EP1977045A1 - Tapis de sol - Google Patents

Tapis de sol

Info

Publication number
EP1977045A1
EP1977045A1 EP06831445A EP06831445A EP1977045A1 EP 1977045 A1 EP1977045 A1 EP 1977045A1 EP 06831445 A EP06831445 A EP 06831445A EP 06831445 A EP06831445 A EP 06831445A EP 1977045 A1 EP1977045 A1 EP 1977045A1
Authority
EP
European Patent Office
Prior art keywords
mat
layer
face
peripheral attachment
mat according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP06831445A
Other languages
German (de)
English (en)
Inventor
Anthony Richard Marsh
Gordon Harper
Gary E. Steadman
Mark Lukasik
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Woodpath Ventures Ltd
Original Assignee
Woodpath Ventures Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Woodpath Ventures Ltd filed Critical Woodpath Ventures Ltd
Publication of EP1977045A1 publication Critical patent/EP1977045A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C9/00—Special pavings; Pavings for special parts of roads or airfields
    • E01C9/08—Temporary pavings
    • E01C9/086—Temporary pavings made of concrete, wood, bitumen, rubber or synthetic material or a combination thereof
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G1/00—Scaffolds primarily resting on the ground
    • E04G1/24—Scaffolds primarily resting on the ground comprising essentially special base constructions; comprising essentially special ground-engaging parts, e.g. inclined struts, wheels

