Note: Descriptions are shown in the official language in which they were submitted.
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
INDUSTRIAL MATS HAVING COST EFFECTIVE CORE STRUCTURES
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of US application no. 16/030,263
filed July
9, 2018, which is a is a continuation-in-part of US application no. 15/155,685
filed May 16,
2016, which is a continuation-in-part of application no. 15/081,340 filed
March 25, 2016,
now US Patent no. 9,476,164, which is a continuation-in-part of US application
no.
15/056,212 filed February 29, 2016, now US Patent no. 9,447,547, which in turn
is a
continuation-in-part of US application no. 14/839,888 filed August 28, 2015,
now US patent
no. 9,315,949, which claims the benefit of US provisional applications nos.
62/054,186 filed
September 23, 2014, 62/138,143 filed March 25, 2015 and 62/158,196 filed May
7, 2015.
US application no. 15/155,685 also claims the benefit of US provisional
applications
nos. 62/211,662 filed August 28, 2015 and 62/211,664 filed August 28, 2015.
The entire content of each of the foregoing applications is expressly
incorporated
herein by reference thereto.
BACKGROUND
The present invention relates to a reusable system for the construction of
roadways
and equipment support surfaces in areas having poor ground integrity
characteristics. More
particularly, the present invention relates to a system of durable mats which
can be
interconnected to form roadways and/or equipment support surfaces. More
particularly still,
the present invention relates to a reusable system of mats which can be
quickly and easily
positioned in a single layer to form roadways and/or equipment support
surfaces, and which
can thereafter be easily removed and stored until needed again.
Mats for this use are generally known in the art and are available from
Quality Mat
Company, Beaumont, Texas. In remote and unstable environments, a stable
roadway (or any
roadway) often does not exist, such that temporary roadways are assembled by
aligning
planks, boards or mats along the desired path. The mats provide temporary
structures for
various construction projects as well as for use in environmental or disaster
cleanup projects.
These mats enable trucks and other equipment to drive over, store equipment
on, or create
campsites on otherwise unstable, soft or moist land or damaged areas by
providing a
relatively level and stable surface.
1
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
While conventional wood mats provide useful service at a reasonable cost, the
wood
core, which is typically made of white oak, can deteriorate over time due to
moisture causing
gradual rotting and degradation of the wood material. This causes the mat to
be discarded,
because unlike some of the other materials that are used on the upper and
lower layers of the
mat, the core cannot be replaced without essentially making an entirely new
mat.
Also, conventional crane mats that are typically 4 feet wide and utilize 8x8
inch to
12x12 inch beams that are up to 40 feet in length, utilize beams that are made
of oak and
preferably white oak as that material provides acceptable performance of the
mats for a
significant service life at a reasonable cost. Such mats are also available
from Quality Mat
Company, Beaumont, Texas. These mats, which are often called timber mats or
crane mats,
typically utilize virgin wood utilize virgin wood that is shaped and cut to
length to meet
design demands. Due to weather conditions and other environmental factors,
however, the
availability of trees that can be harvested to make such large size and length
beams is
reduced, thus making it difficult to obtain suitable quantities to make large
numbers of mats.
Accordingly, alternatives are needed for crane mat constructions to conserve
the
amount of wood beams that need to be included. Also, the materials that may be
considered
as alternatives need to possess the necessary physical properties to be able
to withstand harsh
outdoor conditions as well as to support heavy equipment. And of course cost
is a factor in
determining the selection of alternate materials, as it is not cost-effective
to provide a mat that
is multiple times more expensive than one that can be made of wood.
Thus, there is a need for improvement in these types of mat constructions both
to
provide longer service lives as well as to conserve natural resources, and
these needs are now
satisfied by the industrial mats of the present invention.
SUMMARY OF THE INVENTION
The invention relates to industrial mats having substantially flat top and
bottom
surfaces and comprising first and second side beams having a height, width and
length with a
top surface, sides, and a bottom surface; a core structure located between and
connected to a
side of first and second side beams, with the support structure having a
height that is less than
that of the side beams, a width and a length, with the support structure
comprising first and
second longitudinal members; a plurality of joining rods that attach the side
beams to the
support structure, with the joining rods passing through the sides of the side
beams and the
sides of the longitudinal members of the support structure; one or more first
elongated
members attached to the upper portion of the support structure, wherein the
top surface of the
2
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
mat is formed by the top surfaces of the beams and the first elongated
member(s); and one or
more second elongated members attached to the lower portion of the support
structure,
wherein the bottom surface of the mat is formed by the bottom surfaces of the
beams and the
second elongated member(s).
The first and second longitudinal members are typically rectangular beams or
members that provide flat side faces for contact with the side beams; the side
beams are made
of solid cut wood or engineered lumber; the first and second elongated members
have the
same thickness and are boards or sheets made of solid cut wood, engineered
lumber, plastic
or recycled materials; and the elongated members are bolted to the support
structure.
Preferably, the side beams are timbers of engineered lumber or oak or other
hardwoods, or
are solid or filled or unfilled hollow rectangular plastic members that
optionally may be
reinforced, the longitudinal members are timbers of pine or other softwoods,
and the first and
second elongated members are boards of uniform width which are spaced to
provide water
drainage between adjacent boards.
These mats generally include side beams having width and height dimensions of
between about 1x6 inches and about 24x24 inches and a length of between about
4 and 60
feet and longitudinal members having width and height dimensions of between
about 1x5
inches and about 24x22 inches, wherein the height and length of the
longitudinal members is
0.5 to 2 inches less than that of the side beams on each peripheral side of
the longitudinal
members. Preferably, the beams have width and height dimensions of between
about 8x8
inches and about 16x16 inches and lengths of between about 6 and 30 feet and
the
longitudinal members have width and height dimensions of between about 8x6
inches and
about 16x14 inches, wherein the height and length of the longitudinal members
is about 1 to
2 inches less than that of the side beams on each peripheral side of the
longitudinal members.
The invention includes crane mats that include between 2 and 4 longitudinal
members
of pine or softwood timbers. To strengthen the mat while reducing weight, a
steel plate can be
provided between each pair of adjacent beams or longitudinal members. These
steel plates
have a thickness of between about 1/8 inch and about 1 inch, and a height and
length that are
essentially the same as to 2 inches less than that of the longitudinal members
on each
peripheral side of the steel plates. Preferably, the height and length of the
steel plates are
about 1/2 inch as to 2 inches less than that of the longitudinal members on
each peripheral side
of the steel plates.
The side beams preferably have the same dimensions and are attached to the
longitudinal members to locate their upper surfaces about 1 to about 3 inches
above the
3
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
longitudinal members and to locate their lower surfaces about 1 to about 3
inches below the
longitudinal members, wherein the first and second plurality of elongated
members each have
a thickness of about 1 to about 3 inches to provide the substantially flat
upper and lower
surfaces of the mat.
Some of the first and second plurality of elongated members and adjacent
longitudinal
members have one or more openings to provide access to one or more of the
joining rods to
facilitate lifting or manipulation of the mat. And these mats can include
lighting elements
embedded in the elongated members to provide light to assist in the use of the
mat during the
night or on days that are dark due to poor weather conditions.
To provide mats that can be interlocked together when installed, the first
side beam
may be sized to provide about one half the height of the mat, with the first
side beam attached
to an upper portion of the support structure, or the second side beam is sized
to provide one
half the height of the mat and is attached to the second side of the support
structure in a lower
position, or both the first and second beams are sized as recited in order to
provide
interlocking structures. Thus, the first side beam of one mat sits upon the
second side beam
of an adjacent mat to form an interlocked structure of conjoined mats.
Preferably, the first
side beam may be sized to provide about one half the height of the mat, with
the first side
beam extending above the support structure by about 1 to about 3 inches with
the elongated
member or members adjacent the first side beam having a thickness of about 1
to about 3
inches. Additionally, the second side beam may be sized to extend below the
support
structure by about 1 to about 3 inches with the elongated member or members
adjacent the
first side beam having a thickness of about 1 to about 3 inches.
Another embodiment of the invention relates to an inventory of industrial mats
having
different core or internal constructions of wood, engineered wood,
thermoplastics,
elastomers, thermosetting plastics, metal, or of coated or encapsulated
components. Each mat
that has a different core or internal construction includes identification
means that indicates
the core or internal construction of that mat. The identification means
comprises an external
color code, a radio frequency identification (RFID) tag, or an alphanumeric
indicator applied
to an outer surface of the mat or that is provided upon a plate that is
applied to an outer
surface of the mat.
When the identification means comprises an external color code, that color
code is
placed in the same position on each mat for easy identification. Typically,
the external color
code is placed along a longitudinal side of each mat so that the color coding
is visible when
the mats are stacked upon each other.
4
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
Alternatively, the identification means may be a RFID tag that is attached to
the mat
and that can be scanned to identify the core or internal construction of the
mat. The
identification means can also be another electronic device that includes a
processor, storage,
and wireless communications circuitry.
Furthermore, the identification means can be an external alphanumeric
indicator that
is applied to an outer surface of the mat or that is provided upon a plate
that is applied to an
outer surface of the mat. These are preferably placed on the mat is an area
where they are
visible and where they would not be subject to contact by equipment that is
placed on or that
travels over the mat. Again, the side of the mat is a good location for such
identification
means.
And in addition to the mat identification means, each mat can be provided with
a
surface color that indicates a potential use or non-use of the mat. These
colors can include
red to indicate that portions of the mat need to be kept free of equipment,
yellow for
indicating that caution is needed or green to indicate portions of the mat
that are designed to
accommodate travel or movement by trucks or heavy equipment upon and over the
mat.
A further embodiment of the invention relates to an inventory of industrial
mats
having different core or internal constructions that are not visible because
of the inclusion of
side, end, upper and lower components which hide the core or internal
construction from
view, wherein each mat includes an electronic device that includes a
processor, storage, and
wireless communications circuitry that is configured to transmit
identification, location,
usage or physical property information of the mats over a wireless
telecommunications
network.
The electronic device is configured to communicate with electronic devices in
other
mats using a local network. In particular, the electronic device is configured
to communicate
real time location information to a server. Preferably, the electronic device
includes one or
more sensor including a vibration sensor that generate vibration data and the
electronic
device is configured to store the vibration data and transmit the vibration
data to a server.
Also, the electronic device is configured to send messages of such information
to
other devices through other electronic devices in other mats. The electronic
device may also
be configured to store an identification of the mat and manufacturing date of
the mat and to
transmit the identification and manufacturing date to a server. It also can be
configured to
include information such as the weight of the mats, their load capabilities,
markets or
applications where the mats are to be used, the style and type of mats,
maximum load limits,
age of the mat e.g., by quarter, condition of the mats (i.e., service hours,
damage or wear
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
conditions, etc.). The information can be provided with color coding for ease
of viewing and
interpretation.
