringbone pattern on the top surface of the first section while
FIG. 19 illustrates linear channels provided on the bottom surface
of the third section.
[0190] FIG. 20 also illustrates lifting elements 825 four of which
are provided on rectangular mat 800, which would typically have a
larger size of about 8'.times.16'. The lifting elements 825 are
shown with a lifting ring 830 which is standing vertically in an
operative position to be engaged by lifting equipment.
[0191] FIGS. 21A and 21B further illustrate this feature. In FIG.
21A, the lifting element is shown with ring 830 in the operative
position. Also shown is recess 835 which is configured to have the
same shape and depth as ring 830. FIG. 21B illustrates the ring 830
pivoted downwardly to fit within recess 835 so that the upper
surface of the mat is generally planar. This would avoid workers
tripping over the lifting element if it were not retracted into the
surface of the mat.
[0192] FIG. 22 further illustrates lifting element 825. Also shown
is recess 835 which receives lifting ring 830 when pivoted downward
into a retracted position so that the surface of the mat is
relatively flat. Lifting element 825 includes lifting ring 830
which is mounted on a base member 840 that has a central aperture
845. On the opposite side of mat 800, lifting element includes a
base plate 850 with an upstanding post 855 that has two legs 860A
and 860B each of which includes an aperture 865A and 865B. The base
fits into an elongated opening on the lower surface of the third
section 820 so that it is seated therein. Post 855 extends through
the mat so that it can align with base member 840 of lifting ring
830. The base member 840 is joined to the legs of the post by a
bolt member 875 that passes through apertures 845, 865A and 865B.
The bolt member is secured in position either by machine threads
which are provided in the apertures or by the use of a nut that
engages the opposite end of the bolting member 875.
[0193] FIG. 23 illustrates base plate 850 in position in the
surface of third section 820. While it is not critical that the
plate be seated in the surface of section 820, by doing so this
provides a smooth flat base for the mat 800.
[0194] FIGS. 24A, 24B, and 24C illustrate a variation of lifting
element 825. In these figures, lifting element 880 includes a
similar construction with lifting element 885 and with a similar
base member and post with leg extensions, but the base plate 890 is
configured differently. As shown, base plate 890 is circular and
includes two cut out portions 895. The base plate and cut out
portions are received in recess 837 that includes protrusions 838.
The protrusions engage the cut out portions of the base plate so
that it can be secured in the recess without rotational movement so
that the lifting element can be secured to the mat 800.
[0195] FIG. 24B illustrates that this lifting ring 885 maybe
positioned to sit in a slot 839 so that the ring can be held in the
operative position. After the mat 800 has been lifted or installed,
ring 885 can be rotated so that it can retreat back into opening
835 as in the preceding embodiment to provide a relatively flat
working surface on the mat.
[0196] And while these lifting elements 825, 880 are preferred for
use with the panel mats of the invention, a number of other designs
for such lifting elements can be used. Instead of the circular
lifting ring, a D- or U-shaped member can be used with the
remaining structure and recesses adjusted accordingly. So long as
the lifting element includes an engagement opening that is securely
attached to the mat, skilled artisans can configure many different
particular arrangements that would provide the necessary
performance.
[0197] The plastic and elastomeric materials disclosed herein
generally have sufficient strength for many applications, but their
strength and rigidity can be enhanced by reinforcing the material
with appropriate fillers or other materials, such a glass fibers,
other particular matter as is generally known in the art. The
additional placement of a metal wire, bar, rod or plate into the
mold that is used to prepare the sections or in between the
sections before they are sealed together can provide further
strengthening of the panel mats.
[0198] In some embodiments, the panel mats can be made translucent.
When these panel mats are to be used outdoors and the mat materials
are not sufficiently resistant to withstand long term exposure to
sunlight, appropriate additives to improve the UV resistance of the
material can be included.