Definitions

  • the present invention relates to a mat used as ground cover, when ground conditions are not suitable for the passage of vehicles, animals or pedestrians and particularly, but not exclusively to a mat used as ground cover, and formed from rubber.
  • a mat according to the present invention could also be used as a hardstanding, a road crossing for heavy plants to avoid damage to roads, a rigger mat for cranes to form bases and flooring for scaffolding, and to form flooring on upper levels of scaffolding, for example.
  • This list of uses of the mat according to the present invention is not exhaustive.
  • a problem with the existing mat is that in order to create a mat having sufficient strength, the weight of the mat can be unrealistically high.
  • a mat comprising: a first face and an opposite second face spaced apart from the first face by a distance defining the thickness of the mat; first and second reinforcing components positioned within the mat and spaced apart thickness-wise from one another; and a plurality of cavities.
  • the mat In use of the mat, the mat will be placed on a surface such that the first face or the second face is in contact with the surface.
  • the opposite face will thus be the face on which loads are applied to the mat during use.
  • the presence of the cavities forming the mat produces a mat having a sufficient stiffness to weight ratio.
  • the stiffness of the mat makes handling of the mat by, for example two people, a forklift truck or a truck mounted crane, easier than is the case with mats having a lower stiffness.
  • the mat may take the shape of the surface on which it is positioned when in use.
  • the size and spacing of the cavities may be varied in order to produce a mat having appropriate strength and stiffness.
  • the first and second reinforcing components are spaced apart from each other in a direction extending through the thickness of the mat and provide greater strength and stiffness to the mat.
  • the first and second faces of the mat are preferably parallel to one another to define a mat having substantially uniform thickness across the length and width of the mat.
  • the first and second reinforcing components each preferably lie in a plane which is substantially parallel to the planes of the first face and second faces of the mat.
  • each of the reinforcing components extends substantially across the length and width of the mat.
  • each reinforcing component extends across an area which is substantially equal to or slightly smaller than, the area of each of the faces of the mat.
  • the mat is formed from rubber.
  • the mat when the mat is formed from rubber it may be formed from recycled vehicle tyres. Such a mat is environmentally efficient.
  • the first and second reinforcing components are preferably embedded in the mat. Any other convenient material could be used for example a plastics material.
  • the mat comprises a grid pattern of rows and columns defining the plurality of cavities .
  • the grid pattern is advantageously formed internally within the mat.
  • the cavities formed in the mat allow a mat having a given strength to be more lightweight than one of the same strength formed with a solid layer or layers.
  • the first reinforcing component comprises a plurality of reinforcing rods embedded in the rows and columns of the grid pattern of rows and columns
  • the second reinforcing component comprises a second plurality of reinforcing rods embedded in the rows and columns of the grid pattern of rows and columns, the first and second reinforcing components together forming a three dimensional reinforcement rod matrix.
  • each of the first and second reinforcing components comprises a grid, preferably formed from a wire mesh.
  • the grid may be formed from a plurality of wires extending longitudinally, and a plurality of second wires extending transversely.
  • the longitudinal wires are preferably welded to the transversely extending wires to form the grid.
  • Other types of configuration of the wires are also possible.
  • the first reinforcing component may be formed in a portion of the mat into which the cavities do not extend.
  • the first reinforcing component may be positioned nearer to the first face of the mat than to the portion of the mat in which the cavities are formed.
  • the second reinforcing component may be formed in a portion of the mat into which the second plurality of cavities do not extend.
  • the second reinforcing component may be positioned closer to the second face of the mat than to a portion of the mat where the recesses are formed.
  • the reinforcing components may comprise a mesh having an arbitrary configuration, which need not follow the pattern formed by the rows and columns defining the cavities.
  • first and second reinforcing components may comprise short random or oriented short fibrous materials distributed within the mat and providing a distributed reinforcement throughout the mat.
  • the cavities may take any desirable shape and may for example be substantially square, rectangular or triangular in cross section. Alternatively they may be cylindrical, having a substantially circular cross-section.
  • the first face of the mat has a slip resistant surface profile. This means that when the mat is positioned in situ over, for example ground where ground conditions are not suitable for the passage of vehicles and/or pedestrians, the slip resistant surface of the first face of the mat prevents or reduces the chances of any users of the mat slipping when passing over the mat.
  • the slip resistant surface may be achieved by forming the mat such that the first face of the mat has a particular surface profile.
  • the slip resistant surface may be achieved through appropriate use of materials. For example when the mat is made from rubber it will have a high surface friction resulting in a slip resistant surface.
  • the second face of the mat has a slip resistant surface. This serves to prevent or reduce the chances of the mat moving relative to the ground on which it is positioned.
  • the second face of the mat may be formed similarly to the first face of the mat to achieve the slip resistant surface.
  • the mat further comprises a core material formed within one or more of the cavities.
  • the core material may be any convenient material such as a plastics material such as expanded polystyrene (for example, Styrofoam®), hardboard or cardboard.
  • a plastics material such as expanded polystyrene (for example, Styrofoam®), hardboard or cardboard.
  • the core material may be used to facilitate manufacture of the mat according to the present invention.
  • the core may be shaped to define the cavities formed within the mat.
  • the mat may be formed by a moulding process in which the cavities are defined by the core material and the mat is formed around the core material.
  • the mat may thus be formed as a laminate.
  • the core material may be provided in the form of a sheet, and may be shaped to produce appropriate cavities within the mat.
  • the core material comprises a plurality of discrete portions of core material mounted on a mesh grid.
  • the mesh grid provides support to the discrete portions of material, and enables each discrete portion to be spaced apart from each other discrete portion by a predetermined distance. This means that during the moulding process used to form the mat, no discontinuity is introduced by the presence of the core material. In other words, the material forming the remainder of the mat is able to flow between the discrete portions of core material during the moulding process thus introducing continuity of material throughout the thickness of the mat.