Another feature of the invention relates to a method for providing an
identification of
mat properties or usage for an inventory of mats, which comprises providing an
inventory of
mats as described herein and viewing the identification means to determine the
hidden core or
internal construction of the mats so that the appropriate mats can be selected
and provided to
a customer or user, or for retrieving over a wireless telecommunications
network
identification, location, usage or physical property information of the mats
from the storage
of the electronic device.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended drawing figures provide additional details of the invention,
wherein:
Figure 1 is an exploded view of one embodiment of the mat of the invention
which
includes a core structure of fiberglass reinforced polyester beams and outer
wood board
layers;
Figure 2 is a side view of a reinforced polyester beam for use in the mat of
Figure 1;
Figure 3 is a view of the assembled mat of Figure 1;
Figure 4 is a perspective view of another embodiment of the mat of the
invention to
illustrate an open celled honeycomb structure for the core;
Figure 5 is a perspective view of another embodiment of the mat of the
invention to
illustrate an open celled hexagonal honeycomb structure for the core structure
and the
presence of additional sheet members to retain particulate filler in the
cells;
Figure 6 is an exploded view of a mat that includes a steel I-beam frame, wood
skins,
a foam core structure and bumpers on all sides of the mat;
Figure 7 is an exploded view of a mat that includes a steel I-beam frame,
polymer
skins, a foam core, and bumpers on all sides of the mat;
Figures 8 and 9 are exploded views of a mat that includes a fiberglass
reinforced tube
section frame, polymer skins, a foam core structure that interlocks with the
skins and
bumpers on all sides of the mat;
Figure 10 is an exploded view of a mat that includes a fiberglass reinforced
tube
section frame, wood boards, a laminated oak core structure and an outer oak
edge
construction that protects the tube section;
Figure 11 is an exploded view of a mat that includes a metal frame, upper and
lower
wood boards and wood bumpers;
6
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
Figure 12 is a perspective view of another embodiment of a mat according to
the
present invention;
Figure 13 is an exploded view of the mat of Figure 12 to illustrate the
various
components present therein;
Figure 14 is a perspective view of the support structure for the mat of Figure
12;
Figure 15 is a perspective view of yet another embodiment of a mat according
to the
present invention;
Figure 16 is a partial sectional view of the support structure for the mat of
Figure 15;
Figure 17 is a view of certain peripheral components for the mat of Figure 12;
Figure 18 is a perspective view of a crane or pipeline mat according to the
present
invention;
Figure 19 is an exploded view of the crane or pipeline mat of Figure 18;
Figure 20 is an exploded view of an interlocking mat having a steel frame and
woodblock core;
Figure 21 is a view of the constructed mat of Figure 20 with a portion of the
corner
removed to show the welded frame and core structure;
Figure 22 is an exploded view of an interlocking mat having a grating of a
fiberglass
reinforced thermosetting material;
Figure 23 illustrates the assembled mat of Figure 22;
Figure 24 is a perspective view of a crane mat having a core construction of
pine
timbers that are protected by oak beams and boards;
Figure 25 is an exploded view of the crane mat of Figure 24 to illustrate the
various
components of the mat;
Figure 26 is a partial perspective view of the end of the crane mat of Figure
24;
Figure 27 is a partial perspective view of the end of the crane mat of Figure
24 with
certain out components removed to better illustrate the internal components of
the mat;
Figure 28 is a schematic view of a software application for monitoring
locations,
properties and usage of the mats; and
Figure 29 is a functional block diagram from an on-board device that provides
identification feature and potentially other functionality such as tracking.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a number of different mats each having an
environmentally
resistant core and that includes replaceable elongated members, such as wood
boards, on the
7
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
top and/or bottom surfaces of the mat. These members can be replaced as they
wear or are
damaged while the environmentally resistant core can be reused and provided
with new
elongated members. The core is typically made of steel components,
thermoplastic members,
thermoplastic units, and thermoset gratings. In some cases, wood can be used
for core
components.
The new and improved industrial mats of the present invention now provide
additional advantages over conventional mats. For one, the use of a support
structure that is
not made of wood conserves timber resources which would otherwise be harvested
to provide
the long length beans for construction of the mats. Now, only the side beams
of wood are
used with the support structure providing the remaining width of the mat. And
in the
preferred arrangements, the support structure is not of the same height as the
side beams to
allow other, thinner elongated members to be applied to the top and bottom of
the support
structure so that the upper and lower surfaces of the mat are substantially
uniform. These
members may be wood but shorter lengths and thinner cross sections are used.
The wood members of the mat that are to experience abuse or wear are
preferably
made of hardwoods such as white oak, red oak, beech, hickory, pecan, ash or
combinations
thereof Also, engineered wood materials as described herein can instead be
used. And as
disclosed further herein, certain longitudinal members of the core
construction can be made
of softwoods such as pine because it is a lower cost, readily available wood
material. As
softwoods are not as abrasion and abuse resistant as hardwoods, the invention
contemplates
using the softwoods as internal components and protecting them with upper,
lower and side
materials of hardwoods, engineered lumber or plastic materials.
For other embodiments, the use of fiberglass reinforced thermosetting resins,
generally in the form of a pultrusion, for the side beams and elongated
members can be used
to essentially eliminate any wood in the mats. This further conserves timber
resources.
The term "fiberglass reinforced thermosetting plastic material" or "fiberglass
reinforced plastic" means a thermosetting material that is reinforced
generally with glass
fibers or other types of fiber strengthening materials, such as carbon,
aramid, basalt or other
fiber materials. The thermosetting material is usually a polyester, epoxy,
vinylester or even a
phenol formaldehyde resin. Skilled artisans are well aware of these and
equivalent materials
that are suitable to meet this definition.
The use of a non-wood support structure enables that component to be reused in
the
event that the side beams or elongated members become damaged or experience
deterioration
due to use and exposure to harsh environmental conditions. By being made of
more robust
8
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
and environmentally resistant materials, it is possible to disconnect the
joining rods to take
apart the mats and remove the damaged side beams or elongated members, and
then add new
components to the structure to form a new mat. In effect, this reduces the
demand for wood
beams or elongated members by 50 to as much as 100%.
Certain terms that are used herein are defined hereinbelow to assist in the
understanding of the invention.
The term "industrial mat" is intended to cover relatively large mats having
widths of
at least about 4 feet with lengths running from about 4 feet to 40 feet and
incorporating
elongated members, beams, or other components having square or rectangular
cross sections
of sizes of at least about 1x6 inches to 24x24 inches with lengths from about
4 feet to as
much as 40 feet or more. Preferred dimensions are described throughout the
specification.
As noted, previous and current mats of this type that are commercially
available are primarily
constructed of monolithic wood.
The term "non-wood" to describe the support structure is used for its ordinary
meaning. The components of the structure are generally not made of wood but
instead are
made of meat, a thermosetting plastic or other materials that are resistant to
degradation due
to environmental factors such as moisture from water, snow or ice, organisms
that can cause
wood rot, or similar external factors that affect wood.
The term "substantially" is used for its ordinary meaning to indicate that the
dimensions are not precise or exact. A skilled artisan can readily determine
what tolerances
are acceptable to provide a surface that is considered to be flat based upon
the size of the side
beams and the type of service that the mat is expected to provide. There is no
requirement
that the beams and elongated members be flush with each other along the top
and bottom
surfaces of the mat. Typically, the term "substantially' will mean that the
top surfaces of the
beams and elongated members can vary by as much as a few inches although in
the more
preferred embodiments the variance is less than 1 inch.
Additionally, all dimensions recited herein are approximate and can vary by as
much
as 10 % to in some case 25 %. In some situations, the term "about" is used
to indicate
this tolerance. And when the term "about" is used before reciting a range, it
is understood
that the term is applicable to each recited value in the range. Often, the
craftsmanship and
engineering procedures that are followed in construction of these mats
minimize these
tolerances as much as possible or industrially practical.
The invention contemplates the use of various components in the mat structure.
Typically, elongated members of wood boards have been used and the term
"elongated
9
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
members" as used herein means structures that assimilate wood boards or are
otherwise
configured with rectangular cross sections and lengths which are preferably
the full length of
the mat. Shorter lengths of these structures can be used, however, as they are
typically bolted
to the other components to form the mat. These elongated members are typically
solid but
they can be hollow tubular components which are optionally filled with other
materials such
as foams or particles. The sizes for such elongated members are about 1 to 4
inches thick,
about 6 to 12 inches wide and typically the length of the mat. Shorter boards
can be used if
desired and often are used when the mat is longer than 20 feet but full length
boards for the
entire length of the mat is preferred when possible. Lengths of 12 to 16 feet
are common.
For solid members, the preferred dimensions are 2 inches thick, 8 inches wide
and a length
that is the same as that of the mat (e.g., often 12, 14 or 16 feet or longer
if desired).
Other embodiments utilize components in the form of a structured unit. This
can be a
sheet or plate, or a layer which is solid or that includes cells or other
openings to reduce
weight or provide openings to facilitate joining of the components by bolting
or permanent or
other non-permanent means. Typically, the size of such units ranges from about
1 to 4 inches
thick, about 4 to 12 feet wide and typically the length of the mat. It is also
possible to use
multiple units in large mats, such as units that represent a portion (e.g.,
1/3 or 1/2) of the size
of the mat. The preferred dimensions are about 2 to 4 inches thick, 8 feet
wide and a length
that is the same as that of the mat (e.g., often 12, 14 or 16 feet or longer
if desired).
Typically bolting is used as it allowed the components of the outer layers of
the mat to
be removed if damaged or deteriorated and replaced with other components while
the
environmentally resistant core of the mat can be reused. For certain mats,
some or all of the
components that are used can be permanently joined together by welding or an
adhesive.
A wide range of thermoplastic or polymeric materials can be used for the core
structure of the mats of this invention. These materials would be molded or
cast to the
desired size and thickness of the mat. Useful materials include:
Acrylonitrile butadiene styrene (ABS)
Acrylic (PMA)
Celluloid
Cellulose acetate
Cyclo olefin Copolymer (COC)
Ethylene-Vinyl Acetate (EVA)
Ethylene vinyl alcohol (EVOH)
Fluoroplastics (PTFE, alongside with FEP, PFA, CTFE, ECTFE, ETFE)
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
Ionomers
Kydex, a trademarked acrylic/PVC alloy
Liquid Crystal Polymer (LCP)
Polyacetal (POM or Acetal)
Polyacrylates (Acrylic)
Polyacrylonitrile (PAN or Acrylonitrile)
Polyamide (PA or Nylon)
Polyamide-imide (PAT)
Polyaryletherketone (PAEK or Ketone)
Polybutadiene (PBD)
Polybutylene (PB)
Polybutylene terephthalate (PBT)
Polycaprolactone (PCI)
Polychlorotrifluoroethylene (PCTFE)
Polyethylene terephthalate (PET)
Polycyclohexylene dimethylene terephthalate (PC (PC)T)
Polycarbonate
Polyhydroxyalkanoates (PHAs)
Polyketone (PK)
Polyethylene (PE)
Polyetheretherketone (PEEK)
Polyetherketoneketone (PEKK)
Polyetherimide (PEI)
Polyethersulfone (PES)- see Polysulfone
Polyethylenechlorinates (PEC)
Polyimide (PI)
Polylactic acid (PLA)
Polymethylpentene (PMP)
Polyphenylene oxide (PPO)
Polyphenylene sulfide (PPS)
Polyphthalamide (PPA)
Polypropylene (PP)
Polystyrene (PS)
Polysulfone (PSU)
11
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
Polytrimethylene terephthalate (PTT)
Polyurethane (PU)
Polysulfone (PSU)
Polytrimethylene terephthalate (PTT)
Polyvinyl chloride (PVC)
Polyvinylidene chloride (PVDC)
Styrene-acrylonitrile (SAN)
It is also possible to utilize fiberboard as the elongated members or sheets
that form
the core structure. The fiberboard material is made of recycled plastic or
polymeric materials
from used carpets, plastic packaging and the like. They can be provided in the
desired sizes
for use as the core structure of the mats of this invention. In addition to
being
environmentally resistant due to their plastic content, these fiber boards are
environmentally
friendly by allowing recycling of used materials that contain plastic or
polymeric materials.
The core structure may also be made of an elastomeric material. The elastomers
are
usually thermosets (requiring vulcanization) but may also be thermoplastic.
Typical
elastomers include:
Unsaturated rubbers that can be cured by sulfur vulcanization ¨ these are
preferred
from a strength and hardness standpoint:
Natural polyisoprene: cis-1,4-polyisoprene natural rubber and trans-1,4
polyisoprene gutta-percha;
Synthetic polyisoprene;
Polybutadiene;
Chloropene rubber, i.e., polychloroprene;
Butyl rubber (i.e., copolymer of isobutylene and isoprene) including
halogenated butyl rubbers (chloro butyl rubber; bromo butyl rubber);
Styrene-butadiene Rubber (copolymer of styrene and butadiene); and
Nitrile rubber (copolymer of butadiene and acrylonitrile).