[0199] The panel mats can be provided in different sizes, but
generally, square mats or rectangular mats having longitudinal
sides that are twice as long as the mat width are preferred. The
thickness of the mat can vary depending upon the intended use of
the mat. As noted herein, the thickness also determines the size of
the side ramp angled portion. Also, the thickness is determined
based on the thickness of each of the first, second and third
sections. These can be varied as desired for the intended
application, with thicker first and third sections and
perpendicular cell walls in the second section being used for
heavier load bearing installations.
[0200] The panel mats can be made with different materials and
reinforcements for different applications. As the outer surfaces of
the mats may be very similar in appearance, it is not readily
observable as to which panel mat has a particular construction. For
this reason, another aspect of the invention relates to the
providing of each mat with identification means that indicates the
material, reinforcement and construction of the panel mat. Thus,
when a number of different panel mats are maintained in an
inventory, the identification means enables operators to readily
determine which mats have the particular materials and properties
needed for a particular end use, so that the correct mats can be
selected and provided to a jobsite for use by the customer. This
would be necessary whether the mats are being purchased by the
customer or whether the mats are being leased for use.
[0201] There are a number of ways to identify the different
materials and properties of a mat depending upon the specific type
of identification means that are applied to the mat. The preferred
types of identification means include an external color code, a
radio frequency identification (RFID) tag, or an alphanumeric
indicator applied to an outer surface of the mat or that is
provided upon a plate that is applied to an outer surface of the
mat. The simplest identification means to use is an external color
code that is placed upon the mat, preferably in an area that does
not receive much abrasion or wear. Different colors or strips or
color combinations can be used to identify different materials. And
it is highly useful to apply the color code to the same relative
positions on each mat for easy identification. For example, placing
the external color code along a longitudinal side of each mat
allows the color coding to be visible when the mats are stacked
upon each other. This simple visual confirmation can be used to
make sure that the proper mats are selected: even when the mats are
just stacked in the work yard, one can see which ones have the
correct color code for the desired core construction.
[0202] Another use of color can be to identify certain panel mats
that are to be used only by a particular customer. This would
assist in making sure that the mats are properly collected and
delivered. This color can be an additional color beyond that which
is used to identify the mat core, or the mats can have a single
unique color or color pattern (e.g., stripes, dots etc.) that
identifies both the customer and the mat core. And further, the
color can be provided in a particular location or area to confirm
who the customer is to assist in quality control regarding the
correct shipping and delivery of the mats.
[0203] A simpler type of identification means is one that comprises
an external alphanumeric indicator that is applied to an outer
surface of the mat or that is provided upon a plate that is applied
to an outer surface of the mat. These can be carved, burnished or
stamped into or onto the mat again is a location that is not
expected to experience severe abrasion or wear. This can also be
used to identify a particular customer.
[0204] For installations over a grass field or yard, the mat can be
made to be transparent or translucent so that sunlight is able to
pass through the mat to help condition the grass. Additionally, no
third section is generally provided for such applications as to
open bottoms of the cells provide a smaller "footprint" on the
grass to minimize compression of the entire grass surface as would
occur if a mat having a bottom plate or sheet would be used. These
and the other panel mats disclosed herein are useful to provide
temporary flooring for concerts, sporting events, commencement and
graduation events, and the like that require a smaller footprint
than a full football or baseball field.
[0205] And as noted herein, in addition to the mat identification
means, each mat can further be provided with a surface color that
indicates a potential use or non-use of the mat. This can assist in
allowing personnel to properly operate on the mat and to promote
safety. These colors can include, for example, red to indicate that
portions of the mat need to be kept free of equipment, yellow for
indicating that caution is needed, green to indicate portions of
the mat that are designed to accommodate travel or movement by
trucks or heavy equipment over the mat.