  • the mat comprises first and second peripheral attachment flaps.
  • Each of the first and second peripheral attachment flaps is adapted to abut with, or otherwise engage a peripheral attachment flap of a second mat.
  • a large area of the ground may be covered by using a plurality of mats according to the first aspect of the present invention, each of which mats is attached to an adjacent mat by means of corresponding peripheral attachment flaps formed on each mat.
  • the mat further comprises first and second further peripheral attachment flaps.
  • Each of the first and second further peripheral attachment flaps is adapted to abut with, or otherwise engage a further peripheral attachment flap of a second mat.
  • the first and second peripheral attachment flaps may be attached to first and second oppositely disposed edges of the mat, and the first and second further peripheral attachment flaps may be attached to third and fourth oppositely disposed edges of the mat.
  • mats according to the present invention may be attached to other mats in . each of two directions.
  • the first peripheral attachment flap has a first surface profile
  • the second peripheral attachment flap has a second surface profile. This means that in use, the first peripheral attachment flap of a first mat may abut or engage with the second peripheral attachment flap of a second, adjacent mat, in order to create a composite mat. Any number of mats may be joined together to form a composite mat of appropriate size.
  • the first and second further peripheral attachment flaps may be similarly shaped to the first and second peripheral attachment flaps.
  • mats may be joined together at edges of the mats containing no peripheral attachment flap by any suitable means for example through use of clips or plates.
  • the mat comprises: a first layer comprising a first outer face forming the first face of the mat, a first inner face, and a first plurality of recesses formed on the inner face; and a second layer attachable to the first layer and comprising a second outer face forming the second face of the mat, a second inner face, and a second plurality of recesses formed on the second inner face; wherein the first reinforcing component is positioned within the first layer, the second reinforcing component is positioned in the second layer, and the first and second plurality of recesses together form the plurality of cavities.
  • each cavity is formed from a first recess and a corresponding second recess.
  • the first inner face abuts the second inner face to form the mat.
  • the first grid pattern of rows and columns defines the first plurality of recesses
  • the second grid pattern of rows and columns defines the second plurality of recesses
  • first inner face is attached to the second inner face.
  • first and second inner faces may be attached to one another by any convenient means and may for example be adhesively attached to one another.
  • the first and second inner faces may be rigidly bonded to one another.
  • the adhesive that is used to attach the first and second inner faces to one another may also be used to fill the cavities formed by the first and second plurality of recesses. This adds further strength to the mat, and increases area of bonding.
  • the adhesive advantageously comprises high density polyurethane foam.
  • the first layer further comprises a locating protrusion. The locating protrusion assists in the assembly of the mat by ensuring that the first layer is positioned appropriately relative to the second layer.
  • the locating protrusion is receivable within a first locating recess formed in the second inner face.
  • the locating protrusion is located at a second locating recess formed in the first inner face.
  • the first layer comprises a first locating recess formed in the first inner face
  • the second layer comprises a corresponding second locating recess formed in the second inner face
  • the mat further comprises a locator positionable between the first and second inner faces to align each of the first and second locating recesses. The locator serves to align the components.
  • the first peripheral attachment flap forms part of the first layer
  • the second peripheral attachment flap forms part of the second layer
  • first further peripheral attachment flap forms part of the first layer
  • second further peripheral attachment flap forms part of the second layer
  • a composite mat comprising a plurality of mats each of which mats comprises: a first layer comprising a first outer face, a first inner face, a plurality of recesses formed on the inner face, and a first reinforcing component; and a second layer attachable to the first layer and comprising a second outer face, a second inner face, a second plurality of recesses formed on the second inner face, the first layer comprising a first peripheral attachment flap, and the second layer comprising a second peripheral attachment flap.
  • the first layer and the second layer are secured together in an offset fashion so that each of the first and second peripheral attachment flaps extend outwardly from the mat at opposite sides thereof.
  • a peripheral attachment flap from a first mat may then be positioned to abut or otherwise engage a peripheral attachment flap of a second mat thereby creating a composite mat.
  • the first peripheral attachment flap of a first mat is engagable with the second peripheral attachment flap of a second mat.
  • the first and second peripheral attachment flaps have interlocking surface profiles so that when a first peripheral attachment flap of a first mat is engaged with a second peripheral attachment flap of a second mat, the first and second mats are locked together.
  • the first layer of each mat further comprises a first further peripheral attachment flap
  • the second layer of each mat comprises a second further attachment flap
  • Each of the first and second further peripheral attachment flaps is adapted to abut with, or otherwise engage a further peripheral attachment flap of a second mat.
  • the peripheral attachment flaps may be attached to first and second oppositely disposed edges of the mat, and the first and second further peripheral attachment flaps may be attached to third and fourth oppositely disposed edges of the mat.
  • adjacent mats may be joined together by one or more locking pins.
  • adjacent mats could be joined together by any other means, for example by means of clips, or nuts and bolts.
  • a mat comprising a first layer comprising a first outer face, a first inner face, a plurality of recesses formed on the inner face, and first reinforcing component.
  • the mat according to the third aspect of the present invention further comprises a first peripheral attachment flap.
  • a mat comprising a first layer comprising a first outer face, a first inner face, and a first reinforcing component, and a second layer attachable to the first layer and comprising a second outer face, a second inner face, a plurality of recesses formed on the second inner face, and a second reinforcing component.
  • a composite mat comprising a plurality of mats each of which mats comprises: a first layer comprising a first outer face, a first inner face, and a first reinforcing component; and a second layer attachable to the first layer and comprising a second outer face, a second inner face, and a plurality of recesses formed on the second inner face, the first layer comprising a first peripheral attachment flap, and the second layer comprising a second peripheral attachment flap.