Saturated (i.e., non-vulcanizable) rubbers include:
Ethylene propylene rubber (EPM);
Ethylene propylene diene rubber (EPDM);
Epichlorohydrin rubber;
Polyacrylic rubber;
Silicone rubber;
Fluorosilicone Rubber;
12
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
Fluoroelastomers;
Perfluoroelastomers;
Polyether block amides; and
Chlorosulfonated polyethylene.
The elastomeric, thermoplastic or thermosetting materials disclosed herein can
also be
provided with conventional fillers to increase weight and hardness. They also
can be
reinforced with particulates, fibers such as glass, fabric or metal screening
or scrim to reduce
elongation and provide greater rigidity. Also, when the entire mat is made of
elastomeric,
thermoplastic or thermosetting materials, the entire mat can be made as an
integral
component.
The polymeric or elastomeric core structure can be made as a flat sheet
provided that
it has the necessary weight and rigidity. These variables can be controlled by
the selection of
the particular polymer or by providing a particular configuration for the
core. For example,
the core structure can be made with a honeycomb or open cell structure.
The term "honeycomb structure" refers to a structure that has openings or open
cells
therein which can be used to reduce weight or can be filled with other
materials. The shape
of the cells can be hexagonal, square, rectangular, or of another polygonal
shape, or they can
even be round. The cells can be adjacent to each other or spaced as desired
and can extend in
either the horizontal or vertical or direction.
With this construction, the weight of the mat can be increased and the
resistance to
liquid absorption improved by filling the cells of the honeycomb structure of
the core
structure with one or more of various materials, including sand, dirt, gravel,
particles of
plastics, ceramics, glass or other materials, various foam materials, or even
of recycled
materials such as particles of ground vehicle tires or other recyclable
materials. The latter are
preferred to fill the core structure to provide an environmentally friendly or
"green" mat.
The plastic core structure can also be provided in two half sections in the
vertical
direction, i.e., an upper section and a lower section. The upper section can
be designed with
protrusions or raised and lower areas on its lower surface with the lower
section designed
with complementary recesses or lower and raised areas on the surface that
faces the upper
section so that the upper and lower section can be joined together by
engagement of the
protrusions and recesses or raised and lower areas.
Alternatively, the core structure can be made of a metal frame or ladder
structure.
Typically, steel, stainless steel or aluminum are used and the frame or
structure can be bolted,
riveted or welded together. The metal frame or structure if made of steel can
be further
13
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
protected by galvanizing, painting or otherwise depositing powder or liquid
coating material
thereon to prevent moisture from contacting the steel. For example, the entire
core structure
when made of steel can be coated with a paint or even with a thermoplastic or
thermosetting
resin.
The metal frame or ladder structure can be used as is or can be configured
with
netting, mesh or other material that allows any frame openings to be provided
with a filler to
modify the weight of the mat. If additional weight is desired, heavier filler
material can be
used. To fill in the interior sections of the frame without adding too much
weight to the mat,
a plastic or rubber filler of low density particles or foam can be used.
Another embodiment of the invention will utilize wood components for the core
construction, with softwoods such as pine, cedar other conifer tree materials
and preferably
pine utilized for this purpose. Pine is an abundant, low cost wood material
that is readily
available in the sizes needed for industrial mats. It does not possess the
same abrasion and
abuse resistance as hardwoods such as oak. Thus, pine or other softwood can be
used as a
core construction material in the mats of the invention provided that it is
protected by outer
components of the mat that are made of more rugged materials. In a crane mat,
for example,
the outer side beams can be oak timbers of the desired size, with the pine
beams being used at
a smaller size than the oak timbers such that the oak timbers extend both
above and below the
pine timbers. Then, the spaces between the exposed surfaces of the pine and
oak timbers can
be provided with one or more elongated members of wood, engineered lumber,
plastic or
recycle materials. These materials can be used in the form of boards or as a
sheet member to
form with the oak timbers the exposed upper and lower mat surfaces of the mat
which are
configured to be relatively flat. These outer components protect the pine from
damage while
the pine lowers the cost of the mat compared to the more expensive and less
readily available
oak or other hardwoods.
And in a preferred embodiment, each adjacent beams and timbers of the mat
would be
separated by a steel plate which would be slightly smaller than the height and
length
dimensions of the pine timbers. While it is possible for the steel plate to be
have the same
height and length dimensions as the pine timbers, the use of a slightly
smaller plate, for
example, one that is one half inch to 2 inches smaller than the pine timber on
each peripheral
side of the plate is preferred. These plates would also have a preferred
thickness of about 1/8
to 1/2 inch although thicker plates can be used in larger mats. And for
smaller size mats, other
metal plates, e.g., aluminum, can be used instead of steel.
14
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
In the preferred constructions, the steel members do not extend to the upper
or lower
surfaces of the mat and instead are covered by the upper and lower elongated
members. And
when the elongated members are boards, they can be spaced to allow certain
voids to be
present between them which act as channels that allow water to drain from the
mat.
The assembled mat in the preferred embodiments can vary depending upon the
specific type of mat. 2-ply or 3-ply laminated mats will typically include
elongated members
that are about 2x8 inches with the mat having a width of approximately 8 feet
and a length of
about 12, 14 or 16 feet. General industrial mats would typically have a
thickness of
approximately 6 inches which is made up of a core construction that is 2 or 4
inches thick, an
upper layer that is 2 inches thick and a lower layer that is 2 inches thick.
For a three layer
mat, each layer would be 2 inches thick, while for a two layer mat, the core
would be 4 inches
thick and the upper outer layer would be 2 inches thick. A crane or timber mat
would be
about 4 to 8 feet wide with beams having typical width and height dimensions
of 6x6, 8x8,
10x10 or 12x12 inches and a length of between about 20 and 40 feet. The core
structure may
be made of any environmentally resistant material disclosed herein and in the
desired shape
and configuration. The number of top, bottom, and core structure components
will be
dictated by the final dimensions of the mat for the particular application or
end use. Also, the
preferred embodiments will include spacing in between top, middle, and bottom
boards with
is no wider than about 11/2 inches.
The core structure can be made up of different environmentally resistant
materials.
For example, a core structure of a sheet or plate of a thermoplastic or
thermosetting material
can be provided with a thin sheet of metal for additional reinforcement or for
maintaining
filler material in the cells or openings of the sheet or plate. A steel sheet
can be used upon a
layer of a thermoplastic material in the form of a sheet or other structure to
provide stiffening
of the core structure.
The core structure made of environmentally resistant materials prevents
degradation
from exposure to weather conditions in the event that water or other liquids
enter into the
core. Preferred specific environmentally resistant materials for the core
structure include:
various thermosetting materials, including 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 filler (carbon, glass, metal, etc.);
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
a thermoplastic material (any of the various plastics mentioned hereinabove)
and in particular, HDPE, PET and SBR as disclosed in US patent
6,380,309;
a honeycomb structure with filled cells and upper and lower plate surfaces
that
are molded or otherwise constructed, as disclosed in US patent
8,061,929;
open face filled cellular structures of thermoplastics, polyolefins or
vulcanized
rubber as disclosed in US patent 6,511,257;
molded sheets of thermoplastic resin as disclosed in US patent 5,888,612;
a metal structure or frame of aluminum or stainless steel or of steel that is
coated, painted or galvanized to assist in preventing rusting when
contacting water; or
a reinforced plastic composite material as disclosed in US patent 4,629,358.
The edges of the core structure can be protected as disclosed in US patent
application
2014/0193196 or with wood or synthetic laminate to avoid mechanical damage to
core
structure edges. Additionally, a bumper structure of wood or plastic material
as disclosed
herein can also be used.
For certain open cell core structures, reinforcement with sheets or other cell
closing
materials can be used to improve stiffness and strength of the core structure
while also
retaining the filler in the cells or openings.
It is also possible to use a metal plate as the core. The metal plate can
include
openings or apertures to reduce weight. A plate of a thermosetting plastic can
instead be
used, and it can be solid or have openings therein. The plates can be 2 to 4
inches thick. A
fiberglass reinforced thermosetting plastic grating having openings that are
2x2 or 3x3 inches
is preferred.
To reduce the weight of the mat, the core structure can be made of a honeycomb
or
lath structure, or with a plurality of openings. For very open structures, the
cells or openings
can be filled as noted above with a material that is lighter than the metal to
maintain the
weight at a desired level. The openings can be covered with upper and/or lower
sheeting to
retain the filler therein. Any material can be used for the sheeting as the
metal core structure
is providing the necessary strength and rigidity to the mat. Typically, the
sheeting may be
plywood, plastic, metal or composite material, and can be solid or in mesh
form. The
sheeting can be attached to the mat preferably by riveting, bolting or by an
adhesive. The
sheeting and core structure can be maintained in position be being sandwiched
between the
16
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
outer layers, with the entire structure held together by bolting or riveting.
If necessary, holes
for the bolts or other fasteners can be drilled through the metal plate or
sheeting to facilitate
assembly by allowing passage of the fasteners therethrough.
And as noted herein, pine or other soft wood timbers can be used for the core
of the
mat. These materials would have slightly smaller height and length dimensions
and those of
the side beams. For example, for a crane or timber mat that includes side
beams having
typical width and height dimensions of 6x6, 8x8, 10x10 or 12x12 inches and a
length of
between about 20 and 40 feet, the pine timbers would have width and height
dimensions of
about 6x4, 8x6, 10x8 or 12x10 inches with the same length. And when steel
plates are used,
these could have the same height and length as the pine timbers but the could
instead have a
height of about 2 to 4, 4 to 6, 6 to 8, or 6 to 8 inches and a length of
between about 19 feet 8
inches and 39 feet 8 inches, respectively.
Generally, the mat construction for a laminated mat comprises one of the cores
disclosed herein along with upper and lower layers of elongated members or
beams. For the
upper and lower layers, the thickness of the boards will be approximately 1.75
inches but
may be between 1.5 and 3 inches. Length will be as desired but will preferably
be 12, 14 or
16 feet. The width of the boards will vary depending upon location on the
core. That is, the
width of the top and bottom layer boards will be approximately 8 inches
(single width) or 16
inches (double width). Approximately means they may be slightly less such as
7.5 to 8.5
inches or 15 to 17 inches. A typical thickness for the mat is at least about 4
inches and
preferably approximately 6 inches, with the central layer providing a
thickness of about 1 to 4
inches and the upper and lower layers providing a thickness of about 1 to 3
inches.
Generally, the boards have a narrower width than the softwood beams, but of
course, the
dimensions can vary depending upon the specific end use intended for the mat.
Also, the
beams can be manufactured to any particular thickness, width and length, but
the preferred
dimensions disclosed herein approximate those of conventional mats of white
oak or other
materials which are in use in the industry.
In a most preferred embodiment, the mat includes a core structure of an
environmentally resistant material, an outer upper layer positioned above the
core structure
and an outer lower layer positioned below the core, wherein each outer layer
includes a
plurality of elongated members each having a modulus of 1.6 M psi. As noted,
the core
structure is made of materials that provide a load bearing capacity that is
able to withstand a
load of at least 600 to 800 psi or more without damaging or permanently
deforming the core
structure.
17
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
The core structure can include one or two outer layers as desired or necessary
for a
particular installation and stiffness. The core structure components can be
made be of
sections or smaller portions that are joined together to form the desired size
of the core. As
an example, for a thermoplastic core structure of HDPE, sections may be welded
together to
provide the desired size, e.g., four HDPE 4 x 8 foot sections can form the
core structure of a
mat that is 8 x 16 feet. Similarly, eight 4 x 4 foot sections can be joined by
welding to form
the same 8 x 16 foot mat. The same is true of wood, metal or elastomeric
components, which
can be joined mechanically, by adhesives or where applicable by welding. The
core structure
can also be made of upper and lower half sections that can be joined together
by welding, a
mechanical interlocking, by fasteners or by adhesives.
