JP6786583B2 - Mat construction with environmentally resistant core - Google Patents

Description

The present invention relates to reusable systems for constructing road and equipment support surfaces in areas with low ground conservation properties. More specifically, the present invention relates to a system of durable mats that can be interconnected to form road and / or equipment support surfaces. More specifically, the invention can be quickly and easily positioned to form a road and / or equipment support surface that does not overlap, after which it is easily removed and stored again until needed. Regarding the mat reusable system that can be kept.

Mats for this purpose are generally known in the art and are available from Quality Mat, Beaumont, Texas, USA. In remote and unstable environments, stable roads (or no roads) often do not exist, so temporary roads are constructed by arranging planks, boards, or mats along the desired route. Matt provides temporary structures for use in various construction projects, as well as environmental cleanup or disaster area cleanup projects. By providing a relatively horizontal and stable surface, these mats allow trucks and other equipment to move over otherwise unstable, soft or damp ground, or damaged areas. , It is possible to store equipment on it and set up a campground.

While traditional wooden mats provide useful services at a reasonable cost, white oak wooden cores, usually made of white oak, can deteriorate over time due to moisture, causing the wood to gradually rot and deteriorate. This disposes of the mat, as unlike some of the other materials used in the upper and lower layers of the mat, the core cannot be replaced unless a completely new mat is created. Will be done.

Also, it is usually 4 feet (121.94 cm) wide and up to 40 feet (1219.4 cm) in length from 8 x 8 inches (20.32 x 20.32 cm) to 12 x 12 inches (30.48 cm). Conventional crane mats that utilize beams (x30.48 cm) utilize oak, preferably white oak beams. This is because this material provides the mat with acceptable performance at a reasonable cost and with sufficient life. Such mats are also available from Quality Mat, Inc., Beaumont, Texas, USA. These mats, often referred to as mining mats or crane mats, typically utilize solid wood that has been molded to meet the design requirements and cut to a length that meets the design requirements. However, weather conditions and other environmental factors reduce the availability of fellable trees to make long beams of such large sizes, so get enough to make a large number of mats. Is becoming difficult.

Therefore, alternatives are needed in crane mat constructions to save the amount of wooden beams that need to be included. Also, materials that can be considered alternatives need to have the physical properties necessary to withstand harsh outdoor conditions and to support heavy equipment. Of course, mats that are many times more expensive than mats that can be made from wood are not cost effective, so cost is also a factor in deciding the choice of alternative material.

Therefore, improvements in these types of mat constructions are needed to provide longer life and to conserve natural resources, and these needs are met by the industrial mats of the present invention.

The present disclosure includes the following [1] to [21].
[1] Matte
A core structure that provides strength and rigidity to the mat and is provided as one or more components including a sheet, multiple elongated members, a frame, multiple compartments, or a combination thereof, the structural component being resistant to. With a core structure made of environmentally non-wooden material,
Attached directly to the core structure or indirectly via other components, it has a length and width substantially corresponding to the length and width of the core structure, and is the upper or lower surface of the mat. , Or at least one outer layer forming both the upper and lower surfaces of the mat, including a plurality of elongated members, wherein the elongated member of the outer layer is wood, processed wood, thermoplastic material, thermosetting. The material of the elongated member of the at least one outer layer, which is composed of a plastic material or an elastomer material, comprises at least one outer layer different from the material of the structural component of the core.
The at least one outer layer component provides the mat with abrasion resistance, abrasion resistance, and abuse resistance and is removably attached to the core construct to provide the above configuration of the at least one outer layer. A mat that is replaceable when an element is damaged, the core structure is protected and does not deteriorate, and the core structure is reused to replace at least one outer layer component. The mat is designed to be able to form.
[2] The structural component of the core structure comprises a metal, an elastomer material, a thermoplastic material, a thermosetting material, or a combination thereof, with one outer layer forming the upper surface of the mat and another. One or more components in the form of a sheet, a plurality of elongated members, the outer layer forming the lower surface of the mat and optionally present to attach the at least one outer layer to the core structure. Or the mat according to [1] above, which has an additional layer containing a combination thereof.
[3] The structural component of the core structure is an elongated member of a fiberboard or a thermoplastic material or a thermosetting plastic material, and a solid or perforated plate of the fiberboard or the thermoplastic material or the thermosetting plastic material. Or including a sheet, one outer layer forms the upper surface of the mat and comprises a plurality of elongated members of wood or processed wood, another outer layer forms the lower surface of the mat and the elongated members, The mat according to [2] above, comprising a thermoplastic material, a thermosetting plastic material, or an elastoma material in the form of a solid or perforated plate or sheet structure or grid or lattice.
[4] The at least one outer layer is directly or indirectly detachably attached to the core structure by bolting, and the components of the at least one outer layer have an elastic modulus of about 1.6 Mpsi. The item according to any one of the above [1] to [3], wherein the mat has a load bearing capacity capable of withstanding a load of at least 500 to 1000 psi without permanently deforming the core structure. mat.
[5] The core structure has a thickness of about 2.5 to about 4 inches (10.16 cm) and is 1.5 inches (3.81 cm) x 1.5 inches (3.81 cm) to 3 inches. A lattice of fiberglass-reinforced thermosetting plastic material with holes between (7.62 cm) x 3 inches (7.62 cm), or multiple elongated tubulars made of metal, thermoplastic, or thermosetting material. The above [1], which comprises a plurality of elongated tubular members which are members, each of which is the same material or a different material, which is hollow or solid, or which is an independent member, or is connected to form an integral component. ] To the mat according to any one of [4].
[6] The core structure includes a sheet-like or solid, perforated, or honeycomb-structured thermoplastic material, thermosetting material, elastomer material, or polyolefin material, and the honeycomb structure includes a closed or open cell. , The cells of the honeycomb structure optionally include a filler to increase the weight of the mat and to control, eliminate, or achieve absorption of the liquid, and the core structure is in the open cell. The mat according to any one of the above [1] to [5], which comprises an upper sheet and a lower sheet that help hold the filler in the cell when the filler is provided.
[7] The beam further includes a beam or bumper made of wood or plastic material provided on the longitudinal side surface of the core structure to protect the core structure from damage due to transportation or installation of the mat. The mat according to any one of the above [1] to [6], wherein the bumper is optionally provided at the end of the core structure.
[8] A mat having an upper surface and a lower surface.
With first and second side beams having top, side, and bottom surfaces,
It is a non-wooden support structure that is located between the first side beam and the second side beam and connects the first side beam and the second side beam, and is an upper portion, a lower portion, and the like. And has side portions, has a height less than the height of the side beams, has a width and length, and includes first and second longitudinal members that are connected to each other by a plurality of cross members. Non-wooden support structure and
A plurality of connecting rods for attaching the side beam to the support structure, the connecting rod passing through the side surface of the beam and the support structure, and
Including a first plurality of elongated members attached to the upper portion of the support structure.
A mat in which the upper surface of the mat is substantially flat and is formed by the beams, the first plurality of elongated members, or both upper surfaces thereof.
[9] Further including a second plurality of elongated members attached to the lower portion of the support structure, the bottom surface of the mat is substantially flat, and the beam or the second plurality of elongated members. The mat according to the above [8], which is formed by the bottom surfaces of the members or both.
[10] A tubular sleeve in which the connecting rod includes a bolt that passes through the side beam and the support core, facilitating the beam and the longitudinal member through which the bolt is passed for assembly of the mat. The mat according to the above [8] or [9], which comprises.
[11] The beam is between about 1 x 6 inches (2.54 x 15.24 cm) and about 24 x 24 inches (60.96 x 60.96 cm), or about 6 x 6 inches (15.24 x). The first and second longitudinal members have width and height dimensions between 15.24 cm) and about 16 x 16 inches (40.64 x 40.64 cm), and the first and second longitudinal members are about 10 to about 30 inches. Connected to each other by cross members separated by (25.4 to 76.2 cm), the connecting rods separated by about 3 to about 6 feet (91.44 to 182.88 cm), and the mat from about 4. Of [8] to [10] above, having a width between about 8 feet (121.92 to 243.84 cm) and a length between about 4 and about 60 feet (121.92 to 1828.8 cm). The mat according to any one item.
[12] A flat plate in which the side beams are made of solid cut wood, processed timber, or thermocurable plastic, and the first and second longitudinal members are in contact with the side beams, type I. It is constructed as a beam or a rectangular or C-shaped beam, the cross member is composed of a flat plate, and an I-shaped beam or a C-shaped beam, and the plurality of elongated members are solid cut wood, processed timber, and the like. The mat according to any one of the above [8] to [11], which is a board made of heat-curable plastic and in which the elongated member is bolted to the support structure.
[13] The first side beam is sized to provide about half the height of the mat, and the first side beam is attached to the upper portion of the support structure. Alternatively, the second side beam is sized to provide half the height of the mat and is attached to the underside of the second side of the support structure, or the first and Any one of [7] to [12] above, wherein both of the second beams are sized as described above [] to facilitate the formation of an interlock structure of adjacent mats to be connected. The mat described in the section.
[14] Matte
A frame or rudder structure having longitudinal sides and end sides and configured to support other components forming the mat or to allow attachment of other components forming the mat. Support structure in the form of
With an additional layer of elongated members that are attached above or below, or both above and below the support structure, to form the top or bottom surface, or both the top and bottom surfaces of the mat.
Includes at least a bumper member that is removablely attached to the longitudinal side of the frame or rudder structure to protect it from damage from lateral collisions during transport or installation of the mat.
A shape in which the bumper is made of a plastic or elastomeric material, provides an outer surface that extends beyond the sides of the support structure, and has sufficient compression to absorb collisions and impacts and protect the support structure. A mat that has and is removable so that the bumper can be replaced if it is damaged.
[15] When the longitudinal side surface of the support structure includes an I-shaped beam having an open cavity facing outward, the bumper is attached to the I-shaped beam and fitted into the cavity of the I-shaped beam. Or
When the longitudinal side of the support structure comprises a beam having a flat outer surface, the bumper by an additional member or lip that holds the bumper in place in contact with the flat outer surface of the beam. The mat according to the above [14], which is positioned adjacent to the longitudinal side surface.
[16] The mat according to [14] or [15], wherein the bumper is also provided on one or both end side surfaces of the support structure.
[17] The support structure is made of a metal or hollow, filled hollow, or solid, glass fiber reinforced thermosetting plastic material rectangular tube member, and the elongated member is The mat according to the above [14], [15], or [16], which is composed of wood, processed wood, or a thermoplastic material or a thermosetting plastic material.
[18] The holes in the support structure are wooden boards that give the mat greater weight, compressive strength, or toughness, and the core of the wooden board is configured to fit into the holes in the support structure. , Wooden boards bolted to each other so that they do not move inside the mat, recycled rubber tire material located within the open area of the support structure, sand, or other particulate or solid filler. The filler is held in place within the support structure by a mesh, screen, or sheet fixed to the top and bottom of the support structure, or a foam located within the open area of the support structure. The mat according to any one of the above [1] to [17], which comprises one or a combination of extruded polymer materials.
[19] A D-shaped ring, an O-shaped ring, wherein the support structure includes a steel member, and the mat is directly connected to the steel member to allow the mat to be lifted overhead. [1] The above [1], further comprising a lifting element including a chain or cable, wherein the steel member of the support structure is optionally coated or painted to provide additional environmental resistance to the support structure of the mat. ] To the mat according to any one of [18].
[20] Radio frequency identification (RFID) tags, which allow the mat to be monitored when used in an inventory system or for rent.
A lighting element that is embedded in the elongated member and supplies light to assist in the use of the mat at night or in the dark daytime due to bad weather conditions, or
Color coding, which identifies the composition of the mat, identifies the mat for a particular customer or end user, or indicates that the mat is rented or leased.
The mat according to any one of the above [1] to [19], further comprising one or more of the above.
[21] A method of extending the life of an industrial mat having wooden components.
A step of configuring the industrial mat to have a core structure that provides strength and rigidity to the mat, wherein the core structure comprises a sheet, a plurality of elongated members, a frame, a plurality of compartments, or a combination thereof. Provided as one or more components, with steps in which the structural components of the core structure are made of environmentally resistant non-wood material.
At least one removable outer layer that is attached directly to the core structure or indirectly via other components, forming either the top or bottom surface of the mat or both the top and bottom surfaces of the mat. A step of providing at least one outer layer, wherein the at least one removable outer layer comprises an elongated member made of wood, processed wood, a thermoplastic material, a thermosetting plastic material, or an elastomer material. The mat is provided with abrasion resistance, abrasion resistance, and abuse resistance, and the material of the elongated member of the at least one outer layer is different from the material of the structural component of the core.
The at least one outer layer elongated member damaged or deteriorated during use is replaced by removing one or more of the damaged or deteriorated elongated members, while being protected and not degraded. A method comprising reusing the core structure to regenerate the mat by forming a regenerated mat in which the elongated member or other component of the at least one outer layer has been replaced.
The present invention provides a mat that includes a core structure that provides the mat with strength and rigidity. This core structure is provided as one or more components including a sheet, a plurality of elongated members, a frame, a plurality of compartments, or a combination thereof. These components of the core structure are composed of environmentally resistant non-wooden materials. The mat also includes at least one outer layer that is attached directly to the core structure or indirectly via other components, said at least one outer layer to the length and width of the core structure. It has substantially corresponding lengths and widths and forms the top or bottom surface of the mat, or both the top and bottom surfaces of the mat. The at least one outer layer includes a plurality of elongated members, and the at least one elongated member is composed of wood, processed wood, a thermoplastic material, a thermosetting plastic material, or an elastomer material, and the at least one outer layer. The material of the elongate member of is different from the material of the structural components of the core. Thus, the at least one outer layer component provides the mat with abrasion resistance, wear resistance, and abuse resistance and is removablely attached to the core construct to provide the at least one outer layer component. The core structure is protected and does not deteriorate and is reused to form a mat in which the components of the at least one outer layer have been replaced, while the core structure is designed to be replaceable when damaged. Can be done.

The environmentally resistant material of the structural components of the core structure can be selected from treated wood, metals, elastomeric materials, thermoplastic materials, thermosetting materials, or combinations thereof. The core structure is an essential component of the mat and the environmentally resistant material can withstand repeated exposure to rain and snow conditions without deterioration or wear, so the mat will be used initially and for some time. It is designed to provide sufficient strength and rigidity to the mat even after it has been used.

One outer layer forms the upper surface of the mat and another outer layer forms the lower surface of the mat. Optionally, an additional layer containing one or more components in the form of a sheet, a plurality of elongated members, or a combination thereof can be present to attach the at least one outer layer to the core structure. .. Preferably, the at least one outer layer is detachably attached to the core structure either directly or indirectly by bolting. The component of the at least one outer layer typically has an elastic modulus of about 1.6 Mpsi.