  • the first layer of each mat further comprises a first further peripheral attachment flap
  • the second layer of each mat further comprises a second further attachment flap
  • Each of the first and second further peripheral attachment flaps is adapted to abut with, or otherwise engage a further peripheral attachment flap of a second mat.
  • the peripheral attachment flaps may be attached to first and second oppositely disposed edges of the mat, and the first and second further peripheral attachment flaps may be attached to third and fourth oppositely disposed edges of the mat.
  • a method for forming a mat comprising the steps of: a) mixing a binding agent with granulated rubber to form a rubber mixture; b) placing the rubber mixture into a mould; c) spreading out the rubber mixture to form a first layer having substantially uniform thickness across the layer; d) placing a first reinforcing component into the mould over the first layer; e) applying force to the reinforcing component; f) placing a filler material over the first layer; g) placing a second reinforcing component into the mould over the filler material; h) applying further rubber mixture into the mould to form a second layer; i) spreading out the second layer over the second reinforcing component; j) placing a top portion of the mould onto the second layer; k) placing the mould in a press to apply pressure to the mould; and 1) releasing the pressure after a predetermined period of time application.
  • each of the first and second reinforcing components comprises a grid in the form of a wire mesh comprising a plurality of transversely extending wires and a plurality of longitudinally extending wires, each of the transversely extending wires being welded to each of the longitudinally extending wires formed at intersections between longitudinally and transversely extending wires, and the filler material is in the form of a panel of material.
  • the method comprises the further step of forming recesses in the filler panel prior to placing the filler panel in the mould, which recesses are spaced apart by distances corresponding to the spacing of the intersections of the first and second reinforcing components, the filler panel being placed in register with, the first reinforcing component and placed in the mould.
  • the filler panel is formed with, recesses that are spaced apart from one another such that when the panel is positioned in the mould over the first reinforcing component, the recesses are each positioned over an intersection of the grid forming the reinforcing component.
  • the filler material may be in the form of discrete portions of filler material mounted on a support grid.
  • the support grid may be sized and shaped to correspond to the size and shape of each of the first and second reinforcing components. This means that the discrete portions of core material may be positioned on the supporting grid such that when the filler material is positioned within the mould, spaces or recesses defined between adjacent discrete portions of filler material will be in register with intersections between longitudinally and transversely extending wires in each of the first and second reinforcing components.
  • Figure 1 is an exploded schematic view of a mat according to an embodiment of the first aspect of the present invention
  • Figure Ia is a schematic representation of a portion of a reinforcing component forming part of a mat according to the invention.
  • Figure 2 is a schematic representation of a second embodiment of a mat according to the first aspect of the present invention.
  • Figure 3 is a bottom plan view of a first layer forming part of a third embodiment of a mat according to the first aspect of the present invention
  • Figure 4 is a detailed bottom plan view in partial section of detail C in Figure
  • Figure 5 is a front view in section of the mat of Figure 3 secured to a second mat according to an embodiment of the first aspect of the invention, to form an embodiment of a composite mat according to a second aspect of the invention
  • Figure 6 is a front view in section of another embodiment of a mat according to a first aspect of the present invention secured to a second mat according to the first aspect of the invention with an alternate means of securing the mats to form a composite mat according to the second aspect of the invention
  • Figure 7 is a detailed bottom plan view of an alternate means of securing mats constructed in accordance with the first aspect of present invention
  • FIGS. 8a and 8b are schematic representations of a further embodiment of a mat according to the first aspect of the present invention in which the peripheral attachment flaps include substantially L-shaped apertures;
  • Figure 9a is a schematic representation of a pin adapted to be inserted into the apertures shown in the attachment flap portions of the mat shown in Figures 8a and 8b;
  • Figure 9b is a schematic representation of a spike adapted to be inserted into a mat of the type shown, for example, in the mat illustrated in Figure 11 ;
  • Figure 10 is a schematic representation of another embodiment of a mat according to the first aspect of the present invention in which the peripheral attachment flaps comprise further means of securing one mat to another;
  • Figure 11 is a schematic representation of a further embodiment of a mat according to the first aspect of the present invention of similar construction to the mat shown in Figures 8 a and 8b;
  • Figure 12 is a schematic plan view of a composite mat according to the second aspect of the present invention formed from two mats of the type shown in Figure 11 joined together by means of peripheral attachment flaps;
  • Figure 13 is a cross-sectional representation through section AA of Figure
  • Figure 14 is a detailed cross-section of the detail indicated by B in Figure 13;
  • Figure 15 is a detailed cross-sectional representation of an end portion of the composite mat shown in Figure 13;
  • Figures 16 and 17 show composite mats according to the second aspect of the present invention formed from a plurality of the mats shown in Figure 11 ;
  • Figure 18 is a schematic representation of a further embodiment of a mat according to the first aspect of the present invention.
  • Figure 19 is a schematic representation of a mat according to the first aspect of the present invention having further peripheral attachment flaps;
  • Figure 20 is a schematic representation of a composite mat according to the second aspect of the invention formed from a plurality of the mats of Figure 19;
  • Figure 21 is a schematic representation of a mat according to yet another embodiment of the present invention.
  • Figure 22 is a cross-sectional representation of a portion of the mat of Figure 21; and Figure 23 is a schematic representation of a portion of the mat of Figure 21 in which the first reinforcing component has been pulled away from the remainder of the mat.
  • an embodiment of a mat according to the first aspect of the present invention is designated generally by the reference numeral 10.
  • the mat 10 comprises a first layer 12, and a second layer 28.
  • the first layer comprises a first inner face 14, and a first outer face 16.
  • the second layer 28 comprises a second outer face 30, and a second inner face 32.
  • the second layer 28 comprises a plurality of recesses 38 defined by a plurality of rows 34 and columns 36, to define a grid pattern.
  • the recesses 38 are substantially rectangular in cross-section, and the grid pattern defined is a waffle pattern grid 33.