Additional layers or components can be added to the core structure or mat, but
the
most preferred construction includes outer layers above and below the core
structure as noted
herein. The outer layers are preferably made of white oak as disclosed in US
patents
4,462,712 (three layer) and 5,822,944 (two layer), the entire content of each
of which is
expressly incorporated herein by reference thereto. The mats are generally
designed with
water channels on the outer layer(s) to drain water from the mat. This is
achieved by the
spacing of the elongated members or by the provision of grooves in a sheet or
other wider
surface that is presented on the outermost layers of the mat. The grooves are
generally
rectangular in shape and typically have a width of about 1.25 inch and a depth
of about 1
inch. It is of course also suitable to use channels that are U-shaped instead
of being
rectangular and that have a similar size as this achieves the same purpose of
providing a path
for moisture to be removed from the mat.
And while symmetrically formed mats are preferred, it is also possible to
provide a
core structure that has a different number of layers or plies on one surface
than another. For
example, the top surface of the core than include two layers or plies of
components such as
elongated or sheet members, while the lower surface can include only a single
layer or ply of
such components. And the materials used for the components of one outer layer
does not
have to be the same as the materials used for other outer layers. Thus, the
mat designer has
abroad range of possibilities for mat construction to tailor a specific mat
for a particular
installation or need.
Instead of wood, it is also possible to use engineered lumber for the outer
plies or
layers that are present above and below the core structure, either as a solid
sheet or in the
form of boards. Other materials that can be used our plastic layers or layers
of recycled
materials that are extruded into a final form of a plate or boards. These
recycled materials
18
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
can include material from carpets, tires, water bottles, food containers or
other industrial
plastic materials, as well as plastic resins that include components obtained
from rice hulls,
soybeans or other organic materials. Rice hulls can also be used as a filler
in plastic
materials. These recycled plastic materials have good environmental and impact
resistance
and can be made extruded into a desired shape of any length. They typically
can be made
into boards although with the sight sized equipment, sheets can also be
provided.
Referring now to the Figures, Figure 1 illustrates mat 100 that includes an
upper outer
layer 105 and lower outer layer 110 which are used to surround core structure
115. The core
structure includes a plurality of reinforced polyester beams 125 and the outer
layers include
single width wood boards 130. The reinforced polyester beams 125 are oriented
perpendicular to the boards of the upper and lower outer layers. As shown in
Figure 2, the
reinforced polyester beam 125 is in the form of a rectangular tube that has
two internal wall
supports 120 running along the interior of the tube.
Boards 125 are applied to the core structure 115 by nailing, screwing, bolting
or
riveting of the boards 125 to the reinforced polyester beams 125 of the core
structure 115.
When bolting is used, the bolts can extend from the upper boards to the lower
boards through
the reinforced polyester beams 125. The nails, screws or bolt heads and nuts
are recessed
below the top surface of boards 130 and below the bottom surface of boards 130
to present
relatively smooth upper and lower surfaces of the mat 100.
Alternatively, the boards can be attached to the core structure 115 by an
adhesive or
other means that provide a secure attachment. For example, when the core
structure is made
of a thermosetting material, the sheet and boards can be made of the same
material as a
unitary component. For a metal core, holes can be drilled to allow the bolts
to pass
therethrough.
As shown in Figures 1 and 3, eleven (11) boards are used. The third, sixth,
and ninth
boards (135, 140, 145 respectively) of the lower outer layer are offset to
provide an
interlocking feature for the mat. And while offsetting of certain boards is
preferred for
providing an interlocking with adjacent mats, this is not always needed such
that interlocking
can be considered to be an optional yet desirable feature. Interlocking is
often preferred to
avoid staking of the mats to the ground or to avoid including other more
complex
components for use in connecting adjacent mats together.
And while the interlocking is shown on opposite sides of the mat, the mats can
be
interlocked together in any direction using the top or bottom layers with
appropriate
configuring of the components of those layers.
19
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
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 which are
attached to the
boards in recesses 170 so that the lifting element 150 can remain flat when
the mat 100 is in
use. Two lifting elements are shown but a skilled artisan can determine how
many elements
are needed for lifting of any particularly sized mat. If desired, lifting
elements can also be
provided on the boards attached to the lower outer layer 110 for versatility
in the handling
and transportation of the mat. The lifting elements are provided on the boards
that are
attached to the skin portion so that if the lifting elements or boards are
damaged they can be
easily removed and replaced.
The provision of single width boards enables the upper and lower moldings to
have
water channels 175 on the upper surface of the skin to drain water from the
mat.
Figure 3 illustrates the final shape and configuration of the mat 100 after
assembly.
Figure 4 illustrates a second mat 200 according to the invention which
includes a
lower outer layer 130 and a core structure 215 that has a plurality of cells
260. As some of
the components are the same as in Figures 1-3, the same numerals used are used
to designate
the same components for the mat of Figure 4. The core structure 215 may be
made of a
thermoplastic 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 grating
having square or rectangular openings therein. The openings or cells of the
core structure
may be filled with a foam or other material that expands to fill the cells 260
and remains
adhered thereto. In this situation, no cover member is needed to retain the
filler material in
the core structure 215. For that situation, or for the situation where the
cells are filled with
particulate matter, upper and lower layers 130 as described above can be
applied to the core
structure 215 to assist in retaining the particulate material in the cells
260.
Figure 5 illustrates a third mat 300 according to the invention which includes
a lower
outer layer 130, an upper outer layer 330 and a core structure 315 that has a
plurality of cells
360. As some of the components are the same as in Figures 1-4, the same
numerals used are
used to designate the same components for the mat of Figure 5. The core
structure 315 may
be made of a thermoplastic material or metal and the cells 360 are of
hexagonal shape to
provide larger openings can be left open or filled with particulate material
as disclosed
herein. In particular, the cells may be filled with foam, particulates or
other non-adherent
materials, e.g., rubber crumbles from recycled automobile tires. For such
particulates, the
cells 360 can be covered by one or more sheet members either above, below or
both above
and below the core structure to retain the non-adhering filler materials in
the cells. The sheet
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
members can be made of wood boards, plywood, plastic sheeting, metal sheeting,
e.g., steel
or aluminum, or the like. When the sheet members are only provided to hold the
filler
materials in the cells, they can be relatively thin e.g., 1/8 to1/2 inch is
sufficient although
larger thicknesses can be used if desired to add weight to the mat. The core
structure and
sheet members can then be used as a core structure with outer layers applied
as in the other
embodiments.
Alternatively, when sheet members are not needed, the lower layer 130 and
upper
layer 330 can be wood boards that retain the filler in the cells 360 as shown
in Figure 5. In
this embodiment, when the core structure 315 is molded of plastic material,
the areas between
where the boards are placed would be made of solid plastic rather than open
cells so that the
particulate material does not exit the cells through the spacing between the
boards. These
boards would have a thickness of 1.6 inch or greater depending upon the needed
weight of
the mat. The filler also contributes to the weight of the mat.
Of course, if the material of the core structure 315 and lower 130 and upper
330
layers provides sufficient weight, the cells do not need to be filled and the
additional sheet
members are not needed. Additional sheet members are also not needed if the
cells are filled
with an adherent filler material. The boards 130 of the upper and/or lower
outer layers can be
attached by bolting which passes through the cells. If desired, and
preferably, the upper outer
layer 330 is provided so that the final mat structure has an appearance that
is similar to that of
Figure 3.
Another embodiment of the invention is a variation on that of Figure 5. The
core
structure is made of a plastic material that has cells made with flat upper
and lower surfaces.
These surfaces support the sheet members if the cells are filled and instead
support the lower
and upper layers if the cells are not filled. These cells thus act as shock
absorbers to provide
resilient compression to the mat.
In a preferred embodiment of the invention, the mat includes bumpers which
protect
the sides of the mat from damage during transport and installation. These
bumpers are
generally configured as a rails, rods or beams of a material that protects the
sides and core
structure of the mat from damage when being moved around from warehouse to
truck to
jobsite. As the mats are relatively heavy, around 2000 pounds, they are moved
by heavy
equipment such as front end loaders or cranes, and are typically dragged or
dropped into
position. The bumpers also provide protection to the side edges of the mats
due to such
movements and manipulation as well as some resistance to penetration by teeth
or tines of the
moving equipment. In one embodiment, the bumpers are made of a durable, tough
and
21
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
resilient material such as a plastic or elastomer, in particular, HDPE or a
rubber material
having a Shore D hardness of 10 to 50 is preferred. The bumpers are preferably
molded or
extruded into the desired shape or shapes for releasable attachment to the
mat.
Figure 6 shows mat 400 which is configured as a Crane/Pipeline mat, typically
having
dimensions of 8 inches thick by 4 feet wide and 18 feet long. These are used
primarily for
drilling rigs and similar applications such that these mats are much more
robust and tough
compared to mats for temporary roadways. To provide sufficient strength, the
mat preferable
includes a steel ladder frame 405 that provides the periphery of the mat. The
frame 405
includes a number of cross-members to provide rigidity and strength to the
frame to support
the other mat components. The openings are provided to allow connections to be
made and
to reduce the overall weight of the mat compared to one made of solid steel. A
core structure
410 is present within the ladder frame 405 and upper and lower wood skins 415,
420 are
provided to protect the core structure 405. The core structure 410 of the mat
is a solid or
foam core structure preferably molded from HDPE or a similar polymer. The use
of a
polymeric core structure and the geometry/shape of the cells helps reduce the
overall weight
of the mat while providing sufficient internal support so that the mat can
provide the
necessary strength against compression and compaction. The wood skins 415, 420
provide
sufficient durability to equipment or vehicles that move over or that are
supported by the mat.
Also, the mat has openings that allow water or other liquids to pass through
during use. As
the core structure is made of environmentally resistant materials, there is no
need to provide a
hermetic seal about the core structure components of the mat.
As shown in Figure 6, the bumpers 425 are 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 in the open area of the I-beam that forms the periphery of the
mat. The bumpers
have a shape that fits within the open cavity of the I-beam without completely
filling the area,
as this allows the bumper to be compressed to absorb shock. If desired, the
bumpers can be
bolted, riveted or joined to the I-beam by an adhesive so that they are
retained in position.
As shown, the bumpers in the enlarged view of mat 400 have a tri-tube
arrangement
430, of a "+" shape, that has a larger tube 430A in the center and the smaller
tubes 430B,
430C located above and below the central tube. The tubes can be extruded in
the shape that
is shown or separate tubes can be made and then joined by welding, adhesive
bonding or
even by mechanical fasteners. This shape is not critical, however, and other
shapes that are
round, polygonal or that have combinations of different shapes can be used for
the bumpers if
desired. For certain materials, the bumper can fill the entire open side
cavity of the I-beam,
22
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
or it can partially fill the cavity provided that the bumper contacts the
inner wall of the I-
beam and extends towards the periphery of the mat so that it can absorb shock
or impact
forces.
In other embodiments disclosed herein, the bumpers can be made of wood. Wood
is a
useful relatively low cost material that has a history of good service in oil
field mat
applications.
The bumpers are preferably located on all sides of the mat. To retain the
bumpers in
position in the I-beams, rather than using an adhesive of bolting, the upper
and lower layers
of the mat can be provided with an additional member that is nailed to the
upper and lower
wood skins to retain the bumpers in place to prevent their dislodgement from
the I-beam.
The bumpers provide protection to the sides of the mat as well as to avoid
damage to the core
structure components.
Figure 7 illustrates another Crane/Pipeline mat 500 that also includes a steel
ladder
frame 505 that provides the periphery of the mat. A similar foam core
structure 510 is
present within the ladder frame 505 and upper. Instead of upper and lower wood
skins,
however, the mat 500 of Figure 7 includes upper 515 and lower 520 vacuum
formed polymer
skins to protect the core structure 510. These skins can be formed to a
thickness of up to
00.6" or greater. The skins preferably include lips 530 that engage the upper
and lower
portions of bumpers to retain them in place in the I-beams. Again, the bumpers
are shaped as
a plurality of joined tubes as shown in Figure 6 with upper and lower tubes
being of smaller
cross section than the center tube. The upper and lower tubes can also be
shaped to engage in
full contact the I-beam inner surfaces while being recessed from the end of
the central tube so
that the lips 530 can maintain the bumpers in place. Other shapes for the
bumpers are
acceptable provided that they can fit in the I-beam and provide an outer
surface that can
absorb shock and impact. For the configurations shown the tubes can collapse
somewhat to
absorb such forces.