In a preferred configuration, the structural components of the core structure are elongated members of the thermoplastic or thermosetting plastic material, and solid or perforated plates or sheets (ie holes or holes) of the thermoplastic or thermosetting plastic material. A plate or sheet containing a random or orderly set of) is provided with two outer layers, one outer layer containing multiple elongated members of wood or processed wood, forming the top surface of the mat. , Another outer layer forms the underside of the mat and contains a thermoplastic material, a thermosetting plastic material, or an elastomer material in the form of an elongated member, solid or perforated plate or sheet structure or grid or lattice. , The latter two are specific embodiments of a plate or sheet structure with openings.

Another embodiment of the invention relates to a method of extending the life of an industrial mat having wooden components. This method is a step of constructing an industrial mat to have a core structure that provides strength and rigidity to the mat, the core structure comprising a sheet, multiple elongated members, a frame, multiple compartments, or a combination thereof. Provided as one or more structural components, with steps in which the components of the core structure are made of environmentally resistant non-wood material, and attached directly to or indirectly through the core structure. A step of providing at least one removable outer layer that forms either the top or bottom surface of the mat, or both the top and bottom surfaces of the mat, wherein the at least one removable outer layer is Includes elongated members made of wood, processed wood, thermoplastics, thermosetting plastics, or elastomers to provide the mat with abrasion resistance, abrasion resistance, and abuse resistance, at least one of the above. The material of the elongate member of the outer layer comprises different steps from the material of the structural components of the core structure. The method is then protected while replacing at least one outer layer elongated member that has been damaged or worn during use by removing one or more of the damaged or worn elongated members. The non-degraded core structure comprises the step of regenerating the mat by reusing it to form a regenerated mat in which the at least one outer layer elongated member or other component has been replaced.

In this method, the at least one outer layer component can be attached to the mat by a bolted configuration and can be removed by loosening the bolted configuration. The replacement component is then attached to the core structure using the same bolted configuration.

In addition, the mat can include beams or bumper members made of wood or plastic material provided on the longitudinal sides of the core structure to protect the core structure from damage due to transport or installation of the mat. The beam or bumper member is optionally also provided at the end of the core structure. The beam or bumper member is also configured to be removable and attachable to the core structure so that it can be replaced when damaged to form a recycled mat with the beam or bumper member replaced. ing.

The mats of the present invention are usually designed to provide sufficient load bearing capacity. A fully supported mat (a mat properly placed on a properly leveled ground surface) is 12 inches (30.48 cm) in diameter without degrading the properties of the mat or causing permanent deformation of the mat. Must withstand a load of 10 tons per surface. The support structure, depending on the individual construction of the support structure, has a compression resistance of between about 500 and 800 psi and as much as 1000 psi when properly installed on a properly leveled ground surface. This provides compression resistance when a large vehicle or device moves on or is placed on the mat, avoiding permanent deformation of the core structure.

The core structure can be any of a plurality of elongated tubular members made of metal, thermoplastic material, or thermosetting material, each tubular member being the same material or a different material. Sometimes it is hollow, sometimes it is solid, or it is an independent member, and sometimes it is connected to form an integral component. Thermoplastic materials, thermosetting materials, elastomer materials, or polyolefin materials can be present in sheet form, or in solid or honeycomb structure. Honeycomb structures can have closed or open cells. Honeycomb cells can optionally include fillers to increase the weight of the mat and to control, eliminate, or achieve liquid absorption. If desired, when the open cell of the core structure comprises a filler, an upper sheet and a lower sheet can be included to help hold the filler in the cell.

Another embodiment of the present invention is a crane mat having a top surface and a bottom surface, wherein the first and second side beams having the top surface, the side surface, and the bottom surface, and the first side beam and the second side beam. A non-wooden support structure that is located between and connects the first side beam and the second side beam, and a plurality of connecting rods that attach the side beams to the support structure, and are connecting rods that pass through the sides of the beam and the support structure. And a first plurality of elongated members attached to the upper portion of the support structure. The support structure has an upper part, a lower part, and a side part, has a height smaller than the height of the side beam, has a width and a length, and is connected to each other by a plurality of cross members. And has a second longitudinal member.

The upper surface of the mat is substantially flat and is formed by the upper surface of the beam, the first plurality of elongated members, or both. The mat can include a second plurality of elongated members that are attached to the lower portion of the support structure. The bottom surface of the mat can be substantially flat and is formed by the bottom surface of the beam, the second plurality of elongated members, or both.

Connecting rods typically include bolts that pass through the side beams and support cores. Preferably, the beam and longitudinal member include a tubular sleeve that facilitates the passage of bolts through it for mat assembly. The first and second elongated members typically have the same thickness, each connecting rod preferably comprises a root angle bolt and nut configuration, where the bolt is a side beam and longitudinal member of the support structure. It passes through the sleeve in the central area of the and is secured in place by the nut.

The beams are generally between about 1 x 6 inches (2.54 x 15.24 cm) and about 24 x 24 inches (60.96 x 60.96 cm), or about 6 x 6 inches (15.24 x 15. It has width and height dimensions between 24 cm) and about 16 x 16 inches (40.64 x 40.64 cm), and the first and second longitudinal members are about 10 to about 30 inches (25. They are connected to each other by cross members that are 4 to 76.2 cm apart, the connecting rods are about 3 to about 6 feet (91.44 to 182.88 cm) apart, and the mats are about 4 to about 8 feet (121). It has a width between .92 and 243.84 cm and a length between about 4 and about 60 feet (121.92 to 1828.8 cm).

In a preferred embodiment, the side beams can be composed of solid cut wood, processed timber, or thermosetting plastic, and the first and second longitudinal members are flat plates in contact with the side beams. It is configured as an I-shaped beam or a rectangular or C-shaped beam. The cross member can be configured as a flat plate and an I-shaped or C-shaped beam, and the plurality of elongated members is a board composed of solid cut wood, processed timber, or thermosetting plastic. .. The elongated member is bolted to the support structure.

The first and second longitudinal members of the support structure and the plurality of cross members usually form a frame, the mat having a width of 4 to 8 feet (121.92 to 243.84 cm), and the support structure. Has a width of about 2 to 8 times the width of one side beam, and the mat has a width of about 4 to 12 times the width of one side beam.

The side beams generally have the same dimensions, with their top surface positioned approximately 1.5 to 3 inches (3.81 to 7.62 cm) above the support structure and their bottom surface approximately 1.5 to 1.5 cm above the support structure. Attached to the support structure to be located 3 inches (3.81 to 7.62 cm) below, the first and second elongated members are approximately 1.5 to 3 inches (3.81 to 7.62 cm). ) To provide a substantially flat top and bottom surface of the mat.

To provide an interlock structure for adjacent mats to be connected, the first side beam of the mat is sized to provide about half the height of the mat and the first side beam. Is attached to the upper part of the support structure. Alternatively, or in addition to this, the second side beam can be sized to provide half the height of the mat and in the lower position on the second side of the support structure. It is attached. In order to stabilize certain of these mats, an additional first beam of the same dimensions as the first beam is provided and placed below the first side beam of the first mat. An additional second side beam of the same dimensions as the second beam was provided and placed on top of the second side beam of another mat to provide a substantially flat top and bottom of the connected structure. Stabilize the outermost side of the connected structure.

Yet another embodiment of the invention includes a support structure in the form of a frame or ladder structure having longitudinal and end sides of the mat, the support structure comprising other components forming the mat. With respect to a mat that is configured to support or allow attachment of other components that form the mat. The mat includes an additional layer of elongated members that are attached above or below the support structure, or both above and below, to form the top or bottom surface of the mat, or both the top and bottom surfaces. The mat also includes a bumper member that is removablely attached to at least the longitudinal sides of the frame or rudder structure to protect it from damage from lateral collisions during transport or installation of the mat. The bumper is made of a plastic or elastomeric material and has a shape that provides an outer surface that extends beyond the sides of the support structure and has sufficient compression to absorb collisions and shocks and protect the support structure. The bumper member is removable so that it can be replaced in case of damage, and the support structure and the upper and lower layers of the elongated member can be reused. In addition, the upper and lower layers of the elongated member can also be replaced when needed and the environmentally resistant support structure can be reused.

The longitudinal side of the support structure can include an I-beam with an open cavity facing outward, and a bumper is attached to the I-beam and fits into the cavity of the I-beam. Alternatively, the longitudinal side of the support structure can include a beam with a flat outer surface, the bumper being provided with an additional member or lip that holds the bumper in place in contact with the flat outer surface of the beam. Positioned adjacent to. Other bumper embodiments are also disclosed herein.

In another preferred embodiment, the support structure is composed of a rectangular tube member made of steel or hollow, filled hollow, or solid, glass fiber reinforced thermosetting plastic material, and is an elongated member. Consists of wood, processed wood, or thermoplastic or thermosetting plastic materials. Also, the open area of the support structure is a wooden board that gives the mat greater weight, compressive strength, or toughness, and the core of the wooden board is configured to fit into the holes in the support structure. Wooden boards bolted to each other so that they do not move inside the mat, recycled rubber tire materials located within the open area of the support structure, sand, or other particulate or solid filler, the particulate filler. A filler that is held in place within the support structure by a mesh, screen, or sheet secured to the top and bottom of the support structure, or a foam or extrusion polymer material that is located within the open area of the support structure. One or a combination of these can be provided.

To protect the mat from transport or installation damage, the mat may include a protective member at least on the longitudinal sides of the core structure to protect the core structure from transport or installation damage to the mat. These protective members can be beams or bumpers made of wood or plastic material and can also be provided at the front and rear ends of the core structure.

When protective members are provided, a preferred embodiment includes a frame configured to support the core mat and form a perimeter around the core mat, and upper and lower layers that protect the top and bottom surfaces of the core. Can include. This frame includes a steel I-beam, which is advantageous because the bumper is received in the outer cavity of the I-beam. Alternatively, the box-shaped frame is composed of a rectangular tube member of glass fiber reinforced plastic, and the bumper rests on the outside of each box-shaped frame member. The bumper can extend over the top and bottom of the mat. Alternatively, the bumper is held in place by the lip members associated with the upper and lower layers of the mat. If desired, the lip member can also be integrated with the upper and lower layers of the mat.

Bumpers are generally configured with a narrow upper and lower profile and a wider central profile for mat mounting, and the upper and lower layers are made of plastic or elastomeric material. Elastomer. If desired, the box-shaped frame member can also be filled with inserts such as molded solids, foams, or pellet materials. For brevity, the box frame structure is protected by a wooden structure positioned adjacent to the outside. The core may be a molded solid or foam material, or it may be made of oak.

Lifting elements including D-shaped rings, O-shaped rings, chains, or cables connected directly to the steel members are provided to lift and move the mat when the support structure contains steel members. Allows the mat to be lifted overhead. To improve the environmental resistance of the mat, the steel members of the support structure can be coated or painted.

Finally, the mat is embedded in a radio frequency identification (RFID) tag, elongated member that allows the mat to be monitored when used in an inventory system or for rent, at night or bad. Identify lighting elements that provide light to aid the use of mats in the dark daytime due to weather conditions, or mat configurations, identify mats for specific customers or end users, or rent or lease mats It can include one or more of color coding, indicating that it is.

The accompanying drawings provide additional details of the present invention.

It is a development view which shows one Embodiment of the mat of this invention which includes the core structure of the glass fiber reinforced polyester beam and the outer wooden board layer. It is a side view which shows the reinforced polyester beam used in the mat of FIG. It is a figure which shows the mat of the assembled state of FIG. It is a perspective view which shows another embodiment of the mat of this invention for demonstrating the open cell honeycomb structure of a core. FIG. 5 is a perspective view showing another embodiment of the mat of the present invention showing the presence of an open cell hexagonal honeycomb structure for the core structure and an additional sheet member for holding the particulate filler in the cell. FIG. 5 is a developed view showing a mat including a steel I-beam frame, a wooden exodermis, a foam core structure, and bumpers on all sides of the mat. FIG. 5 is a developed view showing a mat including a steel I-beam frame, a polymer outer skin, a foam core, and bumpers on all sides of the mat. FIG. 5 is a development view showing a mat including a glass fiber reinforced tube compartment frame, a polymeric outer skin, a foam core structure interlocking with the outer skin, and bumpers on all sides of the mat. FIG. 5 is a development view showing a mat including a glass fiber reinforced tube compartment frame, a polymeric outer skin, a foam core structure interlocking with the outer skin, and bumpers on all sides of the mat. FIG. 5 is a development showing a mat including a glass fiber reinforced tube compartment frame, a wooden board, a laminated oak core structure, and an outer oak edge structure that protects the tube section. FIG. 5 is a developed view showing a mat including a metal frame, upper and lower wooden boards, and wooden bumpers. It is a perspective view which shows the other embodiment of the mat by this invention. FIG. 12 is a developed view of the mat of FIG. 12 showing the various components presented herein. It is a perspective view which shows the support structure of the mat of FIG. It is a perspective view which shows the still another embodiment of the mat by this invention. It is a partial cross-sectional view which shows the support structure of the mat of FIG. It is a figure which shows the specific peripheral component of the mat of FIG. It is a perspective view which shows the crane or the pipeline mat by this invention. It is a development view which shows the crane or the pipeline mat of FIG. It is a development view which shows the interlock type mat which has a steel frame and a wooden block core. It is a figure which shows the state which made the mat of FIG. 20, which shows the frame and the core structure which were welded by removing a part of a corner. It is a developed view which shows the interlock type mat which has the lattice of the glass fiber reinforced thermosetting material. It is a figure which shows the state which assembled the mat of FIG.

Here, the present invention provides an improved mat having better environmental resistance by providing a core structure made of an environmentally resistant material. The term "environmentally resistant material" means a material that does not deteriorate due to water, moisture, or other environmental conditions as compared to traditional wood materials such as white oak commonly used for such mats. In addition to the thermoplastic and thermosetting materials disclosed herein, the term also includes elastomers and even metals such as steel, aluminum, or stainless steel. Steel rusts when exposed to moisture or water, but this is a surface phenomenon that does not affect the physical properties of the material and merely spoils the appearance of its surface and is not considered a deterioration of the material. To avoid this, the steel components can be coated or painted to provide a better appearance and additional environmental resistance. Under certain conditions, treated wood can withstand rot and deterioration better than untreated wood and will therefore be considered an environmentally resistant material due to its increased resistance to rot.