[0206] Of course other colors can be used in any of the foregoing
embodiments according to a particular code or correspondence of
each color to a specific use or prohibited use. These colors can be
tailored to the mat user's particular requirements so that work
operations upon or around the mats can be optimized for safety,
efficiency and expediency. Coloring can also be used to define
certain areas of the worksite or to help the mats blend into
surrounding areas, so that the jobsite can look as clean and
undisturbed as possible. For these reasons the use of conventional
paints and other surface coatings enhance the usefulness of the
mats for any particular application. These paints or coatings would
need to be compatible to bond with the materials of the mat. If
necessary, appropriate primers or other chemicals can be used to
assure strong bonding of the paints or coatings to the mats.
[0207] And in another embodiment, the upper surface of the mat may
be provided with a portion of a word or design, such as the name,
nickname or abbreviation, mascot or emblem of a school or
university. Typically, the desired word or design is incorporated
into the material that forms the top section of the mat. This can
be done in any one of a number of ways that are known to skilled
artisans in the plastic or elastomeric molding field. Thus, after
the mats are installed, the word or design can be visible on the
temporary flooring. For example, installation on a football field
can include the school name or emblem on the temporary flooring in
the same location as it would be on the field, so that person
observing the installation from the stands can view the name or
emblem. This is particularly useful for graduations or other events
requiring a large temporary flooring area for chair seating or
marching processions wherein the temporary flooring protects the
field.
[0208] Alternatively, for mats that are to be re-used, the portions
of the words or designs on a particular mat that makes up the
temporary flooring can be painted onto the mat, built into the
plastic during molding of the mat, or provided as a wrapping or
film that is applied onto the mat. When painted onto the mat
surface, a clear protective layer can be provided above the painted
surface to protect the design from abrasion due to movement of
chairs or people over the mat.
[0209] Additionally, the words or designs can be logos or artwork
applied on top of the mats. These can be provided as a film or
sheet that is adhered to the mat surface. Preferably, for outdoor
use, the film or sheet would also provide a non-skid surface and
would be strong enough to bond and not peel off when exposed to
various weather conditions.
[0210] Of course for any particular word, logo emblem of other
design that is to be provided, a specific arrangement of the mats
during installation is required. This can be achieved by numbering
the mats so that they are installed in the right order and location
so that the logo appears properly and correctly. And if the mats
are to be used for different installations at different schools,
only the mats that contain the emblem or logo need to be changed
out and replaced with a different logo or emblem to customize the
mat for use at the different school.
[0211] The preferred sizes of the panel mats of the invention
generally range from 1'.times.1' to 12'.times.12' with rectangular
and preferable square arrangements preferred. In certain instances,
larger size mats of as large as 8 feet wide by 16 feet long may be
provided for a specific end use. These larger size mats will need
to be moved and installed by equipment rather than individual
workers. For this, they would include lifting elements of the types
disclosed herein. They also may require specific vehicles for
shipping and transport of the panel mats to and from a job site.
For this reason, the smaller sizes of the mats (from 2 by 2 feet to
4 by 4'' square or 2 by 4 to 4 by 8 feet rectangular mats are
preferred as being the most versatile for many manually installed
applications. In addition to being sufficiently lightweight to be
installed by personnel, they also are easy to ship via conventional
vehicles such as trucks or tractor trailers.
[0212] Therefore, in sum, it is to be realized that the optimum
dimensional relationships for the parts of the invention can
include variations and tolerances in size, materials, shape, form,
function and use are deemed readily apparent and obvious to the
skilled artisan, and all equivalent relationships to those
illustrated in the drawings and described in the specification are
intended to be encompassed by the claims appended hereto.
[0213] Unless defined otherwise, all technical and scientific terms
used herein have same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. Also, as
used herein and in the appended claims, the singular form "a",
"and", and "the" include plural referents unless the context
clearly dictates otherwise. All technical and scientific terms used
herein have the same meaning.
[0214] The foregoing detailed description is considered as
illustrative only of the principles of the invention. Further,
since numerous modifications and changes will readily be apparent
to those having ordinary skill in the art, it is not desired to
limit the invention to the exact constructions demonstrated.
Accordingly, all suitable modifications and equivalents may be
resorted to falling within the scope of the invention.
* * * * *