The lip portions of the upper 515 and lower 520 skins can be a separate
component
that is attached to those layers or it can be molded or formed as an integral
part of those
layers. Generally, the upper 515 and lower 520 skins are made of a molded
plastic or
elastomeric material because such materials provide environmental resistance
and impart
durability and toughness to the mat. Also, the core structure 510 can be
provided in two
halves, an upper half that is attached to the upper skin and a lower half that
is attached to the
lower skin. These halves can be designed with protrusions or raised and lower
areas so that
they can be joined together by engagement of the protrusions and recesses or
raised and
23
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
lower areas. This reduces installation time and also assures that the core
structure and skins
interlock to provide the best resistance against compressive forces.
In the embodiments of Figure 6 and 7, the steel frame can be painted or coated
with a
sacrificial metal (i.e., galvanized or phosphatized) to provide improved
environmental
resistance to the mat. While rusting of the steel is not detrimental to the
operation of the mat,
it does not provide a good cosmetic appearance such that the painting and
coating
compensate for that by minimizing rusting. Stainless steel can also be used
but that material
is more expensive. Aluminum can also be used but some strength to the mat is
lost with that
lighter weight construction. The metal ladder frame is advantageous because,
in addition to
its strength and ease of working, it can be configured to allow direct
attachment of the lifting
elements to the frame 505 to provide a more robust connection that facilitates
lifting and
manipulation of the mat.
As in Figure 6, the mat of Figure 7 has a reduced overall weight by
incorporating the
molded or structural foam core structure in the steel frame. Whether the upper
and lower
layers are made of wood or of a plastic or elastomeric material, the entire
structure is bolted
or riveted together to form the final mat.
To further reduce the weight of the mat while also improving its environmental
resistance, a box frame of fiberglass reinforced plastic (FRP) can be used
instead of the steel
frame. This is shown in Figure 8, in mat 600, that has a FRP box frame 605.
The box frame
605 may be made of rectangular or square tubular structures. If desired, the
FRP box frame
605 can be configured as a ladder frame as shown in Figures 6 and 7. The FRP
frame
provides lower weight and good durability and resistance to moisture of other
liquids that
may permeate into the core. To provide additional crush resistance to the
frame 605, the
open center portions of the tubes can be filled with foam, recycled rubber
tire material or
other filler material 610. A polyurethane foam can also be used for this
purpose. The filler
material can also be selected to provide additional weight to the mat if
desired.
The plastic of the FRP material would be any one of the thermosetting plastics
of the
types mentioned herein but thermosetting polyesters and epoxies are preferred.
Figure 8 illustrates another feature of the invention where the molded foam
core
structure 612 is locked in place by engaging pockets 617 in the upper 615 and
lower 620
polymer skins.
When a box frame is used, the bumpers 625 are configured with a flat surface
to abut
against the frame 605. The bumpers 625 are configured with upper and lower
portions that
are less wide than the central portion of the bumpers so that the skins 615,
620 can include
24
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
lips 630 that engage the bumpers 625 to hold them in place against the box
frame 605. These
lips are essentially the same as those shown in Figure 7. The bumpers protect
the FRP box
frame from damage since the FRP box frame is not as strong as the steel ladder
of Figures 6
and 7. The FRP beams may be made by a pultruded process as this results in a
light but
strong construction.
In Figure 8, the upper 615 and lower 620 polymer skins can be configured with
protrusions or honeycombs that interlock with the core structure 612 to form a
more rigid
structure. Alternatively, the foam core structure 612 can be omitted and the
open center of
the mat filled recycled rubber tire material or other particulate filler
material as is done with
the central opening of the pultruded FRP box frame.
Alternatively, rather than fit into the structure on the sides of the mat, the
bumpers can
be designed with a "C" shaped cross section so that they can contact the top,
side and bottom
of the pultruded FRP box frame members. The top and bottom surfaces of the
bumpers can
extend above the upper and lower surfaces of the mat or they can be designed
to remain flush
with those surfaces by providing a thickness on the top and bottom bumper
portions that
correspond to the thickness of the top and bottom layers. Alternatively, the
bumpers can be
bolted, screwed, snap riveted or adhered to the FRP box frame with an
adhesive.
Figure 9 illustrates the same type of mat as in Figure 8 such that the same
numbers are
used to describe it. The main difference in the mat 700 of Figure 9 is that
the box fame 605 is
not filled and is open 710 as for certain embodiments, the filler is not
necessary. The
bumpers in Figures 8 and 9 have a "T" shape with the central portion
protruding beyond the
sides of the mat to provide protection of the FPR frame and core.
Figure 10 illustrates another embodiment of a Crane/Pipeline mat 800 that
includes a
box frame 805 of an FRP square tube. The box frame 805 surrounds a laminated
wood core
810. Although the wood core 810 is heavier than the foam core of the other
embodiments, it
is much less expensive and can be used in certain installations where the
greater weight or
ruggedness of the mat is needed. The oak core boards are configured to fit
within the
openings of the box frame 805 and are bolted together so that they do not move
around inside
of the mat. Oak boards are also used as the top 815 and bottom 820 surfaces of
the mat 800.
The FRP frame 805 is protected by a rectangular wooden structure 825 which is
also
made of oak boards. The boards are joined together to form a square structure
that is
approximately the same size as the box frame 805 in width and height
dimensions although
the perimeter is larger so that the structure 825 sits outside or and adjacent
to the box frame
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
805. The wood structure 825 acts as a bumper to protect the FRP box frame from
damage
during loading, transport and installation.
To provide additional protection to the box frame 805, the open area of the
frame can
be provided with a stabilizer 830 of foam or extruded polymer. As in Figure 8,
the open area
can be can be filled with recycled rubber tire material or other particulate
or solid filler
material. One variation of the stabilizer 830 is shown in Figure 10 but the
bumpers and solid
foam inserts of the other embodiments can be used as well, depending upon the
desires of the
designer of the mat. The wood structure most likely obviates the need for
stabilizers for most
installations.
Figure 11 illustrates another embodiment of a mat 900 that includes a frame
905
constructed of a metal such as aluminum, stainless steel or steel. The frame
905 is made of
square or rectangular tubing that is welded together to provide a high
strength core
component for the mat. The frame 905 can remain as an open structure as shown
or areas
910 between the cross members can be provided with a particulate filler or
foam that is
retained in place by a mesh, screen or sheets that are secured to the top and
bottom of the
frame. Also, if desired, the tubes can be filled with a foam, rubber particles
or even sand to
add weight and strength to the mat. If desired, a wood core can be used along
with or instead
of the fillers. Preferably, however, the areas are left free of any filler.
The mat 900 includes top 920 and bottom 925 wood boards preferably of oak that
provide a flat surface for movement of vehicles or supporting equipment
thereupon. These
boards also provide upper and lower surfaces of the mat and protection of the
core structure
905. These boards 920,925 also have spacings between them to allow water to
drain from the
upper surface of the mat, into the core structure and out of the lower surface
of the mat. As
the core structure 905 is made of an environmentally resistant material, there
is no concern of
deteriorating the core structure due to contact with water. The top and bottom
wood boards
are joined together about the frame using nails or bolts. Also, the tubular
members of the
frame 905 can also be provided with holes passing therethrough to accommodate
bolting that
is used to attach the wood boards 920,925 to the frame 905.
The frame 905 is also protected by wood boards 915 that provide replaceable
bumpers
for the frame 905. These can be attached to the frame by bolting that engages
holes in the
tubular members, or the wood boards 915 can be attached to the upper or lower
boards 920,
925. As an alternative connection member, the frame 905 can be provided with
studs or bolts
that are welded to the tubular members and that receive the bumpers 915 or the
upper 920 or
lower 925 boards by passing through correspondingly located holes in those
boards. The
26
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
boards are then secured to the frame by appropriate nuts and washers or by
flattening of the
studs. This provides a simple yet robust construction for mat 900 which as
noted allows
replacement of boards that may become damaged during use. In the embodiments
of Figures
9 to 11, the top boards can be 1.25" by 16" wide although smaller sections can
be joined
together if desired. The box frame has a preferred size of about 5.5 by 5.5
inches so that the
mat has an overall thickness of about 6 inches.
All of the mats according to the invention are to be installed on properly
prepared
ground so that they will perform acceptably. Ground preparation must be on a
uniform
material of uniform flatness (i.e., within +/- 12 inches over an 8 x 14 foot
surface). Crushed
stone or rock no larger than 4 inches diameter is acceptable for preparing the
ground as a
substrate for supporting the mats.
All mats according to the invention are designed to meet the following product
specifications for preferred implementations as temporary roadways, equipment
support
surfaces, platforms and similar applications. The mats of the invention do not
cause
contamination of the ground surfaces upon which they are applied.
Preferred overall mat dimensions are approximately 8 feet wide x 6 inches
thick and
are either 12, 14 or 16 feet in length. The interlocking feature will extend
the length of the
mats by about 1 ft at three locations at one end of mat. US patent 4,462,712
discloses mats
which contain interlocking fingers and recesses which are preferred for use in
the present
invention.
The mats typically include two (2) outer layers of individual wood or
composite
boards, having cross section dimensions of 1.75 by 8 inches.
The spacing between individual boards or components in the upper outer layer
is
preferably approximately 1.25 inch to allow water to drain from the mat. This
spacing is
retained in the upper portion of the skin. The slip resistance of the mat is
improved by the
draining of the excess water, especially when used in locations that
experience heavy rain or
snow conditions. The spacing between the individual boards or components can
also be
provided on the lower outer layer of the mat to allow the mat to provide
better gripping onto
the ground. The spacing or similar grooves on the lower outer layer on the
bottom of mat
will keep the mat from moving around on the ground as traffic moves across it.
The spacing
or grooves re even more important when the lower portion of the mat is made of
an
elastomeric or thermoplastic material so that the mat would it grip the ground
sufficiently and
will avoid or reduce sliding or slipping thereon.
27
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
The preferred mats have physical properties that meet or exceed the physical
properties of a conventional white oak mat.
The mat must also provide sufficient load bearing capacity: A fully supported
mat
(one that is properly installed on an approved ground surface preparation)
must withstand a
ton load, spread over a 12" diameter surface without degradation of mat
properties or
permanent deformation of core structure of the mat. The core structure would
have a crush
resistance of between about 600 and 800 psi depending upon the application.
This provides
resistance against compression while not detracting from resistance to torsion
forces that
applied to the mat by vehicles passing thereover. Generally, the cores are
designed so that
they provide some degree of compressibility as large vehicles or equipment
move over or are
placed upon the mat. After the vehicles or equipment are removed from the mat,
it retains its
original thickness. In wet environments, this can cause some water to be
sucked into the mat,
which is another reason why the core structure components are designed to
withstand
moisture. Also, for some embodiments, the mats may be designed with apertures
so that any
water that enters the mat can later exit.
And while the preferred crane or timber mat sizes are about 6x6, 8x8 or 12x12
inches
by 8 feet wide and 20 to 40 feet long, a related type of mat that is used with
these large mats
are the ramp mats or transition mats. These both have the same type of
construction as the
crane mats but are cut down in size to 3x3 inch or 4x4 inch in various lengths
of 10 or 20 feet
or more. These ramp or transition mats are positioned along one or more of the
sides or ends
of crane mats to act effectively as a "step" that allows heavy equipment to
more easily move
onto the larger crane mat.