The present invention provides several different mats, each having an environmentally resistant core and including replaceable elongated members such as wooden, plastic or elastomeric boards on the top and / or bottom of the mat. While these members can be replaced when worn or damaged, the environmentally resistant core can be reused and equipped with new elongated members. The core is usually composed of steel components, thermoplastic members, thermoplastic units, and thermosetting lattices.

The new and improved industrial mats of the present invention offer additional advantages over conventional mats. For one thing, by using a non-wooden support structure, it protects the timber resources that were being cut down to form the long beams for building the mat. Currently, at best only wooden side beams are used with the support structure to form the remaining width of the mat. In a preferred configuration, the support structure may not be flush with the side beams and other thinner elongated members may be applied to the top and bottom of the support structure to make the top and bottom surfaces of the mat substantially uniform. To do so. Although these members are made of wood, they may be short in length and thin in cross section.

The wooden member of the mat is preferably made of a hard material such as white oak, red oak, beech, hickory, pecan, ash, or a combination thereof. Alternatively, the processed wood described herein can be used. Since the treated pine wood is a low-cost and easily available wood, it may be used as a filler.

In other embodiments, glass fiber reinforced thermosetting resins, generally in the form of pultruded articles, are used for the side beams and elongated members to allow basically any wood as a structural component in the core structure of the mat. Avoid being used. This further protects wood resources. As described herein, wood or other material can be used as a filler in the core structure if necessary or desired to recycle materials that would otherwise need to be scrapped. This is because those components are used only to give weight, not to give strength to the mat.

The term "glass fiber reinforced thermocurable plastic material" or "glass fiber reinforced plastic" is generally reinforced with glass fiber or other types of fibrous reinforcing materials such as carbon fiber, aramid fiber, genbuiwa fiber or other fiber material. It means a heat-curable material. The thermosetting material is usually polyester, epoxy, vinyl ester, or phenol formaldehyde resin. Those skilled in the art are familiar with these materials and equivalent materials suitable to meet this definition.

The non-wooden support structure allows this component to be reused if the side beam or elongated member is damaged or deteriorated by use and by exposure to harsh environmental conditions. .. Composed of a more robust and environmentally resistant material, the connecting rod is detached to disassemble the mat, the damaged side beams or elongated members are removed, and then new components are added to the structure to make new A mat can be formed. In fact, this reduces the demand for wooden beams or slender members by as much as 50% to 100%.

To aid in the understanding of the present invention, the specific terms used herein are defined below.

The term "industrial mat" has a width of at least about 4 feet (121.92 cm) and a length in the range of about 4 feet (121.92 cm) to 40 feet (1219.2 cm), at least about 1 x 6 inches. A square or rectangular cross section measuring (2.54 x 15.24 cm) to 24 x 24 inches (60.96 x 60.96 cm) and approximately 4 feet (121.92 cm) to 40 feet (1219.2 cm) or more. It is intended to cover relatively large mats that incorporate elongated members, beams, or other components of length. Preferred dimensions are described throughout the specification. As described, this type of conventional and current mats on the market are mainly constructed from a single piece of wood.

The term "non-wooden" used to describe the support structure is used in its usual sense. The components of this structure are generally not wood, but instead metal, thermosetting plastic, or environmental factors such as water, snow, or ice moisture, microorganisms that can spoil wood, or similar wood. Consists of other materials that are resistant to deterioration due to external factors that affect.

The term "substantially" is used in its usual sense to indicate that the dimensions are not exact or accurate. Those skilled in the art can easily determine how much margin of error is acceptable to form a surface that is considered flat, based on the size of the side beams and the type of service the mat is expected to provide. Can be decided. There is no requirement that the beams and slender members be flush with each other along the top and bottom surfaces of the mat. Generally, the term "substantially" means that the top surfaces of the beams and elongated members may vary by as many as an inch (cm), but in a more preferred embodiment the variation is 1 inch (2. It is less than 54 cm).

In addition, all dimensions described herein are approximate and can vary from ± 10% to ± 25% in some cases. In some situations, the term "about" is used to indicate this margin of error. Also, when the term "about" is used before stating a range, it is understood that the term is applicable to each value described in that range. Due to proficiency and the technical steps taken in constructing these mats, these margins of error are often minimized as much as possible or as industrially feasible as possible.

The present invention contemplates the use of various components in a matte structure. Generally, an elongated member of a wooden board is used, but the term "elongated member" as used herein includes a wooden board or otherwise has a rectangular cross section, preferably the total length of the mat. It means a structure having a length of. However, shorter lengths of these structures can typically be used by bolting them to other components to form a mat. These elongated members are usually solid, but may be hollow tubular components, which are optionally filled with other materials such as foam or particles. The size of such elongated members ranges from about 1 to 4 inches (2.54 to 10.16 cm) in thickness and about 6 to 12 inches (15.24 to 30.48 cm) in width, and is usually long. The length of the mat. If desired, shorter boards can be used, and shorter boards are often used when the mat is longer than 20 feet (609.6 cm), but if possible, the total length of the board It is preferably the total length of the mat. Lengths of 12 to 16 feet (365.76 to 487.68 cm) are common. For solid members, the preferred dimensions are 2 inches (5.08 cm) thick, 8 inches (20.32 cm) wide, and the same length as the length of the mat (eg, 12, 14, or 16). Often feet (365.76, 426.72, or 487.68 cm), but may be higher if desired).

In other embodiments, the components of the form of the structured unit are utilized. This is a cell or other to provide holes to be solid or to reduce weight, or to facilitate the connection of components by bolting or permanent or other non-permanent means. It can be a sheet or plate or layer containing the holes of. Typically, the size of such a unit is about 1 to 4 inches (2.54 to 10.16 cm) thick, about 4 to 12 inches wide (10.16 to 30.48 cm), and length. Usually the length of the mat. Also, for large mats, multiple units may be used, such as units that are part of the size of the mat (eg, 1/3 or 1/2). Preferred dimensions are about 2 to 4 inches (5.08 to 10.16 cm) thick, 8 feet (243.84 cm) wide, and the same length as the length of the mat (eg 12, 14, Or 16 feet (487.68 cm), but may be longer if desired).

Normally, bolting removes the components of the mat's outer layer, allowing the mat's environmentally resistant core to be reused in the event of damage or deterioration, while removing other components. It is used because it allows it to be exchanged for elements. In certain mats, some or all of the components used can be permanently connected by welding or adhesive.

A wide range of thermoplastic or polymeric materials can be used in the core structure of the mat of the present invention. These materials are molded or cast to the desired size and thickness of the mat. Useful materials include:
Acrylonitrile Butadiene Styrene (ABS)
Acrylic resin (PMA)
Celluloid Cellulose Acetate Cyclic Olefin Copolymer (COC)
Ethylene Vinyl Acetate (EVA)
Ethylene vinyl alcohol (EBOH)
Fluororesin (PTFE, as well as FEP, PFA, CTFE, ECTFE, ETFE)
Ionomer Kydex, Trademark of Acrylic Resin / PVC Alloy Liquid Crystal Polymer (LCP)
Polyacetal (POM or acetal)
Polyacrylic acid (acrylic resin)
Polyacrylonitrile (PAN or acrylonitrile)
Polyamide (PA or nylon)
Polyamide-imide (PAI)
Polyaryletherketone (PAEK or ketone)
Polybutadiene (PBD)
Polybutylene (PB)
Polybutylene terephthalate (PBT)
Polycaprolactone (PCI)
Polychlorotrifluoroethylene (PCTFE)
Polyethylene terephthalate (PET)
Polycyclohexylenedimethylene methylene terephthalate (PC (PC) T)
Polycarbonate Polyhydroxyalkanoic acid (PHA)
Polyketone (PK)
Polyethylene (PE)
Polyetheretherketone (PEEK)
Polyetherketone Ketone (PEKK)
Polyetherimide (PEI)
Polyether sulfone (PES)
Chlorinated polyethylene (PEC)
Polyimide (PI)
Polylactic acid (PLA)
Polymethylpentene (PMP)
Polyphenylene oxide (PPO)
Polyphenylene sulfide (PPS)
Polyphthalamide (PPA)
Polypropylene (PP)
Polystyrene (PS)
Polysulfone (PSU)
Polytrimethylene terephthalate (PTT)
Polyurethane (PU)
Polysulfone (PSU)
Polytrimethylene terephthalate (PTT)
Polyvinyl chloride (PVC)
Polyvinylidene chloride (PVDC)
Styrene acrylonitrile (SAN)

Further, a fiberboard can also be used as an elongated member or sheet forming a core structure. The fiberboard material is composed of a plastic material or a polymer material that is recycled from used carpets and plastic packaging. The fiberboard can be prepared in the desired size for use as the core material of the mat of the present invention. In addition to being environmentally resistant due to the plastic inclusions, these fiberboards are environmentally friendly by allowing the recycling of used materials containing plastic or polymeric materials.

The core structure can also be constructed of elastomeric material. Elastomers are usually thermosetting (requires vulcanization), but can also be thermoplastic. The following are typical elastomers.
Unsaturated rubber that can be cured by sulfur vulcanization. These are preferable from the viewpoint of strength and hardness. Unsaturated rubber
Natural polyisoprene: Natural rubber cis-1, 4 polyisoprene and gutta-percha trans-1, 4 polyisoprene,
Synthetic polyisoprene,
Polybutadiene,
Chloroprene rubber, ie polychloroprene,
Butyl rubber containing halogenated butyl rubber (chlorobutyl rubber, bromobutyl rubber) (ie, copolymer of isobutylene and isoprene),
Includes styrene-butadiene rubber (copolymer of styrene and butadiene), and nitrile rubber (copolymer of butadiene and acrylonitrile).
Saturated (ie non-vulcanizable) rubber. Saturated rubber
Ethylene propylene rubber (EPM),
Ethylene propylene diene rubber (EPDM),
Epichlorohydrin rubber,
Polyacrylic acid rubber,
silicone rubber,
Fluorosilicone rubber,
Fluoroelastomer Perfluoroelastomer,
Includes boroether blockamide, and chlorosulfonated polyethylene.

Elastomer materials, thermoplastic materials, or thermosetting materials disclosed herein can also be provided with conventional fillers to increase weight and hardness. The materials can also be reinforced with fine particles, fibers such as glass, fiber or metal screens or scrims to reduce elongation and increase rigidity. Further, when the entire mat is composed of an elastomer material, a thermoplastic material, or a thermosetting material, the entire mat can be configured as an integral component.

The polymer or elastomer core structure can be configured as a flat sheet as long as it has the required weight and rigidity. These variables can be controlled by selecting specific macromolecules or by giving the core a specific configuration. For example, the core structure can be composed of a honeycomb structure or an open cell structure.

The term "honeycomb structure" refers to a structure with holes or open cells that can be used to reduce weight or can be filled with other materials. The shape of the cell can be hexagonal, square, rectangular, or another polygon, or it can be round. The cells may be adjacent or separated from each other as desired, and may extend horizontally or vertically.

This structure allows the weight of the mat to be increased, and the honeycomb-structured cells of the core structure can be made of particles of sand, mud, gravel, plastic, ceramic, glass or other materials, various foam materials, or above ground. The resistance to liquid absorption can be improved by filling with one or more of various materials, such as recycled materials such as vehicle tires or particles of other recyclable materials. It is preferable to fill the core structure with recycled material in order to provide an environmentally friendly or "green" mat.

The plastic core structure can also be provided as two vertically bisected compartments, namely an upper compartment and a lower compartment. The upper compartment is designed with protrusions or uneven areas on its lower surface, and the lower compartment is designed with complementary recesses or bumps on the surface facing the upper compartment. The upper compartment and the lower compartment can be connected by engaging the recesses with the recesses or by engaging the uneven regions with each other.

Alternatively, the core structure can be configured with a metal frame or rudder structure. Generally, steel, stainless steel, or aluminum is used, and the frame or structure can be bolted, riveted, or welded. If the metal frame or structure is made of steel, by galvanizing, painting, or otherwise depositing a powder or liquid coating material on it to prevent moisture from coming into contact with the steel. It can be further protected. For example, when made of steel, the entire core structure can be coated with paint or thermoplastic or thermosetting resin.

The metal frame or rudder structure can be used out of the box or is configured with a net, mesh or other material that allows the filler to be fed into any frame hole to correct the weight of the mat. It can also be. If it is desirable to add weight, heavier fillers can be used. To fill the inner compartment of the frame without significantly increasing the weight of the mat, low density particle or foam plastic or rubber filler can be used.

The mat in the assembled state in the preferred embodiment may vary depending on the type of mat here. Two- or three-tiered laminated mats typically have a width of about 8 feet (243.84 cm) and a length of about 12, 14 or 16 feet (365.76, 426.72, or 487.68 cm). It is a mat and contains an elongated member of about 2 x 8 inches (5.08 x 20.32 cm cm). A typical industrial mat typically has a thickness of about 6 inches (15.24 cm), which is 2 inches (5.08 cm) or 4 inches (10.16 cm) thick. It consists of a core structure, an upper layer 2 inches (5.08 cm) thick, and a lower layer 2 inches (5.08 cm) thick. In a 3-layer mat, each layer is 2 inches (5.08 cm) thick, while in a 2-layer mat, the core is 4 inches (10.16 cm) thick and the upper outer layer is 2 inches thick. It becomes (5.08 cm). For cranes or mining mats, the width is about 4 to 8 feet (121.92 to 243.84 cm) and the beams are 6 x 6 inches (15.24 x 15.24 cm), 8 x 8 inches (20.32 x). It has typical width and height dimensions of 20.32 cm), 10 x 10 inches (25.4 x 25.4 cm), or 12 x 12 inches (30.48 x 30.48 cm) and is approximately It will have a length between 20 feet (609.6 cm) and 40 feet (1219.2 cm). The core structure is any environmentally resistant material disclosed herein and can be configured in any desired shape and configuration. The number of top, bottom, and core structural components is determined by the final dimensions of the mat for a particular application or end application. Also preferred embodiments will include a spacing of less than about 1.5 inches (3.81 cm) between the top board, the center board, and the bottom board.

The core structure can be composed of various environmentally resistant materials. For example, the core structure of a sheet or plate of a thermoplastic or thermosetting material can include a thin metal sheet for further reinforcement or to maintain the filler in the cell or hole of the sheet or plate. .. Steel sheets can be used to stiffen the core structure on top of a layer of thermoplastic material in the form of a sheet or other structure.