  • the first inner face 14 formed in the first layer 12 comprises a corresponding plurality of recesses (not shown) defined by rows and columns to form a waffle pattern grid.
  • the mat 10 is formed by attaching the first layer 12 to the second layer 28 such that the first inner face 14 abuts the second inner face 32.
  • the two layers 12, 28 may be secured to each other in any convenient way.
  • the layers may be adhesively attached to one another. Once the layers have been attached to one another corresponding recesses form cavities within the mat.
  • Each of the first and second layers 12, 28 comprises a plurality of reinforcing rods 400 embedded in the rows and columns forming the waffle grid pattern.
  • the reinforcing rods 400 comprise a plurality of transversely extending rods 402, and a plurality of longitudinally extending rods 404, as shown in Figure Ia.
  • the transversely extending rods 402 are welded to the longitudinally extending rods 404 to form intersections 406 between the transversely extending rods and the longitudinally extending rods.
  • the intersections 406 of the grid formed from the reinforcing rods 400 are positioned at intersections between the rows and columns forming the waffle grid pattern in each of the first and second layers 12, 28.
  • the reinforcing rods 400 define two grids each of which grids is shaped to extend substantially across the mat 10. In other words, the dimensions of each grid are the same as, or slightly smaller than dimensions of cross-sectional area of the mat.
  • the stiffness of the mat is a function of: the dimensions of the reinforcing rods; the thickness of the mat layers; the gauge of the wire; the dimensions of the rows and columns forming the grid ; the physical properties of the material from which the mat is made; and the location or position of the reinforcement component in each layer.
  • the second inner face 32 comprises a plurality of locating protrusions 200, which are each located at a locating recess 38.
  • Each locating protrusion 200 is receivable within a corresponding recess (not shown) formed in the first inner face 14.
  • Locating protrusions 200 thus assist in appropriately positioning the first layer 12 relative to the second layer 28.
  • Each locating protrusion 200 comprises a through bore 210, and each recess into which a corresponding locating protrusion is receivable has a corresponding through bore 220.
  • a locking pin or spike (of the type shown in Figure 9b) may be inserted into the through bores 210, 220.
  • the two layers 12, 28 are thus held together to form a mat 10.
  • the locking pins or spikes may extend entirely through the thickness of the mat and into the ground on which the mat is positioned. The pins will thus serve to hold the mat in position on the ground.
  • Each of the layers 12, 28 further comprises respective peripheral attachment flap 48 having a shaped profile.
  • a composite mat according to a second aspect of the present invention may be created by positioning a second mat adjacent to the first mat 10 such that the peripheral attachment flap 48 forming part of the first layer 12 of the second mat engages with the peripheral attachment flap 48 forming part of the second layer 28 of the first mat 10.
  • each peripheral attachment flap comprises a recessed channel 230 and an extending portion 240.
  • the extending portion 240 of the attachment flap 48 of the second layer 28 of a first mat 10 will abut with the peripheral attachment flap 48 of a first layer 12 of a second mat such that the extending portion 240 of the peripheral attachment flap 48 forming the second layer of the first mat will be positioned within the recess channel 230 of the attachment flap 48 of the first layer of the first mat.
  • the extending portion 240 of the attachment flap forming part of the first layer of the second mat may be positioned within the recessed channel 230 of an attachment flap 48 forming part of the second layer of the first mat.
  • FIG 2 a second mat 10 according to a first aspect of the present invention is shown schematically. Parts that correspond to the parts described with reference to the mat 10 shown in Figure 1 have been given corresponding reference numerals for ease of understanding.
  • the peripheral attachment flaps 48 each extend beyond the respective inner faces 14, 32 (not shown) of the first and second layers 12, 28 from which they extend, in such a manner that a shoulder 250 is formed.
  • the shoulder 250 may be used to appropriately locate the first layer 12 relative to the second layer 28. When the first layer 12 is appropriately positioned relative to the second layer 28, it abuts with the shoulder 250 formed in the second layer 28. Similarly, the second layer 28 will abut with the shoulder 250 formed in the first layer 12.
  • peripheral attachment flap 48 forming part of a first layer 12 in a second mat is positioned to abut with the peripheral attachment flap 48 forming part of the second layer 28 of a first mat.
  • peripheral attachments 48 Due to the sloping profile of the peripheral attachments 48, adjacent mats will form a substantially even surface.
  • Each of the peripheral attachment flaps 48 comprises a plurality of through bores 260.
  • the two mats are positioned so that the through bores 260 formed in corresponding peripheral attachment flaps 48 coincide with one another.
  • Locking pins or spikes may then be inserted through the through bores, and if appropriate into the ground on which the mats are positioned. The locking pins or spikes thus secure adjacent mats together, and also secure the mats to the ground if the locking pins or spikes are positioned to extend into the ground.
  • FIGS 3 and 6 further embodiments of a mat according to a first aspect of the present invention are designated generally by the reference numeral 10.
  • Parts of the mat 10 shown in Figures 3 to 6 and corresponding to parts of the mat shown in Figures 1 and 2 have been given corresponding reference numerals for ease of reference.
  • each first layer 12 comprises a first reinforcement rod grid 26, and each second layer 28 comprises a second reinforcement rod grid 42.
  • the first reinforcement rod grid is formed from a reinforcing rod 24 which is embedded in rows 18 and columns 20 defining recesses 22 in the first layer 12, and the second reinforcement rod grid 42 is formed from reinforcing rod 40 embedded in the rows 34 and columns 36 forming the second layer 28.
  • first layer 12 is secured by adhesive 46 to inner face 32 of second layer 28, with first reinforcement rod grid 26 in parallel spaced relation with second reinforcement rod grid 42, thereby forming a three dimensional reinforcement rod matrix.
  • First layer 12 is secured to second layer 28 in an offset fashion to create peripheral attachment flaps 48 adapted for attachment to an adjoining mat 10 of like construction.
  • peripheral attachment flaps 48 have interlocking surface profiles 49, such that interlocking surface profiles 49 interlock to prevent separation of adjoining mats. Once interlocked, if a force is applied to pull them apart, they will become wedged closer together.
  • peripheral attachment flaps 48 may have holes 52 adapted to receive a spike 54, with a rectangular cross-section or otherwise, along the length of flap 48, as seen in Figure 3.
  • spike 54 can then act to hold mat 10 in place if on a surface that can be penetrated.
  • each of outer face 16 of first layer 12 and outer face 30 of second layer 28 may have slip resistant surface profiles 56, such that either face 16 or face 30 may be used as a travel surface.