Optionally and preferably, the perimeter edges of the mat are provided with
additional
protection to prevent or reduce damage to the core structure construction of
the mat from side
entrance or egress onto the mat from large vehicles with steel tracks. The
edge material helps
protect the core structure and bumpers and is preferably easily removable so
that it can be
replaced when necessary.
When plastic materials are used for the core, they are formulated to be
relatively
inflammable. Flammability of mat shall be defined as Class 2 (B) flame spread
when
measured by ASTM E84 test criteria. The flammability properties of these
materials can be
enhanced by adding the appropriate conventional flame retardant or other
additives that are
known to impart such properties.
The core structure can also be formulated to allow dissipation of static
electricity. For
this purpose, carbon black, metal particles or other conductive fillers can be
added to plastic
28
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
materials that are used for the core. Of course, a metal core structure is
conductive without
any additives.
Although relatively protected by the outer layers, the core, when made of
plastic
materials, can contain UV inhibitors as necessary and in an amount sufficient
to reduce
deterioration of physical properties or color.
For ease in moving of the mats, attachment points can be provided that allow
for
lifting and handling of individual mats. Lifting hardware preferably includes
D-shaped rings,
0-shaped rings, chain, or cables at 2-4 locations on the upper surface of the
outer layer of the
mat. The exact position and attachment of lifting hardware is designed based
on the size and
weight of the mat and is intended to avoid damage to mat during transport and
installation.
The core structure of the mat may or may not be hollow. If hollow components
are
used for the core, whether as tubes of cells that have openings, these
openings are preferably
filled with a non-absorbent filler material. A wide variety of different
plastic, elastomeric or
foam materials in particulate or other forms can be used for this purpose. The
hollow
portions can be used as is or can be provided with the filler material to
increase or decrease
weight as needed. Fillers of glass, ceramic or metal particles can be included
to provide
additional weight or strength to the mat. Other materials such as recycled
rubber tire material
or other environmentally friendly materials can instead be used. Preferably,
the mat has a
weight that is on the order of an oak mat of similar size.
When elongated members are used for the upper and lower layers of the core
structure
construction, they provide additional weight to the mat and can be configured
in different
ways. One way would be to replicate a conventional oak mat and provide a
single width
construction where eleven 6 inch wide (by 12, 14 or 16 feet long) boards are
provided in the
upper and lower layers with three boards (nos. 3, 6, and 9) in the lower layer
offset for
interlocking. Alternatively, a double width construction may be used where
four 12 inch
wide (by 12 or 16 feet long) boards are provided in the upper and lower
layers: each one
separated by a 6 inch board with the three 6 inch boards in the lower layer
offset to provide
interlocking. Other configurations can be used as desired for the particular
end use of the
mat.
If desired, the boards can made of wood or engineered lumber (preferably with
a
tolerance of 1/16 inch) or they can be made of tubes of metal or of a
thermoplastic,
elastomeric, or thermosetting material, with pultruded thermosetting tube
being one example
of a preferred alternative material. The sizes mentioned herein are not
critical and can be
29
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
varied depending upon the intended use of the mats. The values mentioned above
are
representative of typical mats.
The upper, central and lower layers are typically nailed and/or bolted
together to form
the mat. The structure preferably has a modulus of about 1.6 M psi although
plastic mats
may have a lesser modulus when greater flexibility of the mat is desired. The
mat
compression property of 600 to 800 psi is suitable for most applications.
Figures 12 and 13 illustrate a first embodiment of the invention in the form
of a mat
1100 having substantially flat top and bottom surfaces. Although the bottom
surface of the
mat is not shown in these figures, the mat is preferably made with the same
structure on both
surfaces so that either one can be used as the upper surface of the mat that
is to receive
equipment or vehicles thereon. While this facilitates installation in that
there is no
requirement for placement of the mat in a particular orientation, it also
allows the installer to
select the surface of the mat that is in better condition to be used as the
upper surface of the
mat.
The mat 1100 includes first and second side beams (1105, 1110) having top,
side and
bottom surfaces, with the beams having width and height dimensions of between
6x6 inches
and 24x24 inches and a length of at least 4 feet and typically between 10 and
60 feet.
Preferably the lengths of the beams are in the range of 20 to 40 feet and
preferably 30 to 40
feet as these length mats are easier to transport and ship compared to longer
mats. Other
dimensions that are typically used for the side beams are 8x8, 10x10, 12x12,
14x14 and
16x16 although a skilled artisan can select other dimensions as desired.
Typically, the widths and heights of the side beams are of the same dimension
so that
the beams have a square cross-section. Alternatively, for certain designs, the
beams may be
rectangular in cross section, with the width being about twice the dimension
of the height or
vice versa. 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 longer
side as the height or with the longer side as the width, depending upon the
desired use of the
mat. Using the longer side as the width is generally preferred for
interlocking mat
arrangements.
A support structure 1115 is located between and connecting the first and
second side
beams (1105, 1110), with the support structure having upper, lower and side
portions, a
height that is less than that of the side beams, a width and a length. The
support structure,
which is set forth in more detail in Figure 14, includes first and second
longitudinal members
(1120, 1125) that are joined together by a plurality of cross members 1130.
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
The support structure 1115 may be made of steel components with the cross
members
1130 welded to the longitudinal members 1120, 1125 to form a ladder type
structure which
forms a frame for the support structure. At the front and rear ends of the
frame, additional
cross members 1135, 1140 may be provided to form a peripheral rectangular
structure. For
this embodiment, it is preferred that both the longitudinal members and
additional cross
members 1135, 1140 be C-shaped beams having a relatively flat plate with upper
and lower
flanges directed away from one side of the plate. The surface of the flat
plate opposite the
flanges of the longitudinal members faces the side beams 1105, 1110 so that a
close and
secure connection can be made between the two. The flanges of the C-shaped
beam also
serve as a point of connection for elongated members (1145 A, 1145B: 1150A,
1150B).
Bolts 1155 can be attached to the flanges or to the cross members for this
purpose. The
flanges of cross-members 1135, 1140 also face the interior of the support
structure so that the
ends of the ladder frame have relatively smooth faces.
The cross members 1130 can be attached to the C-shaped beam between the top
and
bottom flanges to form vertical connectors of the support structure that
provide the desired
strength and rigidity. As shown in Figures 13 and 14, the resulting structure
is a rectangular
box frame with spaced cross members on the front, back, top and bottom.
The cross members 1130 of the support structure greatly contribute to the
stiffness
and rigidity of the frame. These members are typically spaced 12 to 24 inches
apart for
support structures that are used for the smaller sizes of height and width
beams. For larger
size beams, the spacing can be reduced to 10 to 16 inches in order to provide
sufficient
strength to hold the mat together. The determination of the spacing of the
cross members can
be calculated for any particular size mat using generally known engineering
guidelines and
equations so a more detailed explanation is not needed herein. The cross
members typically
have a height that is at least half the height of the longitudinal members to
which they are
attached and preferably are about the same height as the longitudinal members.
If desired,
reinforcement members can be added to the structure. In one such arrangement,
additional
plates, rods, beams or other structural components can be added to the top
and/or bottom
portions of the support structure between the longitudinal members. This is
certainly
advantageous when supporting the largest or heaviest equipment on the mat.
Also, other
structural members can be provided between the cross members however in most
situations
this is not necessary. If additional reinforcement is needed, care must be
taken for
positioning such members to avoid blocking or interfering with the passage of
the joining
rods through the longitudinal members and into the support structure.
31
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
The C-shaped beam and cross members are typically made of a metal such as
steel so
that the structure can be made by welding the cross members to the beams.
While the
preferred construction of the metal frame of the support structure is by
welding, the frame
components can instead be joined together by brazing, rivets or bolting if
desired depending
upon the size and configuration of the overall support structure. Instead of a
C-shaped beam,
a flat plate (i.e., one without flanges) of the appropriate thickness can be
used. For this
arrangement, the cross members may have an I-beam shape to provide further
strengthening
of the support structure. A C-shaped steel beam is preferred for the
longitudinal members,
however, because the flanges provide additional rigidity and support to the
structure as well
as support for the cross members during installation. Of course, this can be
compensated for
by using a thicker flat plate for the longitudinal members when that
embodiment is to be
used. And the I-shaped beams can be used for the cross member when a C-shaped
longitudinal member is used, with appropriate adjustments made where the
flanges of each
come into contact with each other.
When the components of the support structures are made of metal, steel is
typically
used as that material is readily available and of low-cost. Although not
necessary for most
applications, the support structure can instead be made of a more corrosion
resistant material
such as stainless steel, copper, bronze, or other alloys. When carbon steel is
used, however,
the corrosion resistance can be enhanced by painting or coating the structure
so that it would
be more resistant to moisture. Also, steel can be galvanized or provided with
another type of
protective coating so that it would have a lower tendency to rust when
contacted by moisture.
Aluminum or titanium can also be used for the support structure in specialty
applications. All of these materials generally have higher cost than steel and
can present
joining the problems of greater difficulties in welding or brazing the cross
members to the
longitudinal members. It is possible in an alternative embodiment as noted to
use rivets or
bolting to connect the various longitudinal and cross members together to form
the frame of
the support structure. The sizing of the rivets or bolts as well as the
dimensions for the
welding and brazing, can be readily determined by a skilled artisans using
routine testing if
necessary. The same is true for the thickness of the beams or members that are
used in the
frame structure.
Alternatively, the support structure may be made of a fiberglass reinforced
thermosetting plastic material resin, which is typically a polyester or epoxy
resin. The
components of the structure may be pultruded in the form of a rectangular or
square tube
32
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
which may be hollow or filled with other materials depending on the overall
weight and
compressibility desired for the construction.
When fiberglass reinforced thermosetting plastic material is used to form the
support
structure, the box or ladder frame can be prepared in the desired shape with
the cross
members and longitudinal members joined together with resin prior to curing.
It is also
possible to utilize bolting or other mechanical fasteners to connect these
components
together.
A plurality of j oining rods 1160 are used to attach the side beams to the
support
structure, with the joining rods passing through the sides of the beams and
support structure.
These joining rods 1160 are typically large carriage bolts that include
threaded ends to
receive nuts that when assembled will hold the components together. These rods
are spaced
about 3 to 6 feet apart depending upon the size of the mat. Figure 13 shows
the rods 1160
passing through side beam 1105 and toward the side structure: Figure 14 shows
how the rods
1160 would appear when present in the support structure. These carriage bolts
are typically
made of a high strength steel. Also, in some embodiments, the beams can
include a sleeve
that facilitates passage of the bolts through the support core. The sleeve can
be a flanged
hollow tube that extends through the support core and if desired into one side
beam and part
of the opposite side beam. The tube would terminate in the opposite beam so
that it would
not interfere with the net that engages the threaded end of the bolt. The
sleeves are shown in
Figure 14 as elements 1165.
To form a substantially flat surface on the mat, various elongated members for
upper
and lower elongated members (1145A, 1145B, 1150A, 1150B) are provided. A first
plurality
of elongated members (1145A, 1145B) are attached to an upper portion of the
support
structure 1115 while a second plurality of elongated members is attached to a
lower portion
of the support structure 1115. Thus, the top surface of the mat is formed by
the top surfaces
of the side beams 1105, 1110 and the first plurality of elongated members
1145A, 1145B,
while the bottom surface of the mat is formed by the bottom surfaces of the
side beams 1105,
1110 and the second plurality of elongated members 1150A, 1150B. The flat top
surface of
the mat is best shown in Figure 12.
As the upper and lower surfaces of the mat must be somewhat uniform, the
support
structure and upper and lower elongated members generally have a combined
height that is
the same as that of the side beams. Typically, the support structure is
centered vertically with
respect to the side beams. As an example, the side beams can be 12x12 and the
support
structure would have a height of 8 inches so that the beams extend 2 inches
above the top of
33
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
the support structure and 2 inches below the bottom of the support structure.