The core structure, constructed of environmentally resistant materials, prevents deterioration due to exposure to various weather conditions when water or other liquids enter the core. Specific preferred and specific environmentally resistant materials having a core structure include the following.
Various thermosetting materials such as epoxy, melamine formaldehyde (MF), phenol formaldehyde (PF), polyester, polyurethane (PU), polyimide (PI), silicone (SI), or urea formaldehyde (UF). These materials can be reinforced with fibers or fillers (carbon, glass, metal, etc.).
Thermoplastic materials (any of the various plastics mentioned above herein), and in particular HDPE, PET, and SBR disclosed in US Pat. No. 6,380,309.
A honeycomb structure comprising a filled cell and upper and lower plate surfaces constructed by molding or otherwise, as disclosed in US Pat. No. 806 1929.
An open surface filled cell structure of a thermoplastic resin, polyolefin, or vulcanized rubber disclosed in US Pat. No. 6,51,257.
Molded sheet of thermoplastic resin disclosed in US Pat. No. 5,888,612.
A metal structure or frame of coated, painted, or galvanized aluminum or stainless steel or steel to help prevent rusting when in contact with water.
Reinforcing plastic composition material disclosed in US Pat. No. 4,629,358.

The edges of the core structure shall be protected as disclosed in U.S. Patent Application No. 2014/01/93196, or with a wooden or synthetic laminate to avoid mechanical damage to the edges of the core structure. Can be done. In addition, the wood or plastic material bumper structures described herein can also be used.

In certain open cell core structures, reinforcement with sheets or other cell closure materials can be used to improve the stiffness and strength of the core structure while retaining the filler in the cells or holes.

Moreover, a metal plate can also be used as a core. The metal plate can include holes or openings to reduce weight. A thermosetting plastic plate may be used instead, and the thermosetting plastic plate may be solid or may have holes. These boards can be 2 to 4 inches (5.08 to 10.16 cm) thick. Glass fiber reinforced thermosetting plastic grids with 2 x 2 inch (5.08 x 5.08 cm) or 3 x 3 inch (7.62 x 7.62 cm) holes are preferred.

In order to reduce the weight of the mat, the core structure may be a honeycomb structure, a lath structure, or a structure having a plurality of holes. In high opening structures, cells or holes can be filled with a material lighter than metal as described above in order to maintain the weight at the desired level. The holes can be covered with an upper sheet and / or a lower sheet to hold the filler therein. Any material can be used for the sheet as long as the metal core structure provides the mat with the required strength and rigidity. Generally, the sheet can be plywood, plastic, metal, or composite and may be in solid or mesh form. The sheet can preferably be riveted, bolted, or glued to the mat. The seat and core structure can be held in place by holding the entire structure together by bolting or riveting and sandwiching it between the outer layers. If desired, holes for bolts or other fixtures can be drilled in the metal plate or sheet to allow the fixtures to pass through and facilitate assembly.

In general, a mat construction of laminated mats includes one of the cores disclosed herein and an upper or lower layer of elongated members or beams. In the upper and lower layers, the beam thickness is about 1.75 inches (4.45 cm), but between 1.5 inches (3.81 cm) and 3 inches (7.62 cm). Can be done. The length will be as desired, but is preferably 12, 14, or 16 feet (365.76, 426.72, or 487.68 cm). The width of the beam varies depending on its position on the core. That is, the width of the top and bottom layer boards is approximately 8 inches (20.32 cm) (single width) or 16 inches (40.64 cm) (double width). "About" means that they may be slightly smaller, such as 7.5 to 8.5 inches (19.05 to 21.59 cm) or 15 to 17 inches (38.1 to 43.18 cm). ing. The typical thickness of the mat is at least about 4 inches (10.16 cm), preferably about 6 inches (15.24 cm), with a central layer of about 1 to 4 inches (2.54 to 10.16 cm). ), And the upper and lower layers form a thickness of about 1 to 3 inches (7.62 cm). Of course, these dimensions can vary depending on the intended specific end use of the mat. Beams can also be manufactured to any particular thickness, width, and length, but the preferred dimensions disclosed herein are made of white oak or other materials used in the art. The dimensions are close to the dimensions of conventional mats.

In one of the most preferred embodiments, the mat comprises a core structure of environmentally resistant material, an outer upper layer positioned above the core structure, and an outer lower layer positioned below the core. , Each outer layer contains a plurality of elongated members, each having an elastic modulus of 1.6 MPa. As mentioned above, the core structure is composed of a material that provides a load bearing capacity capable of withstanding a load of at least 600 to 800 psi or more without damaging or permanently deforming the core structure.

The core structure can include one or two outer layers, depending on the desired or required to obtain a particular installation condition and stiffness. The components of the core structure can consist of a plurality of compartments or smaller portions that are connected to each other to form the desired size of the core. As an example, in a thermoplastic core structure of HDPE, multiple compartments can be welded to form the desired size, eg, 4 x 8 feet (121.92 x 243.84 cm) compartments of 4 HDPEs. A mat core structure of 8 x 16 feet (243.84 x 487.68 cm) can be formed. Similarly, eight 4x4 ft (121.92 x 121.92 cm) compartments can be joined by welding to form the same 8 x 16 ft (243.84 x 487.68 cm) mat. The same applies to components made of wood, metal, or elastomers, which can be mechanically connected by glue or, where applicable, by welding. The core structure can also consist of upper and lower halves that can be connected to each other by welding or mechanical interlocking, or by fixtures or adhesives.

Additional layers or components can be added to the core structure or mat, but the most preferred constructs include outer layers above and below the core structure, as described herein. The outer layer consists of white oak as disclosed in US Pat. Nos. 4,462,712 (three layers) and 582,944 (two layers), each of which is expressly incorporated herein by reference. It is preferable to do so. These mats are generally designed with a channel for draining water from the mat on one or more outer layers. This is achieved by spacing the elongated members or by providing grooves on the sheet or other wide surface provided on the outermost layer of the mat. These grooves are generally rectangular and typically have a width of about 1.25 inches (3.175 cm) and a depth of about 1 inch (2.54 cm). Of course, as long as the same purpose of forming a pathway for removing water from the mat is achieved, it is also appropriate to use a channel that is U-shaped rather than rectangular and has a similar size.

Also, symmetrically formed mats are preferred, but it is also possible to provide a core structure in which the number of layers or steps on one surface is different from the number of layers or steps on another surface. For example, on the upper surface of the core, components such as an elongated member or a sheet member may have two layers or two stages, and on the lower layer, these components may have only one layer or one stage. Also, the material used for the components of one outer layer does not necessarily have to be the same as the material used for the other outer layer. Therefore, mat designers have a wide range of possibilities for mat construction to adjust a particular mat to a particular installation condition or need.

Next, with reference to the drawings, FIG. 1 is a diagram showing a mat 100 containing an upper outer layer 105 and a lower outer layer 110 used to surround the core structure 115. The core structure includes a plurality of reinforced polyester beams 125 and the outer layer includes a single width wooden board 130. The reinforced polyester beam 125 is oriented orthogonally to the upper and lower outer layer boards. As shown in FIG. 2, the reinforced polyester beam 125 is in the form of a rectangular pipe with two inner wall supports 120 extending along the interior of the pipe.

The board 125 is attached to the core structure 115 by nailing, screwing, bolting, or riveting the board 125 to the reinforcing polyester beam 125 of the core structure 115. When using bolting, the bolts can extend from the upper board to the lower board through the reinforced polyester beams 125. The heads and nuts of nails, screws or bolts are recessed below the top surface of the board 130 and below the bottom surface of the board 130 to provide a relatively smooth top and bottom surface of the mat 100.

Alternatively, the board can be attached to the core structure 115 by adhesive or other means of achieving a firm attachment. For example, when the core structure is made of a thermosetting material, the sheet or board can also be made of the same material as an integral component. With a metal core, holes can be drilled to allow bolts to pass through.

As shown in FIGS. 1 and 3, 11 boards are used. The third, sixth, and ninth boards (135, 140, 145, respectively) of the lower outer layer are staggered to form an interlock mechanism for the mat. It is preferable to shift a particular board to achieve interlocking with adjacent mats, but this is not always necessary and interlocking can be considered a desirable but optional mechanism. Interlocks are often preferred to avoid fixing the mats to the ground or to include other more complex components used to connect adjacent mats together.

Although showing interlocking on opposite sides of the mat, the mat can use top or bottom layers and appropriately configure the components of those layers to interlock with each other in any direction. ..

Lifting elements 150 are provided on the third and ninth boards of the upper outer layer. These lifting elements 150 are configured as D-shaped rings so that these rings can be mounted within the recesses 170 of the board so that the lifting elements 150 remain flat during use of the mat 100. It has become. Although two lifting elements are shown, one of ordinary skill in the art can determine how many elements are needed to lift a mat of any particular size. If desired, lifting elements may also be provided on the board mounted on the lower outer layer 110 to increase the flexibility of handling and transporting the mat. The lifting elements are provided on the board attached to the exodermis portion so that if the lifting elements or the board are damaged, they can be easily removed and replaced.

By providing the single width board, the upper and lower moldings can have a channel 175 on the upper surface of the exodermis for draining water from the mat.

FIG. 3 is a diagram showing the final shape and configuration of the mat 100 after assembly.

FIG. 4 is a diagram showing a second mat 200 according to the present invention including a lower outer layer 130 and a core structure 215 having a plurality of cells 260. Since some of the components are the same as those shown in FIGS. 1 to 3, the same reference numbers are used to indicate the same components of the mat of FIG. The core structure 215 can be constructed of thermoplastic resin or metal, and the cells can be left open or filled, as disclosed herein. The core structure can also be a fiberglass reinforced thermosetting material in the form of a grid with square or rectangular holes. The holes or cells of the core structure can be filled with a foam material or other material, which expands to fill the cells 260 and remains attached therein. In this situation, no cover member is needed to hold the filler within the core structure 215. In this situation, or in situations where the cell is filled with particulate matter, the upper and lower layers 130 described above can be attached to the core structure 215 to help retain the particulate material within the cell 260.

FIG. 5 is a diagram showing a third mat 300 according to the present invention, which includes a lower outer layer 130, an upper outer layer 330, and a core structure 315 having a plurality of cells 360. Since some of the components are the same as those shown in FIGS. 1 to 4, the same reference numbers are used to indicate the same components of the mat of FIG. The core structure 315 can be constructed of a thermoplastic material or metal and the cell 360 is hexagonal to provide larger holes and should be left open as disclosed herein. It can also be filled with a fine particle material. In particular, the cell can be filled with a foam material, a particulate material, or other non-adhesive material, such as rubber scraps obtained from recycled automobile tires. In the case of such fine particles, the cell 360 is covered with one or more sheet members above, below, or both above and below the core structure to hold the non-adhesive filler in the cell. Can be done. The sheet member can be composed of a wooden board, plywood, a plastic sheet, or a metal sheet such as steel or aluminum. When the sheet members are provided solely to hold the filler in the cell, they can be relatively thin, for example 1/8 to 1/2 inch (0.3175 to 1.27 cm) is sufficient. However, if desired, it can be made even thicker to increase the weight of the mat. The core structure and seat member can be used in this case as a core structure to which an outer layer is attached, as in other embodiments.

Alternatively, when the sheet member is not needed, the lower layer 130 and the upper layer 330 can be wooden boards that hold the filler in the cell 360, as shown in FIG. In this embodiment, when the core structure 315 is molded from a plastic material, the area between the places where the boards are placed is made up of solid plastic rather than open cells, with the particulate material between the boards. Keep out of the cell from the interval. These boards will have a thickness of 1.6 inches (4.064 cm) or more, depending on the required weight of the mat. The filler is also the weight of the mat.

Of course, if the core structure 315 and the materials of the lower layer 130 and upper layer 330 provide sufficient weight, it is not necessary to fill the cells and no additional sheet members are needed. No additional sheet member is required when filling the cell with an adhesive filler. The upper outer layer and / or the lower outer layer board 130 can be attached by bolts threaded through the cell. If desired, and preferably, the upper outer layer 330 is provided so that the final mat structure has a similar appearance as in FIG.

Another embodiment of the present invention is a modification of the embodiment of FIG. The core structure is composed of a plastic material with cells, which is constructed with a flat top and bottom. These surfaces support the sheet member when the cell is filled and instead support the lower and upper layers when the cell is not filled. Therefore, these cells act as shock absorbers to provide the mat with elastic compressibility.

In a preferred embodiment of the invention, the mat comprises a bumper that protects the sides of the mat from damage during transportation and installation. These bumpers are typically constructed as rails, rods, or beams of material that protect the sides and core structure of the mat from damage when moving the mat from the warehouse to the truck and even to the work site. Since the mat is relatively heavy and weighs about 2000 pounds (907.2 kg), the mat is moved by heavy equipment such as a front-end loader or crane and is usually dragged or dropped in place. The bumper also provides protection against damage to the lateral edges of the mat due to such movement and manipulation, and also provides some resistance to biting into the teeth or nails of the mobile device. In one embodiment, the bumper is made of a durable and sturdy elastic material such as plastic or elastomer, with particular preference being HDPE or rubber material with a Shore D hardness of 10-50. The bumper is preferably molded or extruded into one or more desired shapes for removable attachment to the mat.

FIG. 6 shows a mat 400 configured as a crane / pipeline mat, typically measuring 8 inches (20.32 cm) thick x 4 feet (121.92 cm) wide x 18 feet (548.64 cm) long. It is a figure which shows. They are primarily used in drilling rigs and similar application operations, making these mats much more robust and sturdy than temporary road mats. In order to achieve sufficient strength, it is preferable to include a steel rudder frame 405 that forms a peripheral portion of the mat. The frame 405 includes several cross members that provide the frame with rigidity and strength to support other mat components. Holes are formed to allow the connection and to reduce the total weight of the mat compared to that constructed of solid steel. The core structure 410 is located within the rudder frame 405 and is provided with upper and lower wooden outer skins 415, 420 to protect the core structure 405. The mat core structure 410 is a solid or foam core structure preferably formed from HDPE or a similar polymer. Using a polymer core structure and the geometry / shape of the cell, the total weight of the mat, while providing sufficient internal support to allow the mat to provide the required strength against compression and consolidation. Helps reduce. Wooden skins 415, 420 provide sufficient durability for equipment or vehicles that move on or are supported by this mat. The mat also has holes that allow water or other liquids to pass through during use. Since this core structure is made of environmentally resistant material, it is not necessary to provide an airtight seal around the core structural components of the mat.

As shown in FIG. 6, the bumper 425 is configured as an extruded or molded rail or rod that protects the sides of the mat. Generally, a single bumper structure is provided that is received within the open area of the I-beam that forms the perimeter of the mat. The bumper fits into the open cavity of the I-beam, but has a shape that does not completely fill that area, which allows the bumper to be compressed and absorb the impact. If desired, the bumper can be bolted or riveted to the I-beam, or glued together so that it is held in place.