  • first layer 12 is provided as described above.
  • Second layer 28 is also provided, similar to that shown in Figure 3 and 4.
  • first layer 12 and second layer 28 are secured together by adhesive 46 such that reinforcement rod grids 26 and 42 are in parallel spaced relation, and in an offset fashion such that peripheral attachment flaps 48 are present.
  • interlocking ' surface profiles 49 are interlocked such that adjoining mats 10 are secured together.
  • spikes 54 may be passed through holes 52 in flaps 48 to secure adjoining mats 10, or, referring to Figure 6, lip 50 may be engaged with recess 51.
  • Slip resistant surface profile 56 present on either side of mat 10 allows either side to be used as a travel surface.
  • FIG. 8a and 8b a further embodiment of a mat 10 according to the present invention is schematically illustrated.
  • each peripheral attachment flap 48 comprises a plurality of substantially L-shaped slots 300.
  • a peripheral attachment flap 48 extending from a first layer 12 of a first mat 10 is brought into contact with a second outer peripheral flap 48 forming part of the second layer 28 of a second mat 10'.
  • the two mats 10, 10' are positioned so that the L-shaped slots 300 in each of the first and second mats 10, 10' coincide with one another.
  • a locking pin of the type shown in Figure 9a and designated generally by the reference numeral 900 may then be inserted through two coinciding L-shaped slots 300 to lock the mats 10, 10' together.
  • each of the recess channels 230 formed in each attachment flap 48 comprises a plurality of extending pins 920.
  • Each of the raised portions 240 forming each of the peripheral flaps 48 are formed with a plurality of bores 930.
  • the two mats 10, 10' are positioned so that bores 930 formed in the raised portion 240 of the first mat 10 engaged with and receive pins 920 formed in the recess channel 230 of the second mat 10'.
  • the pins 920 formed in the recess channel 230 of the first mat 10 will be receivable within the bores 930 formed in the raised portion 240 of the second mat 10'.
  • two adjacent mats 10, 10' are locked together to form a composite mat.
  • FIG. 11 to 15 a further embodiment of a mat according to a first aspect of the present invention is illustrated schematically. Parts of the mat 10 which. correspond to parts of the mats illustrated in any of Figures 1 to 10 have been given corresponding reference numerals for ease of reference.
  • the mat 10 comprises a plurality of L-shaped slots formed in attachment flaps 48, and further comprises a plurality of through-bores 220 extending through the two layers 12, 28.
  • the through-bores thus will pass through recesses of the type shown in Figure 1 or protrusions of the type shown in Figure 18 and described hereinbelow.
  • a locking pin or spike of the type illustrated in Figure 9b and designated generally by reference numeral 910 may be inserted through the through-bores 220 thus locking the two layers 12, 28 of mat 10 together.
  • a composite mat comprising two mats 10, 10' of the type shown in Figure 11 is designated generally by the reference numeral 150.
  • two adjacent mats 10, 10' may be joined together by overlapping peripheral attachment flaps 48 in the manner shown schematically in Figures 13 and 14.
  • the L-shaped slots 300 together form a through-channel 350 having a substantial Z-shape.
  • the two adjacent mats 10, 10' may thus be held together by inserting a locking pin of the type shown in Figure 9a into two coinciding L-shape slots forming the through-channel 350.
  • the layer 28 includes a second reinforcement rod grid 42 which extends within the second layer 28 in portions of the layer defined by rows 18 and columns 20 (not shown).
  • the grid 42 extends beyond the L-shaped slots 300 and thus the grid extends into the peripheral attachment flap 48. This provides strength to the peripheral attachment flap 48.
  • FIG. 16 and 17 a plurality of mats 10 of the type illustrated in Figure 12 are illustrated.
  • the mats 10 are joined to one another by means of attachment flaps 48 as described in more detail hereinabove.
  • mats 101 and 102 may be joined together by clips.
  • mats 102, 103 and 104 are joined together by means of peripheral attachment flaps 48 as described hereinabove.
  • adjacent mats 10 are joined to one another in an offset interlocking manner. This means that it is possible to attach adjacent mats to one another by means of attachment flaps 48 in a way that allows a composite mat 150 to be formed from interlocking rows and columns of mats 10.
  • the embodiment of the mat illustrated in Figure 17 is particularly suitable for use with hardstandings.
  • FIG. 18 an embodiment of mat 10 according to a first aspect of the invention is illustrated schematically.
  • the second inner face 32 of second layer 28 has formed therein a plurality of protrusions 39 which each locate with a corresponding one of a plurality of recesses formed in the first inner face 14 of the first layer 12.
  • the reinforcing component is formed within a portion 29 of the mat 28. In the mat illustrated in Figure 18 therefore the reinforcing component will be positioned below the protrusions when the mat is orientated as shown in Figure 18.
  • the protrusions may take any particular form.
  • an embodiment of a mat according to the first aspect of the present invention is designated generally by the reference numeral 10.
  • the mat 10 comprises a first layer 12 and a second layer 28.
  • the first layer 12 comprises attachment flaps 56, 54, and the second layer comprises an attachment flap 56.
  • Figure 20 shows a plurality of the mat 10 shown in Figure 20 joined together to form a composite mat 150. Due to the fact that the mat 10 comprises attachment flaps 52, 54 and 56, it is possible to attach individual mats 10 to other mats in each of two directions to build a composite mat.
  • FIG. 21 a further embodiment of a mat according to the first aspect of the present invention is designated generally by the reference numeral 100.
  • the mat 100 is similar to the mats illustrated hereinabove with reference to Figures 1 to 20.
  • the mat illustrated in Figures 21 to 23 differs from the mats illustrated in Figures 1 to 20 in that the mat 100 is formed from a single layer 120 only, and comprises a first face 160 and a second face 300.
  • the mat 100 comprises a first reinforcing component 140 and a second reinforcing component 150 spaced apart from the first reinforcing component 140 through the thickness t of the mat 100.
  • Each of the reinforcing components 140, 150 comprises a plurality of reinforcing rods which are arranged to form a grid (as shown in Figure Ia).
  • each of the reinforcing components 140, 150 comprises a grid formed from a plurality of transversely extending rods 402, and a plurality of longitudinally extending rods 404 such that there are a plurality of intersections 406 between the longitudinally extending rods and the transversely extending rods.
  • the mat 100 further comprises a core material 180 which in this embodiment is formed from expanded polystyrene.
  • the core material is initially in the form of a panel. Recesses 300 are formed in the panel during the moulding process to form the mat (which will be described in more detail hereinabelow). The material forming the mat will fill the recesses 300. This means that cavities 180 are defined by the core material, rather than being air filled.
  • a mat according to the present invention may be made from any convenient material.
  • the mat is formed from flexible durable material, and preferably a rubber- like material.