This provides
room on the top and bottom of the support structure to accommodate 2 inch
thick elongated
members so that the top and bottom of the mat has substantially uniform
surfaces. This type
construction is preferred in that it minimizes the different types of
thickness that need to be
used for the elongated members and also provides a symmetrical mat that be
oriented with
wither surface facing up to receive equipment thereon. In other embodiments,
different
thicknesses of elongated members can be used on the top than on the bottom
with the intent
being that the thinner members are used on the bottom to prevent dirt or other
materials from
entering the support structure, while the elongated members on the top surface
are provide to
support the equipment or vehicles that are located or move upon the mat. In
this
embodiment, it is possible to provide a flat plate on the support structure of
the lower surface
rather than elongated members.
The same is true for the ends of the support structures. The longitudinal
members
1120, 1125 can be shorter than the length of the side beams 1105,1110 by a
distance of about
1 to 24 inches on each end or by a total of 2 to 48 inches. The distance of
the shortened ends
can correspond to the width of the side beams, if desired. The space between
the shortened
ends of the support structure 1115 and the side beams can be filled in with
bumper members
1175, 1180 which then allow the mat to have substantially flat front had rear
ends. These
bumper members can be of the same width as the elongated members so that the
same
material for the elongated members can be used to provide bumper members for
the front and
rear of the support. This creates a symmetrical structure but different
thicknesses of the
bumper members can be used if desired.
In a less preferred embodiment, the longitudinal members 1120, 1125 can be
substantially the same length as that of the side beams 1105,1110 so that the
front and rear
cross members 1135, 1140 form with the ends of the side beams the front and
rear end
surfaces of the mat.
The mat must also provide sufficient load bearing capacity: A fully supported
mat
(one that is properly installed on a suitable prepared ground surface) must be
able to
withstand a 10 ton load, spread over a 12 inch diameter surface without
degradation of mat
properties or permanent deformation of the mat. The support structure would
have a crush
resistance of between about 500 and 800 psi to possibly as much as 1000 psi
depending upon
the application and when properly installed on a suitably prepared ground
surface. This
provides resistance against compression as large vehicles or equipment move
over or are
placed upon the mat.
34
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
The side beams of the mat prevent or reduce damage to the support structure
from
side entrance or egress onto the mat from large vehicles with steel tracks.
These beams can
be replaced when necessary while the support structure can be reused to make a
new mat.
The elongated members as well as the side beams are preferably made of any
type of
wood although oak is typically preferred. These members may also be made of
engineered
wood or lumber since that will be easier to make long lengths without having
to obtain one
piece virgin wood lengths. Additionally a layered veneer laminate can also be
used for these
members or beams. It is expected that the cost for that material would be
about the same as
the price for oak thus making it an attractive alternative.
Engineered lumber (or engineered wood) includes a range of derivative wood
products which are manufactured by binding or fixing the strands, particles,
fibers, or veneers
or boards of wood, together with adhesives, or other methods of fixation to
form wood
composite materials. These materials provide the surprising benefit of
repeatable consistency
of the required sizes, the ability to mix different wood species to arrive at
the final product,
and exceptional properties generally exceeding what is provided from
monolithic boards.
There are three types of engineered wood that can be used in the present
invention:
parallel strand laminate (PSL), which is a beam that can be manufactured up to
about 12x12 inches in any length due to the production of the beam by
a continuous process;
layered stand laminate (LSL), which is a billet that can be made at
thicknesses
of from about 1 to 4 inches, in widths from about 2 inches to 54 inches,
and in lengths of about 8 to 64 feet; and
layered veneer laminate (LVL) which is also a billet that can be made up to
about 4 feet square by any length.
Alternatively, the side beams and elongated members may be made of a
fiberglass
reinforced thermosetting plastic material such as fiberglass reinforced
polyester or epoxy
resins. These materials may be pultruded into a solid form or preferably as a
rectangular or
square tube. If desired, hollow tubes can 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,
crushed rock or
polyurethane foam may be provided inside the tube either before or after
attachment to the
support structure. A polyurethane foam is preferred for this purpose as it can
be injected in a
liquid form after the pultrusion is attached to the support structure. For
stronger or heavier
filler, the joining rods may be initially placed into the beam so that the
filler does not block
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
the insertion of the rods when joining the side beams to the support
structure. Additionally, a
metal or pultruded plastic tubular sleeve can be provided in the beams at the
locations where
the rods are to be inserted, so that the rod has an opening that remains after
the filler is placed
into the beams.
As these mats are relatively massive, provision should be made for moving,
transporting and installing the mat at the desired field location. For this
purpose, holes are
provided in the upper surface, lower surface, or both to provide access to one
or more of the
joining rods. These holes are formed as cut out portions 1185 of the elongated
members
1145, 1150. In this way, the holes allow access by a hook from a crane or
other mechanical
attachment to the joining rods for lifting or manipulation of the mat. For
convenience, the
attachment openings 1185 are provided both on the upper and lower surfaces of
the mat so
that either surface can contact the ground or be exposed on top as the surface
upon which the
equipment is to be installed, thus facilitating installation.
Turning now to Figures 15 and 16, an alternative embodiment of the present
invention
is illustrated, in the form of a mat having side beams configured and
dimensioned to allow
interlocking of adjacent mats. Where like components are used from the
previous
embodiment, the same reference numerals will be used in Figures 15 and 16 and
only the
different features of this alternative embodiment will be described.
Mat 1200 includes side beams 1205, 1210 which are configured and dimensioned
to
represent only one half of the thickness of the mat. On one side of the mat,
beam 1205 is
attached to the upper portion of the support core 1215. This is done in a
manner to extend the
upper surface of beam 1205 above the top surface of the support structure
1215. As in the
prior embodiment, elongated members 1145A, 1145B can be provided on the top
portion of
the support structure 1215 so that the top surface of the mat adjacent the
side beam 1205 is
relatively flat. In a similar manner, side beam 1210, which also has a
thickness that is one
half the thickness of the entire mat, is mounted to a lower end of the support
structure 1215.
The lower surface of side beam 1210 extends below the lower surface of the
support structure
to allow elongated members 1150A, 1150B to be accommodated to form a
substantially flat
surface for the bottom of the mat adjacent beam 1210.
This structure allows one mat to be initially placed on the ground with an
adjacent
mat placed such that beam 1205 sits upon beam 1210. This arrangement can be
continued for
as many mats as necessary to achieve a desired working base for cranes or
other equipment.
The top surface of mat 1200 has a step on the opposite side from beam 1205,
above
beam 1210, while there remains an open space or step below beam 1205 adjacent
the lower
36
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
surface of the matt opposite beam 1210. While these surfaces allow
interlocking of adjacent
mats, it does not provide a stable mat surface on the outermost sides of the
working base. To
compensate for this, modified mats can be provided wherein the outermost end
mats on one
side of the working base can be made with beam 1105, which is the full
thickness of the mat,
on one aside and with beam 1210 on the opposite side to allow interlocking
with adjacent
mats that are configured like mat 1200. Similarly, the outermost end mats on
the opposite
side of the working base can be made with beams 1110 instead of 1210 on one
side beam
1205 on the opposite side.
Alternatively, when the full extent of the entire working base is not known,
of if an
insufficient number of modified mats are not available, the mats on the
outermost sides of the
final working base can be provided with stabilizing beams of the same size and
dimensions as
beam 1205 provided in the space below attached beam 1205 so that the side of
the mat can be
stabilized. The same thing can be done for the outermost mats that have a step
above beam
1210. A separate stabilizing member can be provided of the same size as beam
1210 to finish
the upper surface of the mat at those locations. The stabilizing members can
be attached to
the beams of the mat if desired.
Mat 1200 requires a different system for connecting the beams 1205, 1210 to
the
support structure 1215. The connection of beam 1205 to the support structure
1215 will
require that the joining rods 1260A pass through an upper portion of the
support structure,
whereas beam 1210 is connected to the support structure with joining rods
1260B passing
through the beam and a lower portion of the support structure 1215. This is
best shown in
Figure 16 where the relative positions of the joining rods 1260A, 1260B are
illustrated, along
with sleeves 1265A, 1265B. A number of additional features may be provided in
the mats of
the present invention.
Figure 17 illustrates a further variation of the invention, wherein mat 1200
includes a
radio frequency identification (RFID) tag 1275 which is located in the core.
Alternatively,
this RFID tag 1275 can be embedded in an outer layer in an opening or a
routered pocket to
enable the mat to be monitored in an inventory system or when rented for use.
The tag
provides a unique identification serial number for each mat, such that the
mats which are
being used or rented can be tracked and accounted for as to location of use.
The mats can be
scanned when in a warehouse, when loaded on trucks for delivery, when
delivered to a job
site, or when collected from a jobsite after use. The RFID tags can be active
or passive and if
desired, other tracking devices such as barcodes could similarly be for the
same purposes. It
is preferred, however, that the RFID tag be embedded in the outer layers or
core structure of
37
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
the mat so that it is protected from damage during use. When a barcode or
other surface
mounted tag or indicia is used, it should be placed on a surface portion of
the mat that is less
likely to experience wear or abuse. Thus, the tag may preferably be applied
onto the side of
the mat so that it is not directed exposed to traffic on the mat. It also may
be covered with a
plexiglass film to prevent its removal by abrasion.
In order to manipulate the mats for loading/unloading, or moving from one
location to
another or for installation and retrieval, the mats can include a retractable
lifting element.
This can be the lifting elements described above and those elements lie in a
recess in the top
surface of the mat during use for ease of access and to prevent tripping or
damage to items
moving over the mat or damage to the lifting elements themselves.
Alternatively, a more
complicated design such as that of US patent publication 2008/0292397 can be
used.
To assist in the use of the mat during the night or on days that are dark due
to poor
weather conditions, the mat may include one or more lighting elements, such as
those
disclosed in International application WO 2006/048654. These lighting elements
would
preferably be embedded in the outer layer. Figure 17 illustrates the locating
of LED lights
1285 in the core structure beneath elongated member 1245A. The lighting is
covered with a
clear material 1295 of plexiglass, so that the lighting element may be better
protected against
damage during use. To achieve the desired lighting brightness, the skilled
artisan can provide
the necessary number of lighting elements, or can include lighting elements of
larger size.
Another feature of the invention is the use of color coding to identify the
specific
layers that are used in the construction of the mat. This can also be used to
identify mats for
a particular customer or end user. When mats are rented or leased, the color
coding can be
used to identify which mats belong to the leasing company compared to mats
provided by
others. The color coding can be of a single color or of certain stripes,
patterns, dots or other
indicia that provides a "signature" that identifies the specific core
structure that is present in
the mat or a particular end user or owner of the mat.
Figures 18 and 19 illustrate a crane/pipeline mat 1300 that has a typical
thickness of
about 8 to 12 inches, a typical width of about 4 feet and a typical length of
between 12 and 20
feet. The mat 1300 includes two side beams 1305, 1310, a steel box frame 1320,
an upper
layer of elongated members 1315A, 1315B, 1315C, and a lower layer of elongated
members
1325A, 1325B, 1325C. The core structure can be between 2 and 3 feet wide
depending upon
the width of the side beams.
The steel frame 1320 includes a forward lifting element 1335 and two upper
side
lifting elements 1340. If desired, a rear lifting element and two lower side
lifting elements
38
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
(not shown) can also be provided. These lifting elements allowed the mat to be
lifted
overhead by a crane having a suitable lifting capacity to facilitate loading,
unloading, and
installing of the mats.
The lifting elements can be constructed as desired. If cables or chains are to
be used,
any holes made in the mat for such cables or chains must be drilled through
the entire mat,
and not just looped in between board or component spacings. The chains or
cables must have
at least three drop forged clamps. Cable must be new 3/4 inch steel core,
extra improved
plow (EIPS), right regular lay wire rope, having a minimum breaking strength
of over 29
tons. Chains should be 3/8" high test chain, having a working load limit of
5400 lbs. and a
minimum breaking strength of 16,200 lbs. with 3/8 inch double clevis links, in
order to
provide a safe working load limit of about 5400 lbs.