As shown, the bumper in the enlarged view of the mat 400 is a "+" shaped tri-tube having a large central tube 430A and small tubes 430B and 430C located above and below the central tube. ) Has a structure 430. These tubes can be extruded into the shapes shown, or separate tubes can be made and then joined by welding or adhesive bonding, or by mechanical fixtures. However, this shape is not important, and other shapes, which are round or polygonal, or a combination of various shapes, can be used for the bumper if desired. For certain materials, the bumper may fill the entire open side cavity of the I-beam, or the bumper may contact the inner wall of the I-beam and extend towards the perimeter of the mat for impact. Alternatively, if the impact force can be absorbed, it may be filled only partially.

In other embodiments disclosed herein, the bumper may be made of wood. Wood is a useful, relatively low-cost material with a history of useful mat application operations in oil fields.

The bumpers are preferably located on all sides of the mat. To hold the bumper in place within the I-beam without the use of glue or bolting, the upper and lower layers of the mat are nailed to the upper and lower wooden skins to put the bumper in place. Additional members can be provided to hold and prevent the bumper from coming off the I-beam. The bumper provides protection on the sides of the mat and prevents damage to the components of the core structure.

FIG. 7 is a diagram showing another crane / pipeline mat 500 including a steel rudder frame 505 that also forms a perimeter of the mat. A similar foam core structure 510 is located within the rudder frame 505. However, instead of the upper and lower wooden shells, the mat 500 of FIG. 7 includes an upper vacuum-formed polymer skin 515 and a lower vacuum-formed polymer skin 520 to protect the core structure 510. These exodermis can be formed to a maximum thickness of 0.06 inch (0.1524 cm) or more. These outer skins preferably include a lip 530 that engages with the upper and lower portions of the bumper and holds them in place within the I-beam. Again, the bumper is molded as a plurality of connecting pipes as shown in FIG. 6 having an upper pipe and a lower pipe having a cross section smaller than that of the central pipe. The upper and lower tubes can also be formed to engage in full contact with the inner surface of the I-beam, while recessing from the end of the central tube to allow the lip 530 to keep the bumper in place. .. Other shapes of the bumper are also acceptable as long as the bumper can be fitted within the I-beam to form an outer surface capable of absorbing impact and impact forces. In the illustrated configuration, the tube can collapse to some extent to absorb such forces.

The lip portions of the upper skin 515 and the lower skin 520 may be separate components attached to those layers, or may be molded or formed as an integral part of those layers. Generally, the upper skin 515 and the lower skin 520 are made of molded plastic or elastomeric material, as these materials provide environmental resistance and give the mat durability and toughness. The core structure 510 can also be prepared as two halves, namely the upper halves attached to the upper exodermis and the lower halves attached to the lower exodermis. These halves can be designed with protrusions or concavo-convex regions so that they can be connected to each other by engaging the protrusions with the recesses or engaging the concavo-convex regions with each other. This also reduces installation time and ensures that the core structure and skin interlock to provide the best resistance to compressive forces.

In the embodiments of FIGS. 6 and 7, the steel frame can be painted or coated with sacrificial metal (ie galvanized or phosphoric acid treated) to provide the mat with improved environmental resistance. Steel rust is not harmful to the operation of the mat, but it does not give an aesthetically pleasing appearance, so try to compensate for it by minimizing the rust by painting and coating. Stainless steel can also be used, but this material is more expensive. Aluminum can also be used, but its lightweight construction results in some loss of mat strength. In addition to its strength and ease of processing, the metal rudder frame can be configured so that the lifting element can be attached directly to the frame 505 to provide a more robust connection that facilitates the lifting and operation of the mat. So it is advantageous.

Similar to FIG. 6, the mat of FIG. 7 is reduced in total weight by incorporating the core structure of the foam or structural foam molded into the steel frame. Whether the upper and lower layers are made of wood or of plastic or elastomeric material, the entire structure is bolted or riveted to form the final mat.

In order to further reduce the weight of the mat while also improving the environmental resistance, a box-shaped frame made of glass fiber reinforced plastic (FRP) can be used instead of the steel frame. This is shown in FIG. 8 in a mat 600 having an FRP box-shaped frame 605. The box-shaped frame 605 can be configured with a rectangular or square tubular structure. If desired, the FRP box-shaped frame 605 can be configured as a ladder frame as shown in FIGS. 6 and 7. The FRP frame provides less weight and good durability and resistance to moisture of other liquids that may penetrate the core. To provide additional compression resistance to the frame 605, the open center portion of the tube can be filled with foam, recycled rubber tire material, or other filler 610. Polyurethane foam can also be used for this purpose. The filler can also be selected to increase the weight of the mat, if desired.

The plastic of the FRP material is any one of the types of thermosetting plastics described herein, with thermosetting polyesters and epoxies being preferred.

FIG. 8 also shows another mechanism of the invention in which the molded foam core structure 612 is locked in place by engaging the pocket 617 with the upper polymer skin 615 and the lower polymer skin 620.

When using a box-shaped frame, the bumper 625 is configured with a flat surface that abuts on the frame 605. The bumper 625 is configured to have an upper portion and an outer portion thinner than the central portion of the bumper, and the outer skins 615 and 620 engage with the bumper 625 to press the bumper 625 against the box-shaped frame 605 and hold it in place. The lip 630 to be used can be included. These lips are basically the same as the lips shown in FIG. Since the FRP box frame is not as strong as the steel rudder of FIGS. 6 and 7, the bumper protects the FRP box frame from damage. FRP beams can be made in the draw-molding process, as lead-forming produces lightweight but strong constructs.

In FIG. 8, the upper polymer skin 615 and the lower polymer skin 620 can be configured to include protrusions or honeycombs that interlock with the core structure 612 to form a more rigid structure. Alternatively, the open center of the mat is recycled rubber tire material or other particulate filler, as is done for the central hole of the drawer molded FRP box frame, omitting the foam core structure 612. It can also be filled with.

Alternatively, instead of fitting into the side structure of the mat, the bumper is designed to have a "C" cross section and the bumper is drawn out from the top, sides, and bottom of the FRP box-shaped frame member. It can also be made contactable. The top and bottom surfaces of the bumper may extend above the top and bottom surfaces of the mat, or by making the thickness of the top and bottom bumper portions corresponding to the thickness of the top and bottom layers. It may be designed to remain flush with those faces. Alternatively, the bumper can be bolted, screwed, snap riveted, or glued to the FRP box frame.

FIG. 9 is a diagram showing the same type of mat as in FIG. 8, so the same reference numbers are used in the description. The main difference in the mat 700 of FIG. 9 is that the box-shaped frame 605 is not filled and is in the open state (710) because no filler is required in the specific embodiment. The bumpers of FIGS. 8 and 9 are "T" shaped and have a central portion protruding from the sides of the mat to provide protection for the FRP frame and core.

FIG. 10 is a diagram showing another embodiment of the crane / pipeline mat 800 including the box-shaped frame 805 of a square tube made of FRP. The box-shaped frame 805 surrounds the laminated wooden core 810. The wooden core 810 is heavier than the foam cores of other embodiments, but is much cheaper and can be used in certain facilities where a large weight or toughness of the mat is required. The oak core boards are configured to fit into the holes in the box frame 805 and are bolted together to prevent them from moving inside the mat. The oak board is also used as the top 815 and bottom 820 of the mat 800.

The FRP frame 805 is protected by a rectangular wooden structure 825, also also composed of oak boards. These boards are connected to each other and have approximately the same width and height dimensions as the box frame 805, but the perimeter length such that the structure 825 is located outside and / or adjacent to the box frame 805. Form a longer, square structure. The wooden structure 825 acts as a bumper to protect the FRP box frame from damage during loading, transportation and installation.

To provide additional protection to the box frame 805, an open area of the frame can be equipped with a foam or extruded polymer stabilizer 830. Similar to FIG. 8, the open area can be filled with recycled rubber tire material or other particulate or solid filler. One variant of the stabilizer 830 is shown in FIG. 10, but other embodiments of bumpers and solid foam inserts can also be used, as desired by the mat designer. Wooden structures are most likely to eliminate the need for stabilizers in most facilities.

FIG. 11 is a diagram showing another embodiment of the mat 900 including a frame 905 constructed of a metal such as aluminum, stainless steel, or steel. The frame 905 is composed of a square or rectangular tube that is welded into a high-strength core component of the mat. The frame 905 can remain open as shown, or is held in place by a mesh, screen, or sheet secured to the top and bottom of the frame in the area 910 between the core members. It can also be provided with a fine particle filler or foam. The tube can also be filled with foam, rubber particles, or sand, if desired, to add weight and strength to the mat. If desired, a wooden core can also be used with or in place of the filler. However, these areas are preferably left free of any filler.

The mat 900 includes a top wooden board 920 and a bottom wooden board 925 of oak, which provides a flat surface on which the vehicle or supporting equipment is moved. These boards also form the top and bottom surfaces of the mat and also provide protection for the core structure 905. Further, these boards 920 and 925 have a space between them so that water can be discharged from the upper surface of the mat through the core structure to the outside by the lower surface of the mat. Since the core structure 905 is made of an environmentally resistant material, there is no concern that the core structure will be deteriorated by contact with water. The top and bottom wooden boards are connected to each other around the frame using nails or bolts. Also, the tubular member of the frame 905 may be provided with through holes for accommodating bolts used to attach the wooden boards 920, 925 to the frame 905.

The frame 905 is also protected by a wooden board 915 that forms a replaceable bumper for the frame 905. The wooden board 915 can be attached to the frame by bolts that engage the holes in the tubular member, or can be attached to the upper board 920 or lower board 925. As an alternative connecting member, the frame 905 receives a bumper 915 or upper board 920 or lower board 925 welded to a tubular member by passing through holes in the corresponding positions of those boards, studs or bolts. You can also prepare. These boards can then be secured to the frame with suitable nuts and washers, or by crushing the studs. This provides a simple yet robust construction of the Mat 900 that allows the replacement of boards that can be damaged during use as described. In the embodiments of FIGS. 9-11, the top board can be 1.25 inches (3.175 cm) x 16 inches (40.64 cm) wide, but if desired, smaller compartments can be connected together. You can also do it. The box-shaped frame preferably has a size of about 5.5 x 5.5 inches (13.97 x 13.97 cm) so that the total thickness of the mat is about 6 inches (15.24 cm).

All mats according to the invention are placed on properly leveled ground so that they function reasonably well. Leveling must be done in a uniform material form with a uniform flatness (ie, within ± 12 inches (30.48 cm) on a surface of 8 x 14 feet (243.84 to 426.72 cm)). Stones or rocks less than 4 inches (10.16 cm) in diameter are acceptable for leveling as a base to support the mat.

All mats according to the invention are designed to meet the following product specifications in preferred embodiments of temporary roads, equipment support surfaces, platformes, or similar applications. The mats of the present invention do not cause contamination of the ground surface on which they are placed.

The overall dimensions of the preferred mat are approximately 8 feet (243.84 cm) wide x 6 inches (15.24 cm) thick and 12, 14, or 16 feet (487.68 cm) long. The interlock mechanism extends the length of the mat by about 1 foot (30.48 cm) at three points at one end of the mat. U.S. Pat. No. 4,462,712 discloses mats that include interlocking fingers and recesses, which are preferably used in the present invention.

These mats include two outer layers consisting of individual wooden boards or composite boards, typically having a cross-sectional dimension of 1.75 x 8 inches (4.445 x 20.32 cm).

The spacing between the individual boards or components of the upper outer layer is preferably about 1.25 inches (3.175 cm) to allow water to drain from the mat. This spacing is also retained in the upper portion of the exodermis. Excessive water drainage improves the slip resistance of the mat, especially when used in locations exposed to heavy rain or snow conditions. Spacing between individual boards or components can also be applied to the lower outer layer of the mat to ensure that the mat meshes well with the ground. Spacing or similar grooves in the lower outer layer of the bottom of the mat keep the mat from moving on the ground when there is traffic across the mat. This spacing or groove is even more important when the underside of the mat is made of an elastomer or thermoplastic material, which allows the mat to engage well with the ground and avoid or reduce sliding or sliding on the ground. To do so.

Preferred mats have physical properties that match or exceed the physical properties of conventional white oak mats.

This mat must also provide sufficient load bearing capacity. A fully supported mat (a mat properly placed on a well-leveled ground surface) is 12 inches (30) in diameter without degrading the properties of the mat or permanently deforming the core structure of the mat. It must withstand a load of 10 tons per surface (.48 cm). The core structure has a compression resistance between about 600 and 800 psi, depending on the application. This provides resistance to compression without reducing resistance to torsional forces applied to the mat by vehicles passing over the mat. Generally, the core is designed to provide some degree of compressibility when a large vehicle or device moves on or is placed on the mat. After the vehicle or equipment has been removed from the mat, the mat retains its original thickness. In a moist environment, this can cause some absorption of water into the mat, which is another reason why the components of the core structure are designed to withstand moisture. Also, in some embodiments, the mat can be designed with openings so that all water that enters the mat can escape later.

Preferred crane or mining mat sizes are approximately 6 x 6 inches (15.24 x 15.24 cm), 8 x 8 inches (20.32 x 20.32 cm), or 12 x 12 inches (30.48 cm x 30). Although .48 cm) x 8 feet (243.84 cm) x 20 to 40 feet (609.6 to 1219.2 cm) in length, a related type of mat used with these large mats is the lamp mat ( It is a ramp mat or a transition mat. Both have the same type of configuration as crane mats, but are reduced in size to 3 x 3 inches (7.62 x 7.62 cm) or 4 x 4 inches (10.16 x 10.16 cm) and vary. The length has also been reduced by more than 10 or 20 feet (304.8 or 609.6 feet). These ramp or transition mats are positioned along one or more of the sides or ends of the crane mat to allow heavy machinery to more easily enter larger crane mats. It works effectively as.

Optionally, and preferably, the perimeter of the mat uses a steel track to prevent damage to the mat's core structure from sideways entry into or out of the mat. Or with additional protection to mitigate. This edge material helps protect the core structure and bumper and is preferably easily removable so that it can be replaced when needed.

When plastic materials are used in the core, they are formulated to be relatively flammable. The flammability of the mat shall be defined as Class 2 (B) flame diffusion as measured by ASTM E84 test criteria. The combustion properties of these materials can be improved by adding suitable conventional flame retardant or other additives known to impart such properties.

The core structure can also be formulated to allow the dissipation of static electricity. For this purpose, carbon black, metal particles, or other conductive fillers can be added to the plastic material used for the core. Of course, the metal core structure is conductive without additives.