  • the material may be granular, and advantageously may be granular rubber material reclaimed from used automobile tyres and other rubber products from which reinforcing fibres and metallic wires have been removed.
  • the granular material may be a single size, a combination of sizes, or a range of sizes according to the desired properties of the finished mat.
  • the reinforcing component may advantageously be formed from a metallic wire or wire mesh which may be either welded or woven, or from expanded metal mesh.
  • an adhesive or binder may be added to a granular material, together with a reinforcing material. The materials may then be formed into a continuous piece.
  • the adhesive comprises polyurethane or polyurea type adhesive, or a hybrid of both polyurethane or polyurea.
  • the adhesive is a thermosetting adhesive which is introduced into the material used to form the mat in liquid form. The adhesive may then be hardened over a predetermined time to form a flexible rubber-like product.
  • the mat is not formed from a granular material, but is formed from a rubber material that has been moulded or cast from liquid state, then adhesive may not be required.
  • a predetermined quantity of granular rubber particles and adhesive are blended together until all the particles are coated with adhesive.
  • a portion of the mixture so formed is placed into a bottom half of a mould having an appropriate shape, and spread throughout the mould area. An appropriate amount of the mixture is spread into the mould in order that the mixture has a required thickness or thicknesses.
  • One or more layers of reinforcing material that has been cut to a predetermined shape is then placed within the mould at a predetermined location upon the layer of rubber and adhesive mixture that has previously been introduced into the mould.
  • a further portion of rubber and adhesive mixture is then placed into the mould over the top of the reinforcement component and spread throughout the mould area to form a portion having a required thickness or thicknesses.
  • a top half of the mould is placed in alignment with the now filled bottom half of the mould and the two halves are closed together.
  • the mixture is allowed to cure to a sufficient hardness such that it can be removed from the mould.
  • the mould is then opened and the moulded rubber layer is removed from the mould in preparation for final assembly.
  • the two layers so formed are bonded together to form a mat according to the present invention.
  • the rubber layers may be identically moulded, or they may be individually moulded to be complementary in shape to one another.
  • the surfaces to be bonded i.e., those formed on the inner faces of each layer) are cleaned and coated with a liquid or semi-solid adhesive.
  • the two layers are then aligned so that the finished mat configuration is achieved.
  • the two layers are then pressed together so that they may become adhesively bonded to one another in a substantially permanent manner.
  • the mat may now be used.
  • the liquid When the mat is made from a material in liquid state and is cast from the liquid, the liquid may be poured into an open mould, or injected into a closed mould into which the reinforcement material has been previously placed.
  • the liquid material will then harden either by chemical action or cooling, capturing the wire reinforced within it.
  • the layer so formed is then removed from the mould for final assembly into a mat according to the invention.
  • the rubber and wire reinforcement may be introduced into the mould as a layered construction of uncured rubber sheets and wire reinforcement.
  • This combined sheet would be placed into the mould and compressed sufficiently for the uncured rubber to flow into all mould extremities.
  • the rubber is cured through the application of heat and then the layer is removed from the mould for final assembly into the mat.
  • a predetermined quantity of granular rubber particles is mixed with a binding agent.
  • a portion of the mixture so formed is placed into a bottom half of a mould having an appropriate shape, and spread throughout the mould area until a first layer having substantially uniform thickness is produced.
  • a layer of reinforcing material in the form of a grid of intersecting rods that has been cut into a predetermined shape is placed within the mould at a predetermined location upon the upper layer of the rubber mixture. Pressure is applied to the reinforcing material in order that the reinforcing material is positioned just below tihe surface of the first layer of rubber.
  • the reinforcing grid may be in the form of a wire mesh panel which has dimensions that are slightly smaller than the overall length and width of the mat to be produced.
  • the mesh has longitudinal and transverse wires that are spaced apart by a predetermined amount.
  • the wires are spaced apart by two inches, although in anotitier example they could be spaced apart by three or more inches.
  • the wires are welded together where they intersect to form a sheet of wire mesh.
  • the spacing between the wires and the diameter of wire can be adjusted to increase or decrease the load bearing capabilities and the rigidity of the mat.
  • the wire diameter can range from a number 12 to a number 2 gauge for example.
  • the use of a lighter wire creates a mat with less rigidity.
  • a panel of light weight filler such as Styrofoam® is used having a surface area about 5% less than the surface area of the mat.
  • Recesses are formed in the panel of light weight filler. The spacing of the recesses corresponds to the spacing of the intersections in the wire mesh.
  • the panel is then placed over the first reinforcing material such that a centre of each recess formed in the panel is located at an intersection of the welded transverse and longitudinal wires forming the sheet of wire mesh.
  • the size of the recesses formed in the panel of light weight filler is determined by the wire grid spacing.
  • the size of the recesses in the panel can vary up to 100% of the size of the grids formed in the wire mesh. For example, for a wire mesh with a 3 inch by 3 inch grid, each recess could be 3 inches in diameter.
  • the strength and weight of the mat may be varied appropriately. Large recesses formed in the panel will result in a heavier but stronger mat, since more of the rubber material will be able to fill the recesses.
  • a second reinforcing component also in the form of wire mesh is then placed into the mould on top of the panel of filler material.
  • the second sheet of wire mesh is positioned such that the intersections between the transverse and longitudinal wires are centred in each of the recesses formed in the filler panel.
  • a second layer of rubber mixture is then placed into the mould and spread over the top layer of wire mesh and filler mesh.
  • a top portion of the mould is placed on top of the second layer of rubber mixture and the mould is placed into a press where it is pressed.
  • the pressure is released from the mould and the mould is recovered from the press.
  • the top of the mould is then removed the moulded matter is extracted from the mould.
  • the filler material may be in the form of a plurality of discrete portions of filler material mounted on a wire mesh.
  • the spacings of the wires forming the supporting wire mesh may correspond to, or be in register with, the spacing of the wires forming each of the first and second reinforcing components.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Road Paving Structures (AREA)

Abstract

La présente invention concerne un tapis comprenant une première face et une seconde face opposée, séparée de la première par une distance définissant l'épaisseur du tapis, un premier et un second élément de renfort disposés à l'intérieur du tapis et séparés l'un de l'autre par l'épaisseur du tapis, et une pluralité de cavités.
EP06831445A 2005-12-23 2006-12-22 Tapis de sol Withdrawn EP1977045A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0526339A GB2433539A (en) 2005-12-23 2005-12-23 Mat for use in temporary road, scaffolding and the like
PCT/GB2006/004884 WO2007072034A1 (fr) 2005-12-23 2006-12-22 Tapis de sol

Publications (1)

Publication Number Publication Date
EP1977045A1 true EP1977045A1 (fr) 2008-10-08

Family

ID=35841155

Family Applications (1)

Application Number Title Priority Date Filing Date
EP06831445A Withdrawn EP1977045A1 (fr) 2005-12-23 2006-12-22 Tapis de sol

Country Status (3)

Country Link
EP (1) EP1977045A1 (fr)
GB (1) GB2433539A (fr)
WO (1) WO2007072034A1 (fr)

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GB2472844A (en) * 2009-08-21 2011-02-23 Promote Products Ltd Scaffold board
US9039325B2 (en) 2013-03-08 2015-05-26 Newpark Mats & Integrated Services Llc Liquid containment system for use with load-supporting surfaces
FR3042097A1 (fr) * 2015-10-08 2017-04-14 Solution Technique Caoutchouc Plaque pour le revetement de sol, destinee a equiper une enceinte pour l'elevage d'animaux
US9506255B1 (en) * 2015-10-20 2016-11-29 Signature Systems Group, Llc Modular flooring device and system
CN105672088A (zh) * 2016-01-27 2016-06-15 吕爱萍 一种冰雪地汽车道路组合耐磨应急层毯
CN105672082A (zh) * 2016-01-27 2016-06-15 林建凯 一种飞机雪地起落层毯
CN105672089A (zh) * 2016-01-27 2016-06-15 林建凯 一种飞机雪地起落耐磨层毯
CN105603847A (zh) * 2016-01-27 2016-05-25 陈小燕 一种飞机雪地起飞降落分水毯
CN105507107A (zh) * 2016-01-27 2016-04-20 林建凯 一种飞机雪地起落防滑层毯
CN105672081A (zh) * 2016-01-27 2016-06-15 吕爱萍 一种冰雪地汽车道路组合防滑应急层毯
DK179338B1 (da) * 2016-10-18 2018-05-14 Ikadan System As Midlertidigt gulvsystem samt fliser til samme
US20220136181A1 (en) * 2019-02-28 2022-05-05 Newpark Mats & Integrated Services Llc Overlapping modular mat system including mat components having fortifying members
CN110747711B (zh) * 2019-11-04 2022-09-09 河南省交通规划设计研究院股份有限公司 一种装配式临时道路及其制作方法
US20230309728A1 (en) * 2022-03-31 2023-10-05 Newpark Mats & Integrated Services Llc Fiber-reinforced load-supporting mats

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Also Published As

Publication number Publication date
GB2433539A (en) 2007-06-27
WO2007072034A1 (fr) 2007-06-28
GB0526339D0 (en) 2006-02-01

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