Although relatively protected by the outer layer, the core, when composed of a plastic material, contains UV inhibitors in an amount sufficient to reduce the deterioration of physical properties or color, if necessary. be able to.

To facilitate the movement of the mats, attachment points can be provided to allow the individual mats to be lifted and handled. The lifting hardware preferably includes a D-shaped ring, an O-shaped ring, a chain, or a cable at two to four locations on the top surface of the outer layer of the mat. Accurate positioning and mounting of the lifting hardware is designed based on the size and weight of the mat and is intended to avoid damage to the mat during transportation and installation.

The core structure of the mat may or may not be hollow. When hollow components are used in the core, whether they are perforated tubes or cells, those pores are preferably filled with a non-absorbable filler. A wide variety of different plastics, elastomers, or foam materials in fine particles or other forms can be used for this purpose. The hollow portion may be used as it is, or may be provided with a filler to increase or decrease the weight as needed. The mat can also be given additional weight or strength, including fillers of glass, ceramic, or metal particles. Other materials, such as recycled rubber tire materials or other environmentally friendly materials, may be used instead. Preferably, the mat has the weight of an oak mat of similar size.

When the elongated members are used in the upper and lower layers of the core structure structure, the elongated members provide additional weight to the mat and can be constructed in various ways. One method duplicates a conventional oak mat and 11 pieces 6 inches (15.24 cm) wide (x 12, 14, or 16 feet long (365.76, 426.72, or 487.68 cm)). ) Boards are provided in the upper and lower layers, and the three boards in the lower layer (third, sixth, and ninth) are offset due to interlocks, forming a single width construct. is there. Alternatively, four 12-inch (30.48 cm) wide (x 12 or 16-foot (365.76 or 487.68 cm) long) boards are provided in the upper and lower layers, each 6 inches (15.). Double-width constructs can also be used that are separated by a 24 cm) board and the three 6-inch (15.24 cm) boards in the lower layer are offset to provide interlocking. Other configurations may be used to suit the needs of the particular end application of the mat.

If desired, the board can also be constructed of wood or processed lumber (preferably with a tolerance of ± 1/16 inch (0.15875 cm)), or metal or thermoplastic material, elastomer material, or The thermosetting tube can also be constructed of a thermosetting material, and a draw-molded thermosetting tube is an example of a preferred alternative material. The sizes described herein are not important and may vary depending on the intended use of the mat. The above values represent typical mats.

The upper, middle, and lower layers are usually nailed and / or bolted to each other to form a mat. This structure preferably has a modulus of elasticity of about 1.6 MPa, but the plastic mat may have a modulus of elasticity less than this when it is desirable that the mat be more flexible. Matte compression characteristics of 600 to 800 psi are suitable for most application operations.

12 and 13 are views showing a first embodiment of the present invention in the form of a mat 1100 having a substantially flat top and bottom surface. Although the bottom surface of this mat is not shown in these figures, the mat may be constructed with the same structure on both sides so that both sides can be used as the top surface of the mat that receives the equipment or vehicle. preferable. This eliminates the need to position the mat in a particular orientation and facilitates installation, and the installer can choose to use the surface of the mat in better condition as the top surface of the mat. ..

The mat 1100 includes first and second side beams (1105, 1110) having top, side, and bottom surfaces, which are 6 x 6 inches (15.24 x 15.24 cm) and 24 x 24. It has dimensions of inches (60.96 x 60.96 cm) in width and height, is at least 4 feet (121.92 cm), and is typically between 10 and 60 feet (304.8 to 1828.8 cm). Has a length. Preferably, these lengths of the beam range from 20 to 40 feet (609.6 to 1219.2 cm), preferably 30 to 40 feet (914.4 to 1219.2 cm). This is because mats of these lengths are easier to transport and transport than longer mats. Other dimensions commonly used for side beams are 8x8, 10x10, 12x12, 14x14, and 16x16, but those skilled in the art may choose other dimensions as desired. it can.

Normally, the width and height of the side beams are the same dimensions so that the beams have a square cross section. Alternatively, in certain designs, the width can be approximately twice the height dimension, or vice versa, to give the beam a rectangular cross section. Other typical dimensions are 6x12, 6x18, 8x10, 8x12, 12x14, 12x16, 12x24, and 18x24. These rectangular beams may be connected to the support structure with the long side as the height or may be connected to the support structure with the long side as the width, depending on the desired use of the mat. In general, it is preferable to use the long side as the width in order to interlock the mat structure.

The support structure 1115 is located between the first side beam 1105 and the second side beam 1110 and connects them, and this support structure has an upper part, a lower part, and a side part. , Has a height less than the height of the side beam, and has a width and length. This support structure, shown in more detail in FIG. 14, includes first and second longitudinal members (1120, 1125) that are connected to each other by a plurality of cross members 1130.

The support structure 1115 can be composed of steel components, and the cross member 1130 is welded to the longitudinal members 1120 and 1125 to form a ladder-type structure that forms the frame of the support structure. Additional cross members 1135, 1140 can be provided at the front and rear ends of the frame to form a perimeter rectangular structure. In this embodiment, both the longitudinal member and the additional cross members 1135, 1140 have a relatively flat plate with upper and lower flanges oriented away from one side of the plate, C. It is preferably a type beam. The surface of the flat plate on the opposite side of the flange of the longitudinal member faces the side beams 1105 and 1110 so that they can be closely and firmly connected. The flange of the C-shaped beam also functions as a connection point for the elongated members (1145A, 1145B, 1150A, 1150B). For this purpose, bolts 1155 can be attached to flanges or cross members. The flanges of the cross members 1135 and 1140 also face the inside of the support structure so that the ends of the rudder frame have a relatively smooth surface.

The cross member 1130 attaches to a C-beam between the top and bottom flanges to form a vertical connector in a support composition that provides the desired strength and stiffness. As shown in FIGS. 13 and 14, the resulting structure is a rectangular box-shaped frame with spaced cross members at the front, rear, top, and bottom.

The cross member 1130 of the support structure greatly contributes to the stiffness and rigidity of the frame. These members are 12 to 24 inches (30.48 to 60.96 cm) apart in the support structure typically used for small size (height and width) beams. For larger size beams, this spacing can be reduced from 10 to 16 inches (25.4 to 40.64 cm) to provide sufficient strength to keep the mat in one piece. Further details are not needed herein, as the determination of the spacing of the cross members can be calculated using generally known technical guidelines and formulas for mats of any particular size. The cross members usually have a height of at least half the height of the longitudinal members to which they are attached, preferably approximately the same height as the longitudinal members. Reinforcing members can also be added to this structure if desired. In one such configuration, additional plates, rods, beams, or other structural components can be added to the top and / or bottom portion of the support structure between the longitudinal members. This is especially advantageous when supporting the largest or heaviest equipment on the mat. Other structural members may also be provided between the cross members, but in most situations this is not necessary. Care must be taken to position these members so that they do not impede or interfere with the passage of the connecting rods through the longitudinal members into the support structure if additional reinforcement is required.

C-shaped beams and cross members are usually composed of metals such as steel so that this structure can be made by welding the cross members to the beam. The metal frames of the support structure are preferably constructed by welding, but if desired, depending on the size and configuration of the entire support structure, instead the frame components are brazed, riveted, or bolted to each other. It can also be connected. Instead of C-beams, flat plates of appropriate thickness (ie, plates without flanges) can also be used. In this configuration, the cross member can have an I-beam shape to further strengthen the support structure. However, C-shaped steel beams are preferred for longitudinal members, as the flanges provide additional rigidity and support to the structure and support for the cross members during installation. Of course, when using that embodiment, this can be compensated for by using a thicker flat plate for the longitudinal member. Further, when a C-shaped longitudinal member is used, the flanges of the respective members can be appropriately adjusted so as to come into contact with each other, and the I-shaped beam can be used as the cross member.

When the components of the support structure are made of metal, steel is usually used because it is an easily available and low cost material. Although not required for most applications, the support structure can instead be constructed from a more corrosion resistant material, such as stainless steel, copper, bronze, or other alloys. However, when carbon steel is used, corrosion resistance can be improved by painting or coating the structure to make it more resistant to moisture. The steel can also be galvanized, or another type of protective coating can be formed on the steel to make it more resistant to rust when in contact with moisture.

For special applications, aluminum or titanium can also be used for the support structure. All of these materials are generally more costly than steel and can present the problem of making it more difficult to weld or braze the weft to the longitudinal member. In an alternative embodiment, various longitudinal members and cross members can be connected to each other using rivets or bolts to form a frame of support structure, as described. The size of the rivet or bolt and the dimensions for welding and brazing can be readily determined by those skilled in the art using routine tests as needed. The same applies to the thickness of the beam or member used in the frame structure.

Alternatively, the support structure may be composed of a glass fiber reinforced thermosetting plastic material resin, which is usually a polyester or epoxy resin. The components of this structure can be pultruded in the form of rectangular or square tubes, which can be hollow or made of other materials, depending on the total weight and compressibility desired for this structure. It may be filled.

When forming a support structure using fiberglass reinforced thermosetting plastic material, a box or rudder frame may be prepared in the desired shape and the cross members and longitudinal members may be connected with resin before curing. it can. Bolts or other mechanical fixtures can also be used to connect these components.

Multiple connecting rods 1160 are used to attach the side beams to the support structure, which pass through the sides and support structure of the beam. These connecting rods 1160 are usually large root angle bolts that include threaded ends that receive nuts that will hold the components together when assembled. These rods are separated by about 3 to 6 feet (91.44 to 182.88 cm), depending on the size of the mat. FIG. 13 shows how the rod 1160 passes through the side beam 1105 towards the side structure, and FIG. 14 shows what the rod 1160 looks like when it is in the support structure. These root angle bolts are usually constructed of high-strength steel. Also, in some embodiments, the beam can include a sleeve that facilitates the passage of the bolt through the support core. The sleeve can be a flanged hollow tube that extends through the support core and, if desired, into a portion of one side beam and the other side beam. The tube terminates inside the opposite beam so that it does not interfere with the nut that engages the threaded end of the bolt. The sleeve is shown as element 1165 in FIG.

Various elongated members are provided for the upper and lower elongated members (1145A, 1145B, 1150A, 1150B) to form a substantially flat surface on the mat. The first plurality of elongated members (1145A, 1145B) are attached to the upper portion of the support structure 1115, and the second plurality of elongated members are attached to the lower portion of the support structure 1115. Therefore, the upper surface of the mat is formed by the upper surfaces of the side beams 1105, 1110 and the first plurality of elongated members 1145A, 1145B, and the bottom surface of the mat is formed by the side beams 1105, 1110 and the second plurality of elongated members 1150A, 1150B. Formed on the bottom of the. The flat top surface of the mat is best shown in FIG.

Since the top and bottom surfaces of the mat must be fairly uniform, the support structure and the upper and lower elongated members generally have the same total height as the height of the side beams. Normally, the support structure is centered perpendicular to the side beams. For example, the side beam is 12 x 12, the support structure has a height of 8 inches (20.32 cm), the beam extends 2 inches (5.08 cm) above the top of the support structure, and the support structure. It extends 2 inches (5.08 cm) below the bottom of the beam. This provides room for the 2 inch thick elongated members in the top and bottom of the support structure, leaving the top and bottom of the mat with a substantially uniform surface. This type of construction is preferred as it minimizes the various types of thicknesses that need to be used on the elongated members and provides a symmetrical mat that can receive the device with either side facing up. In other embodiments, an elongated member on the top surface is provided to support a device or vehicle located on or moving on the mat, while a mud or other substance supports the structure at the bottom. Elongated members with different thicknesses at the top and bottom can be used with the intention of using thinner members to prevent entry. In this embodiment, the support structure on the lower surface may be provided with a flat plate instead of an elongated member.

The same applies to the end of the support structure. Longitudinal members 1120, 1125 are only about 1 to 24 inches (2.54 to 60.96 cm) at each end, or 2 to 48 inches (5.08 to 121) in total, from the length of side beams 1105 and 1110. It can be shortened by .92 cm). The shortened end length may, if desired, correspond to the width of the side beam. The gap between the shortened ends of the support structure 1115 and the side beams can be filled with bumper members 1175, 1180, in which case the mat can have substantially flat front and rear ends. .. These bumper members can be made the same width as the elongated members and the same material as the elongated members can be used to provide the front and rear bumper members of the support. This gives a target structure, but if desired, bumper members of different thickness can be used.

In a less preferred embodiment, the longitudinal members 1120, 1125 are made substantially the same length as the side beams 1105, 1110, with front and rear cross members 1135, 1140, along with the ends of the side beams. It is also possible to form the front end surface and the rear end surface of the mat.

This mat must also provide sufficient load bearing capacity. A fully supported mat (a mat properly placed on a properly leveled ground surface) is 12 inches (30.48 cm) in diameter without degrading the properties of the mat or causing permanent deformation of the mat. Must withstand a load of 10 tons per surface. The support structure, when properly installed on a properly leveled ground surface, has a compression resistance of between about 500 and 800 psi, and in some cases as much as 1000 psi, depending on the application. This provides compression resistance when a large vehicle or device moves on or is placed on the mat.

The side beams of the mat use steel tracks to prevent or reduce damage to the mat's support structure due to large vehicles entering or exiting the mat from the side. These beams can be replaced when needed, but the support structure can be reused to create new mats.

The elongated members and side beams are preferably constructed of any type of wood, but usually oak is preferred. These members can also be made of processed wood or sawn timber. This is because, in that case, it is not necessary to obtain the length of a single solid wood, and it is easy to make it long. In addition, layered veneer laminates can also be used for these members or beams. The cost of the material is about the same as the price for oak, which is expected to be an attractive option.

Processed lumber (or processed wood) is a variety of derivative wood products produced by joining or fixing strands, particles, fibers, or veneers or boards of wood with an adhesive or other fixing method to form composite wood. Includes (derivative wood product).

These materials are amazing, with consistent reproducibility of the required size, the ability to mix different wood types to reach the final product, and superior properties that generally outperform the properties obtained from a single board. Offer benefits.

There are three types of processed wood that can be used in the present invention.
Parallel strand laminate (PSL). This is a beam that can be manufactured in any length up to about 12 x 12 inches (30.48 x 30.48 cm) because the beam is made in a continuous process.
Layered stand laminate (LSL). It is about 1 to 4 inches (2.54 to 10.16 cm) thick, about 2 inches (5.08 cm) to 54 inches (137.16 cm) wide, and about 8 to 64 feet (from 243.84). It is a billet that can be produced with a length of (1950.72 cm).
Layered veneer laminate (LVL). This is also a billet of any length that can be made up to about 4 square feet (3716.12 square centimeters).

Alternatively, the side beams and elongated members may be made of a glass fiber reinforced thermosetting plastic material such as glass fiber reinforced polyester or epoxy resin. These materials can be pultruded into solid form, or preferably as rectangular or square tubes. If desired, the hollow tube can also be filled with any one of a variety of materials to contribute to the overall strength or compression resistance of the tube. Typically, crumb rubber, recycled tires, or other plastic or elastomeric materials, sand, rock rupture, or polyurethane foam can be provided inside the tube before or after attachment to the support structure. Polyurethane foam is preferred for this purpose because it can be injected in liquid form after the drawer part has been attached to the support structure. In the case of stronger or heavier fillers, the connecting rod can be placed first in the beam to prevent the filler from interfering with rod insertion when connecting the side beams to the support structure. In addition, a tubular sleeve made of metal or draw-molded plastic may be provided at the position in the beam where the rod will be inserted so that the rod has holes that remain after the filler is placed in the beam. it can.

Since these mats are relatively large and heavy, it is necessary to provide provision for moving, transporting, and installing the mats to the desired site location. For this purpose, holes are drilled in the top and / or bottom to provide access to one or more of the connecting rods. These holes are formed as cutout portions 1185 of the elongated members 1145 and 1150. In this way, these holes allow the crane hooks or other mechanical fittings to access the connecting rods that lift or operate the mat. For convenience, mounting holes 1185 are provided on both the top and bottom surfaces of the mat so that either side may come into contact with the ground or be exposed above as the surface on which the equipment will be installed. To facilitate.

Next, with reference to FIGS. 15 and 16, an alternative embodiment of the present invention in the form of a mat having side beams having a configuration and dimensions that allow interlocking between adjacent mats is shown. If components similar to those of the previous embodiment are used, the same reference numbers will be used in FIGS. 15 and 16 and only the different features of this alternative embodiment will be described.

The mat 1200 includes side beams 1205, 1210 having a configuration and dimensions that are only half the thickness of the mat. On one side of the mat, the beam 1205 is attached to the upper portion of the support core 1215. This is done so that the upper surface of the beam 1205 extends higher than the upper surface of the support structure 1215. Similar to the immediately preceding embodiment, the elongated members 1145A and 1145B can be provided on the upper portion of the support structure 1215 so that the upper surface of the mat adjacent to the side beam 1205 is relatively flat. Similarly, a side beam 1210, which is also half the thickness of the entire mat, is attached to the lower end of the support structure 1215. The lower surface of the side beam 1210 extends below the lower surface of the support structure to accommodate the elongated members 1150A and 1150B so that a substantially flat surface can be formed on the bottom of the mat adjacent to the beam 1210. It has become.

With this structure, one mat can be placed first on the ground and adjacent mats can be placed such that the beam 1205 rests on the beam 1210. This arrangement can be continued for the required number of mats to achieve the desired working base for the crane or other equipment.

The upper surface of the mat 1200 has a step above the beam 1210 on the opposite side of the beam 1205, and an open space or a step is left below the beam 1205 next to the lower surface of the mat on the opposite side of the beam 1210. .. These surfaces allow interlocking between adjacent mats, but a stable mat surface cannot be obtained on the outermost side of the work substrate. To compensate for this, the mat at the outermost end on one side of the work board is composed of beams 1105 of the full thickness of the mat on one side and beams 1210 on the other side of the mat 1200. A modified mat can be provided that allows interlocking between adjacent mats configured as such. Similarly, the mat at the outermost end on the opposite side of the work base can be configured with a beam 1110 on one side instead of a beam 1210 and a beam 1205 on the other side.

Alternatively, if an insufficient number of modified mats are not available when the entire range of the entire work base is unknown, the space under the beam 1205 attached to the outermost mat of the final work base. A stabilizing beam of the same size and size as the beam 1205 provided on the mat can be provided to stabilize the sides of the mat. The same can be done for the outermost mat having a step above the beam 1210. Separate stabilizers of the same size as the beam 1210 can be provided to finish the top surface of the mat at those positions. The stabilizing member can be attached to the beam of the mat, if desired.

The mat 1200 requires different systems to connect the beams 1205, 1210 to the support structure 1215. The connection of the beam 1205 to the support structure 1215 requires the connecting rod 1260A to pass through the upper portion of the support structure, whereas the beam 1210 is supported by the connecting rod 1260B passing through the lower portion of the beam and the support structure 1215. Connected to. This is best shown in FIG. 16 where the relative positions of the connecting rods 1260A, 1260B along with the sleeves 1265A, 1265B are shown. The mat of the present invention may also be provided with some additional mechanisms.

FIG. 17 is a diagram showing yet another variant of the invention in which the mat 1200 includes a radio frequency identification (RFID) tag 1275 located within the core. Alternatively, the RFID tag 1275 can be embedded in a hole or hollow pocket in the outer layer so that the mat can be monitored by an inventory system or when used for rent. This tag provides each mat with a unique identification serial number so that the mats in use or rent can be tracked and the location of use can be described. The mat can be scanned when it is in the warehouse, loaded onto a truck for delivery, delivered to the work site, or collected from the work site after use. RFID tags may be active or passive, and if desired, other tracking devices such as barcodes can be used for the same purpose. However, it is preferred that the RFID tag be embedded in the outer layer or core structure of the mat to protect it from damage during use. When using barcodes or other surface mount tags or seals, they must be placed on the surface portion of the mat that is less prone to wear or abuse. Therefore, it is preferable that the tag can be attached to the side surface of the mat so as not to be directly exposed to the traffic on the mat. The tag can also be covered with a plexiglass film to prevent it from coming off due to rubbing.

Mats can include retractable lifting elements for loading / unloading, moving from one position to another, or manipulating the mat for installation and repair. This can be the lifting elements described above, which provide easy access and prevent tripping or damage to the article moving on the mat, or damage to the lifting element itself. To prevent it, it is located in the recess on the top of the mat during use. Alternatively, more complex designs can be used, such as those of US Patent Publication No. 2008/0292397.

To aid in the use of mats at night or during dark days with bad weather conditions, the mats may also include one or more lighting elements, such as those disclosed in WO 2006/048654. These illuminating elements are preferably embedded in the outer layer. FIG. 17 shows the LED luminaire 1285 located in the core structure under the elongated member 1245A. The luminaire is covered with plexiglass transparent material 1295 to better protect the luminaire from damage during use. To achieve the desired illumination brightness, one of ordinary skill in the art can provide the required number of luminaires or include larger sized luminaires.

Another feature of the invention is the use of color coding to identify the individual layers used in the matte construction. It can also be used to identify mats for a particular customer or end user. When mats are rented or leased, color coding can be used to identify which mats belong to the leasing company compared to mats provided by others. The color coding may be monochromatic, or may be a particular stripe, pattern, dot, or specific stripe, pattern, dot, or that provides a "signature" that identifies a particular core structure or a particular end user or owner of the matte that resides within the matte. It may be another seal.

18 and 19 have a typical thickness of 8 to 12 inches (20.32 to 30.48 cm), a typical width of about 4 feet (121.92 cm), and a typical length. Is a view showing a crane / pipeline mat 1300, where is between 12 and 20 feet (365.76 to 609.6 cm). The mat 1300 includes two side beams 1305 and 1310, a steel box frame 1320, an upper layer of elongated members 1315A, 1315B and 1315C, and a lower layer of elongated members 1325A, 1325B and 1325C. The core structure can be between 2 and 3 feet (60.96 to 91.44 cm) wide, depending on the width of the side beams.

The steel frame 1320 includes a front lifting element 1335 and two upper lifting elements 1340. If desired, a rear lifting element and two lower lifting elements (not shown) can also be provided. These lifting elements allow the mat to be lifted overhead by a crane having the appropriate lifting capacity to facilitate loading, unloading, and installation of the mat. The lifting element can be constructed as desired. When using cables or chains, any holes drilled in the mat for these cables or chains must be drilled throughout the mat, not simply through the gaps between the boards or components. .. The chain or cable must have at least three drop casting clamps. The cable is a new 3/4 inch (1.905 cm) steel core, extra improved plow (EIPS), right regular lay wire rope with a minimum breaking strength of over 29 tonnes. It can be a wire rope). The chain is 3/8 inch with a working load limit of 5400 lbs and a minimum breaking strength of 16200 lbs with a double clevis link of 3/8 inch (0.9525 cm) to achieve a safe working load limit of about 5400 lbs. It should be a high test chain (0.9525 cm).

Other lifting elements may also be used, such as those described in U.S. Patent Application No. 62/21164, filed August 28, 2015, which expressly incorporates all of its contents herein by reference. it can. These lifting elements can be used with any of the mats disclosed herein, as long as a suitable core structure is present.

The components of the mat 1300 are shown more clearly in the development view of FIG. The steel frame 1320 is shown as having a plurality of components including two elongated side components, a front component, a rear component, and two cross members 1345, these components. Are all welded or bolted together to form the frame 1320. The side beam bolting member 1335 is also welded to the box frame 1320. These bolting members are configured to pass through the holes of the side beams 1305 and 1310 and fix the side beams to the steel box-shaped frame 1320. This is done by tightening the nut to the end of the bolted member 1335 after the bolted member 1335 has passed through the hole in the side beam. The holes in the side beams are recessed to prevent bolts and nuts from extending beyond the sides of the beam.

The lifting elements 1330, 1340 are preferably in the form of a D-shaped ring that is welded or bolted to the box frame 1320 or its cross member 1345, as best shown in FIG. The upper layer elongated members 1315A, 1315B, 1315C and the lower layer elongated members 1325A, 1325B, 1325C are also bolted to the box-shaped frame 1320.

Since the box frame 1320 defines open areas within it, it is best to fill these open areas with a material that contributes to the toughness and weight of the mat. In particular, scrap pieces produced in the manufacture of other mats, or fillers for wooden members 1350, which are wood ends or processed wood, can be used. Also, since the purpose of these fillers is simply to increase the weight of the mat and not to be exposed to wear or abuse, cheaper wood materials such as treated pine can also be used. Instead of wood material, the open area of the core can also be filled with other materials disclosed herein.

20 and 21 are views showing yet another mat 1400 including a steel frame core 1410. This core is used in an interlock mat with an upper layer 1405 and a lower layer 1415 of an elongated member. These elongated members can be composed of wood, processed wood, or thermosetting materials, elastomer materials, rubber materials, or thermosetting plastic materials. Plastic materials, and elastomer or rubber materials may be used alone or reinforced as known in the art to provide additional strength, or friction or wear resistance, or in other forms. The physical properties may be improved. Wood is preferred because it provides the mat with protection against friction and abuse at a relatively low cost. As shown, the three elongated members 1415A, 1415B, 1415C in the lower layer deviate from the other elongated members and interlock with adjacent mats of similar configuration, as disclosed elsewhere herein. It forms a locking configuration.

The steel frame 1410 includes four side members and two cross members 1420, which can be welded or bolted to each other to form the frame. The open space within the box-shaped frame can be filled with materials that contribute to the toughness and weight of the mat. In particular, scrap pieces produced in the manufacture of other mats, or fillers for wooden members 1450, which are wood ends or processed wood, can be used. Also, since the purpose of these fillers is simply to increase the weight of the mat and not to be exposed to wear or abuse, cheaper wood materials such as treated pine can also be used. Instead of wood material, the open area of the core can also be filled with other materials disclosed elsewhere herein.

To protect the steel frame from damage, a rectangular bumper configuration 1440 is provided along all outer sides of the steel box frame.

Similar to other embodiments, the D-shaped lifting element 1445 can be provided at various positions on the top and bottom of the mat at positions where it can be welded to the cross member 1420 of the steel frame. These allow the mat to be lifted and transported and placed in a suitable position during installation.

FIG. 22 shows a glass fiber reinforced polyester or epoxy grid 1505 in which the environmentally resistant core of the mat 1500 has a thickness of 3 inches (7.62 cm) and a grid hole of 2 x 2 inches (5.08 x 5.08 cm). It is a figure which shows the preferable embodiment of this invention. The same upper wooden structure 1510 and lower wooden structure 1515 of FIGS. 20 to 21 can also be used for this mat, all of its components being bolted. As described herein, the grid may be larger or smaller in the range of about 2.5 to 4 inches (6.35 to 10.16 cm). It can have holes between 1.5 x 1.5 inches (3.81 x 3.81 cm) and 3 x 3 inches (7.62 x 7.62 cm). The grid can be made to be essentially the same length and width as the entire mat. That is, they may have exactly the same dimensions, or each dimension may be shortened by 1 inch (2.54 cm) or 2 inches (5.05 cm) so that the grid is protected by the wider wooden portion of the mat. You may. Instead of making it as individual material, in certain situations, make some smaller grids and place two, three, four, or six adjacent grids next to each other to make the total length of the mat. And sometimes it is preferable to have full width. This is shown in the figure as four smaller grids that, when placed adjacent to each other, have the same overall size as the upper and lower layers of the mat. These smaller compartments may be arranged horizontally across the full width of the mat, or these smaller compartments may have different widths totaling the full width of the mat.

Of course, the solid glass fiber reinforced thermosetting resin sheet having the thickness described in the present specification can be used alone or with openings or holes. As shown, bolts pass through the entire structure for maximum strength, and these bolts are placed in recessed holes so that the bolts and nuts do not extend beyond the top and bottom surfaces of the mat. ..

In an alternative embodiment for FIG. 22, the grid may instead be a metal sheet with openings for reducing the weight of the mat. The metal sheet can be 2 inches (5.08 cm) thick, with holes for bolts used to connect the components of the mat, as well as additional holes to reduce the weight of the sheet. It has both. The holes may be random or uniform, with diameters ranging from 1 to 6 inches (2.54 to 15.24 cm) for circular holes and 2 for rectangular or square holes. It can range from × 2 to 4 × 4 inches (5.08 × 5.08 to 10.16 × 10.16 cm). Metal grid or weld rod configurations can also be used if desired. The metal sheet can be made in the same size as the mat, or can be divided into sections that become the size of the entire mat when they are integrated, like the lattice.

From the above, it can be seen that there are numerous combinations and configurations of new and useful mats, including environmentally resistant core structures. Specific additional specific embodiments include the following combinations of mat components:
(1) Upper outer layer of elongated wooden member or laminated wooden member, core structure of elongated thermoplastic board or integral unit of sheet or molded structure, and lower outer layer of elongated wooden member or laminated wooden member. The thermoplastic board is preferably an HDPE board of approximately 2 inches (5.08 cm) x 8 inches (20.32 cm) x 8 feet (243.84 cm), whereas the integrated unit is composed of HDPE and is 8 feet. (243.84 cm) x 12, 14, or 16 feet (365.76, 426.72, or 487.68 cm) and about 2 inches (5.08 cm) thick with a flat closure It has the geometric shape of an open cell or an open cell. The wooden member will be about the same size as the HDPE board.
(2) Upper outer layer of elongated wooden member or laminated wooden member, core structure of elongated thermoplastic integral unit of sheet or molded structure, and lower outer layer of elongated thermoplastic board. The thermoplastic resin is preferably HDPE in an integral unit and / or board, but the board can also be composed of an elastomeric material that may or may not be reinforced. The size of the integrated unit shall be 8 feet (243.84 cm) x 12, 14, or 16 feet (365.76, 426.72, or 487.68 cm) and approximately 2 inches (5.08 cm) thick. It has a flat closed or open cell geometry, with elongated members approximately 2 inches (5.08 cm) x 8 inches (20.32 cm) x 8 feet (243.84 cm). The wooden parts will be about the same size as the HDPE or elastomer board.
(3) Upper outer layer of elongated wooden member or laminated wooden member, core structure of lattice of glass fiber reinforced thermosetting plastic material, and lower outer layer of elongated wooden member or laminated wooden member. The wooden member will have a size of approximately 2 inches (5.08 cm) x 8 inches (20.32 cm) x 8 feet (243.84 cm). The lattice is 2 inches thick, has holes of 2 x 2 inches (5.08 x 5.08 cm), and is the size to match the mat, ie 8 feet (243.84 cm) x 12, 14 in length. , Or segments having 16 feet (365.76, 426.72, or 487.68 cm) or being part of the mat can be used (eg, 3, 4 of a mat 8 feet (243.84 cm) wide. , Or 4.5 feet (91.44, 121.92, or 137.16 cm) long compartments, using 4 compartments on the mat).

Although environmentally resistant components may be substituted for the outer layer of the mat, it is generally preferred to have at least one outer layer composed of wooden components. In addition to the elongated members, such components can be sheets, plates, grids, or cell structures, arranged one or more of them to form the length and width dimensions of the mat. .. The elongated member can have the same length as the mat, or smaller segments can be used end-to-end to obtain the desired length that matches the length of the mat.

In addition to the preferred three-layer mat, various two-layer mats are also contemplated in the present invention. This includes one layer of thermoplastic, thermosetting, elastomeric, or metal component and an outer layer of elongated members, usually composed of wood or processed wood, but in some circumstances, instead. , Thermoplastic, thermosetting, or elastomer components, usually as solid components, or filled with other materials, or hollow configurations that can be reinforced with known strengthening or stiffening additives. It can also be used as an element.

The present invention allows one or more outer layers to provide resistance to friction and abuse of the structure core structure, which is resistant to moisture, water, or certain chemicals from the surrounding environment. In that respect, it offers an unexpected advantage over the art. This makes the core structure much more resistant to rotting or other chemical degradation that would otherwise affect the wooden components of the core than when using traditional wooden components. Can have a long life. Finally, they can be replaced to the extent that either the components of the upper outer layer or the lower outer layer are damaged, and all the cores can be reused to form a new mat.

Therefore, in summary, the optimal dimensional plane relationships of the parts of the invention may include variations in size and tolerances, and materials, shapes, forms, functions, and uses are readily apparent to those skilled in the art. And all the equivalent relationships of the relationships illustrated in the drawings and described herein are intended to be within the scope of the claims attached herein.

Unless otherwise defined, all technical and scientific terms used herein have the same meanings commonly understood by those skilled in the art to which the present invention belongs. Also, the singular forms "a," "an," and "the" used in this specification and the appended claims are plural, unless the context clearly indicates otherwise. Including cases. All technical and scientific terms used herein have the same meaning.

The above detailed description is considered to be merely an example of the principle of the present invention. Moreover, it is not desirable to limit the configuration to the exact configuration exemplifying the present invention, as numerous modifications and changes will be readily apparent to those of ordinary skill in the art. Therefore, all suitable modifications and equivalents can be reclassified as being within the scope of the invention.

100 mat 115 core structure 105 upper outer layer 110 lower outer layer 125 reinforced polyester beam 130 wooden board 120 inner wall support 150 lifting element 170 recess 175 waterway 200 second mat 215 core structure 260 cell 300 third mat 315 core structure 330 Upper outer layer 360 cell 425 bumper 530 lip

Claims (21)

It ’s a mat,
A core structure that provides strength and stiffness to the mat and is provided as one or more components including a sheet, multiple elongated members, a frame, multiple compartments, or a combination thereof, the structural component being resistant to. With a core structure made of environmentally non-wooden material,
With beams or bumpers made of wood, processed timber, or plastic or elastomeric material provided on the longitudinal sides of the core structure to protect the core structure from damage due to transport or installation of the mat. ,
The directly to the core structure, or other components through at least one outer layer which is indirectly fitted, has a length and width that correspond to the length and width of the core structure, wherein The at least one outer layer forming the upper or lower surface of the mat, or both the upper surface and the lower surface of the mat, including a plurality of elongated members, wherein the elongated members of the outer layer are wood, processed wood, thermoplastic. Consisting of a material, a thermosetting plastic material, or an elastomeric material, the material of the elongated member of the at least one outer layer comprises at least one outer layer different from the material of the structural component of the core.
The at least one outer layer component provides the mat with abrasion resistance, abrasion resistance, and abuse resistance and is removably attached to the core construct to provide the configuration of the at least one outer layer. A mat that is replaceable when an element is damaged, the core structure is protected and does not deteriorate, and the core structure is reused to replace at least one outer layer component. The mat is designed to be able to form. The structural component of the core structure comprises a metal, an elastomeric material, a thermoplastic material, a thermosetting material, or a combination thereof, with one outer layer forming the upper surface of the mat and another outer layer. One or more components in the form of a sheet, a plurality of elongated members, or theirs, which are present to form the lower surface of the mat and optionally attach the at least one outer layer to the core structure. The mat according to claim 1, which has an additional layer containing a combination. The structural component of the core structure is an elongated member of a fiberboard or a thermoplastic material or a thermosetting plastic material, and a solid or perforated plate or sheet of the fiberboard or a thermoplastic material or a thermosetting plastic material. Including, one outer layer forms the upper surface of the mat and comprises a plurality of elongated members of wood or processed wood, another outer layer forms the lower surface of the mat, elongated members, solid or The mat according to claim 2, comprising a thermoplastic material, a thermosetting plastic material, or an elastoma material in the form of a plate or sheet structure with openings or a grid or lattice. The at least one outer layer is detachably attached directly or indirectly to the core structure by bolting, and the components of the at least one outer layer have an elastic modulus of about 1.6 Mpsi, said. The mat according to any one of claims 1 to 3, wherein the mat has a load bearing capacity capable of withstanding a load of at least 500 to 1000 psi without permanently deforming the core structure. The core structure has a thickness of about 2.5 to about 4 inches (10.16 cm) and is 1.5 inches (3.81 cm) x 1.5 inches (3.81 cm) to 3 inches (7.). A lattice of glass fiber reinforced thermosetting plastic materials with holes between 62 cm) x 3 inches (7.62 cm), or multiple elongated tubular members made of metal, thermoplastic, or thermosetting material. 1. A plurality of elongated tubular members, each of which is the same material or a different material, which is hollow or solid, or is an independent member, or is connected to form an integral component, according to claims 1 to 4. The mat according to any one item. The core structure comprises a sheet-like or solid, perforated, or honeycomb-structured thermoplastic material, thermosetting material, elastomer material, or polyolefin material, and the honeycomb structure comprises a closed or open cell, said honeycomb. The cell of the structure optionally comprises a filler to increase the weight of the mat and to control, eliminate, or achieve absorption of the liquid, and the core structure provides the filler in the open cell. The mat according to any one of claims 1 to 5, comprising an upper sheet and a lower sheet that help hold the filler in the cell when provided. The mat according to any one of claims 1 to 6, further comprising a beam or bumper made of wood or plastic material provided at the end of the core structure. A mat with a top and bottom
With first and second side beams having top, side, and bottom surfaces,
It is a non-wooden support structure located between the first side beam and the second side beam and connecting the first side beam and the second side beam, and has an upper portion, a lower portion, and the like. And has side portions, has a height less than the height of the side beam, has a width and length, and includes first and second longitudinal members that are connected to each other by a plurality of cross members. Non-wooden support structure and
A plurality of connecting rods for attaching the side beam to the support structure, the connecting rod passing through the side surface of the beam and the support structure, and
Including a first plurality of elongated members attached to the upper portion of the support structure.
Wherein the upper surface of the mat is a Tan Taira, the beam, or the first plurality of elongated members, or is formed by the upper surface of both mats. Wherein wherein the support structure the further a second plurality of elongate members attached to the lower portion of the bottom surface of said mat is a Tan Taira, the beam or the second plurality of elongated members, or both, The mat according to claim 8, which is formed by the bottom surface of the above. The connecting rod includes a bolt that passes through the side beam and the support core, and includes a tubular sleeve that facilitates the beam and the longitudinal member through which the bolt is passed for assembly of the mat. The mat according to claim 8 or 9. The beam is between about 1 x 6 inches (2.54 x 15.24 cm) and about 24 x 24 inches (60.96 x 60.96 cm), or about 6 x 6 inches (15.24 x 15.24 cm). ) And a width and height dimension between about 16 x 16 inches (40.64 x 40.64 cm), the first and second longitudinal members are about 10 to about 30 inches (25. They are connected to each other by cross members that are separated by 4 to 76.2 cm), the connecting rods are separated by about 3 to about 6 feet (91.44 to 182.88 cm), and the mat is about 4 to about 8 feet apart. 28. One of claims 8-10, having a width between (121.92 and 243.84 cm) and a length between about 4 and about 60 feet (121.92 to 1828.8 cm). Matt. The side beams are made of solid cut wood, processed timber, or thermocurable plastic, and the first and second longitudinal members are in contact with the side beams, such as flat plates, I-beams, or Constructed as a rectangular or C-shaped beam, the cross member is configured as a flat plate and an I-shaped or C-shaped beam, and the plurality of elongated members are solid cut wood, processed timber, or heat-cured. The mat according to any one of claims 8 to 11, wherein the board is made of sex plastic, and the elongated member is bolted to the support structure. The first side beam is sized to provide about half the height of the mat so that the first side beam is attached to or attached to the upper portion of the support structure. The two side beams are sized to provide half the height of the mat and are attached to the underside of the second side surface of the support structure, or the first and second sides. The mat according to any one of claims 8 to 12, wherein both beams are sized as described in this claim, facilitating the formation of an interlocking structure of adjacent mats to be connected. A mat that has longitudinal and end sides and is configured to support other components that form the mat or to allow attachment of other components that form the mat. , A support structure in the form of a frame or rudder structure, and an elongated member attached to both above and below, or above and below the support structure, to form the top or bottom surface, or both the top and bottom surfaces of the mat. The bumper comprises an additional layer and at least a bumper detachably attached to the longitudinal side of the frame or rudder structure to protect the mat from damage due to lateral impact during transport or installation. The shape, which is composed of a plastic or elastomer material, provides an outer surface extending beyond the sides of the support structure, has sufficient compression to absorb collisions and impacts and protect the support structure, said. A mat that is removable so that the bumper can be replaced if it is damaged. When the longitudinal side surface of the support structure includes an I-beam having an open cavity facing outward, the bumper is attached to the I-beam and fits into or fits into the cavity of the I-beam. ,
When the longitudinal side of the support structure comprises a beam having a flat outer surface, the bumper by an additional member or lip that holds the bumper in place in contact with the flat outer surface of the beam. 14. The mat according to claim 14, which is positioned adjacent to the longitudinal side surface. The mat according to claim 14 or 15, wherein the bumper is also provided on one or both end sides of the support structure. The support structure is composed of a rectangular tube member made of a metal or hollow, filled hollow, or solid glass fiber reinforced thermosetting plastic material, and the elongated member is made of wood or processed. The mat according to claim 14, 15, or 16, which is made of wood, or a thermoplastic material or a thermosetting plastic material. The holes in the support structure are wooden boards that give the mat greater weight, compressive strength, or toughness, and the core of the wooden board is configured to fit into the holes in the support structure. Wooden boards bolted to each other so that they do not move inside, recycled rubber tire material located within the open area of the support structure, sand, or other particulate or solid filler, said particulate filler. , A filler that is held in place within the support structure by a mesh, screen, or sheet fixed to the top and bottom of the support structure, or a foam or extrusion height that is located within the open area of the support structure. The mat according to any one of claims 8 to 17, comprising one or a combination of molecular materials. A D-shaped ring, an O-shaped ring, a chain, or a support structure comprising a steel member, the mat being directly connected to the steel member to allow the mat to be lifted overhead. 8. 18 of claims 8-18, further comprising a lifting element including a cable, wherein the steel member of the support structure is optionally coated or painted to provide additional environmental resistance to the support structure of the mat. The mat according to any one item. Radio frequency identification (RFID) tags, which allow the mat to be monitored when used in an inventory system or for rent.
A specific customer or end user who identifies a lighting element embedded in the elongated member that provides light to assist in the use of the mat at night or in the dark daytime due to adverse weather conditions, or the configuration of the mat. Color coding, which identifies the mat for use or indicates that the mat is rented or leased,
The mat according to any one of claims 1 to 19, further comprising one or more of the above. A way to extend the life of industrial mats
A step of configuring the industrial mat to have a core structure that provides strength and rigidity to the mat, wherein the core structure comprises a sheet, a plurality of elongated members, a frame, a plurality of compartments, or a combination thereof. With steps provided as one or more components in which the structural components of the core structure are made of environmentally resistant non-wooden material rather than traditional wooden components.
The industrial mat is composed of wood, processed timber, or plastic or elastomeric material provided on the longitudinal side surface of the core structure to protect the core structure from damage caused by the transport or installation of the mat. Steps to install a beam or bumper,
At least one removable outer layer that is attached directly to the core structure or indirectly via other components, forming either the top or bottom surface of the mat or both the top and bottom surfaces of the mat. A step of providing at least one outer layer, wherein the at least one removable outer layer comprises an elongated member made of wood, processed wood, a thermoplastic material, a thermosetting plastic material, or an elastomer material. The mat is provided with abrasion resistance, abrasion resistance, and abuse resistance, and the material of the elongated member of the at least one outer layer is different from the material of the structural component of the core.
The elongated member of the at least one outer layer damaged or deteriorated during use is replaced by removing one or more of the damaged or deteriorated elongated members, while being protected and not deteriorated. A method comprising reusing the core structure to regenerate the mat by forming a regenerated mat in which the elongated member or other component of the at least one outer layer has been replaced.