Other lifting elements may be used, such as those described in US patent
application
62/211,664 filed August 28, 2015, the entire content of which is expressly
incorporated
herein by reference thereto. Those lifting elements can be used with any of
the mats
disclosed herein provided that the appropriate core structure is present.
The components of mat 1300 are more clearly shown in the exploded drawing of
Figure 19. The steel frame 1320 is shown as having a plurality of components
including two
elongated side components, a front component, a back component and two cross
members
1345, all of which are welded or bolted together to form the frame 1320. Side
beam bolting
members 1335 are also welded to the box frame 1320. These bolting members are
configured to pass through openings in the side beams 1305, 1310 to secure the
side beams to
the steel box frame 1320. This is done by tightening nuts onto the ends of the
bolting
members 1335 after they pass through the holes in the side beams. The side
beam holes are
recessed so that the bolting and nuts do not extend beyond the sides of the
beams.
The lifting elements 1330, 1340 are preferably in the shape of a D ring which
is
welded or bolted to the box frame 1320 or its cross members 1345 as best shown
in Figure
19. The upper layer elongated members 1315A, 1315B, 1315C, and lower layer
elongated
members 1325A, 1325B, 1325C are also bolted to the box frame 1320.
As the box frame 1320 defines open areas therein, it is best to fill those
open areas
with material that will contribute to the ruggedness and weight of the mat. In
particular, a
filler of wood members 1350 that either are scrap pieces from the production
of other mats or
are end grain or engineered wood can be used. It is also possible to use a
less expensive
wood material such as treated pine because the purpose of these filler
materials is simply to
add weight to the mat and they are not exposed to wear or abuse. And instead
of wood
39
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
material, the open areas of the core may be filled with other materials of the
types disclosed
elsewhere herein.
Figures 20 and 21 illustrate yet another mat 1400 that includes a steel frame
core
1410. The core is used on an interlocking mat that has upper 1405 and lower
1415 layers of
elongated members. These elongated members may be made of wood, engineered
wood, or
of a thermoplastic, elastomeric, rubber, or thermosetting plastic material.
The plastic and
elastomeric or rubber materials can be used alone or can be reinforced as
known in the art to
provide additional strength, abrasion or wear resistance or to otherwise
improve physical
properties. Preferably, wood is preferred as it provides abrasion and abuse
protection to the
mat at a relatively low cost. And as shown, three elongated members 1415A,
1415B, 1415C
of the lower layer are offset from the others to form a configuration for
interlocking with an
adjacent similarly configured mat as disclosed elsewhere herein.
The steel frame 1410 includes four side members and two cross members 1420
which
can be welded or bolted together to form the frame. The open space in the box
frame can be
filled with material that will contribute to the ruggedness and weight of the
mat. In
particular, a filler of wood members 1450 that either are scrap pieces from
the production of
other mats or are end grain or engineered wood can be used. It is also
possible to use a less
expensive wood material such as treated pine because the purpose of these
filler materials is
simply to add weight to the mat and they are not exposed to wear or abuse. And
instead of
wood material, the open areas of the core may be filled with other materials
of the types
disclosed elsewhere herein.
To protect a steel frame from damage, a rectangular bumper configuration 1440
is
provided along all outer side surfaces of the steel box frame.
And as in the other embodiments, D-shaped lifting elements can be 1445 can be
provided in various locations on the top and bottom of the mat in positions
where they can be
welded to the cross members 1420 of the steel frame. These would allow lifting
of the mat
and transport as well as placement into the appropriate locations during
installation.
Figure 22 illustrates a preferred embodiment of the invention wherein the
environmentally resistant core of the mat 1500 is a fiberglass reinforced
polyester or epoxy
grating 1505 having a thickness of 3 inches and with grating openings of 2x2
inches. The
same upper 1510 and lower 1515 wood structures of Figures 20-21 can also be
used for this
mat, with all of the components bolted together. As noted herein, the grating
can have a
greater or lesser thickness ranging from about 2.5 to 4 inches in thickness
with openings of
between 1.5x1.5 inches and 3x3 inches. Of course, it is also possible to
utilize a solid
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
fiberglass reinforced thermosetting resin sheet of the thicknesses mentioned
herein either by
itself or with apertures or openings cut therein. As shown, the bolting would
pass through the
entire construction in order to provide the greatest strength and are placed
in recessed holes
so that the bolts and nuts do not extend past the upper and lower surfaces of
the mat.
For alternative embodiments to Figure 22, the grating can instead be a metal
sheet
with apertures therein to reduce the weight of the mat. The metal sheet can be
2 inches thick
with openings both for the bolts that are used to join the mat components
together as well as
with additional openings to reduce the weight of the sheet. The openings can
be random or
uniform and can range from 1 to 6 inch in diameter for circular openings and
from 2x2 to 4x4
inch rectangular or square openings. A metal grating or welded rod arrangement
can also be
used if desired.
From the foregoing, it is seen that there are numerous combinations and
arrangements
of new and useful mats that include an environmentally resistant core
structure. Certain
additional specific embodiments include the following combinations of a mat
components:
(1) a top outer layer of elongated wood or laminated wood members; a core
construction of elongated thermoplastic boards or monolithic units of a sheet
or molded
structure, and a lower outer layer of elongated wood or laminated wood
members. The
thermoplastic boards would preferably be HDPE boards about 2 inch x 8 inch by
8 feet, while
the monolithic unit would be made of HDPE, sized 8 feet x 12, 14 or 16 feet
long and about 2
inches thick, with a flat, closed cell or open cell geometry. The wood members
would be
about the same size as the HDPE boards.
(2) a top outer layer of elongated wood or laminated wood members; a core
construction of elongated a thermoplastic monolithic unit of a sheet or molded
structure, and
a lower outer layer of elongated thermoplastic boards. The thermoplastic would
preferably
be HDPE for the monolithic unit and/or the boards, while the size of the
monolithic unit
would be 8 feet x 12, 14 or 16 feet long and about 2 inches thick, with a
flat, closed cell or
open cell geometry, and wherein the elongated members would be about 2 inch x
8 inch by 8
feet. Again, the wood members would be about the same size as the HDPE boards.
(3) a top outer layer of elongated wood or laminated wood members; a core
construction of a grating of fiberglass reinforced thermosetting plastic
material, and a lower
outer layer of elongated wood or laminated wood members. The wood members
would have
a size of about 2 inches x 8 inches by 8 feet. The grating would be 2 inches
thick and have
openings of 2x2 inches and would be sized to match the mat, i.e., 8 feet x 12,
14 or 16 feet
41
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
long, or segments representing portions of the mat can be used (e.g., a 3, 4
or 4.5 foot long
section of an 8 foot wide mat with 4 sections used in the mat).
The present invention provides unexpected benefits over the art in that the
outer
layer(s) can provide resistance to abrasion and abuse of the construction core
structure while
the core structure is resistant to moisture, water or even certain chemicals
encountered from
the surrounding environment. This enables the core structure to provide a much
longer
service life than when conventional wood components are used since the core
structure is
resistant to rotting or other chemical degradation that would otherwise affect
wood
components of the core. Finally, to the extent that any of the components of
the upper or
lower outer layers are damaged, they can be replaced so that a new mat can be
made with the
reuse of all of the core.
Figures 24 to 27 illustrate another crane mat 1600 in accordance with the
present
invention. For this embodiment, the crane that includes internal beams made of
softwood
such as pine timbers to reduce the overall cost of the mat. As these timbers
are not as
abrasion and abuse resistance as other materials or components, they are
protected on all
sides by one or more different mat components. In the simplest construction,
the adjacent
pine timbers can be assembled into the core of the mat and protected on either
longitudinal
side with oak beams. The pine timbers would also be configured to be shorter
than the
longitudinal oak beams with the upper and lower surfaces of the pine timbers
protected by
more durable elongated members. In a further embodiment, a steel or metal
plate can be
placed between each adjacent pine timbers as well as between the oak beams and
the adjacent
pine timbers to further strengthen the mat.
All mat components and their arrangement in the mat are best illustrated in
Figure 25.
This crane mat 1600 includes two side beams 1610, 1620 which are made of white
oak and
which have dimensions of about 12 x 12 inches and a length of approximately 16
feet. The
core of the mat is made primarily of three pine timbers, each labeled 1630,
which have
dimensions of approximately 12 inches wide and 8 inches high. The pine timbers
are located
adjacent the center of the height of the side beams such the side beams extend
approximately
1 to 2 inches above and 1 to 2 inches below the pine timbers. To prepare
uniformly flat upper
and lower surfaces of the mat, boards 1640, each of which is approximately 2
inches thick, 8
inches wide and 16 inches long, are provided above and below the pine timbers
as shown.
The boards can be made of wood, engineered lumber, plastic or recycle
materials. The oak
beams and boards thus protect the pine timbers from abuse while reducing the
cost of the mat
due to the substitution of the pine timbers for oak timbers. And when these
boards are spaced
42
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
apart, channels 1655 are formed between them which allow water to drawing from
the mat
during use.
And although the pine timbers are exposed at the forward in rearward ends of
the mat,
these are not usually subjected to great abuse. Additionally, if desired,
bumper members can
be provided on the forward and rearward word ends of the mat to provide
further protection.
Another embodiment of the invention that is shown in Figure 25 is the use of
rectangular steel plates 1650 that are approximately 3/8 of an inch thick and
have dimensions
of 12 inches high and 16 feet long. Four plates are shown, one between each
beam and
timber, to provide additional strength to the mat. While these plates are
shown as being the
same height as the side beams, alternative embodiments utilize plates that are
1 to 2 inches
shorter than the side beams of the mat. When such shorter plates are used, the
upper and
lower surfaces of the mat are thus provided with channels that allow water to
drain from the
mat during use. The plates can be of the same height and length as the pine
timbers, or they
can be 1 to 2 inches shorter than those timbers. The shorter steel plates
reduce the overall
weight of the mat compared to larger steel plates while still providing
additional ruggedness
to the mat.
The side beams, pine timbers and plates are joined together by bolting 1660
which
extends across the width of the mat. A number of bolts are used spaced every 3
to 6 feet of
length of the mat. The bolts pass through each of the beams, plates and
timbers and are
secured in placed by a washer and nut arrangement 1665. The upper and lower
boards 1640
are either nailed or bolted to the pine timbers.
To facilitate lifting of the mats, a new lifting element arrangement is
provided. This
arrangement includes a D-shaped ring 1670 that is pivotally attached to a
steel plate 1675 that
is welded to the steel plates 1650 that are present on the outer sides of the
pine timbers 1630
and as well as in between the pine timbers. The plate is accommodated in the
pine timbers by
a formed slot 1680 into which the plate can be seated. Also, the lifting
element plate 1675
would be welded at its ends to two or three of the longitudinal reinforcement
plates 1650 to
provide a very secure connection that will would allow overhead lifting of the
mat for
installation or removal as well as to facilitate loading or unloading of the
mats on a truck or
train bed. And the D-shaped ring is provided in an opening 1685 in the center
board in such a
way that when not used to lift the mat, the D-shaped ring lies flat in the
opening so as to not
hinder movement of personnel over the mat. And while the two lifting elements
are shown
on the upper surface of the mat, it is desirable to also provide the same
arrangement on the
lower surface of the mat. Furthermore, the number and precise location of the
lifting
43
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
elements is not critical but can be selected by a skilled artisan depending
upon the overall size
and weight of the mat.
Although the mats are provided with different internal core constructions, in
many
situations, the outer surface of the mats are very similar in appearance, such
that it is not
readily observable as to which mat has a particular internal construction. For
this reason,
another aspect of the invention relates to the providing of each mat with
identification means
that indicates the core or internal construction of the mat. Thus, when a
number of different
mats are maintained in an inventory, the identification means enables
operators to readily
determine which mats have a certain core or internal constructions of wood,
engineered
wood, thermoplastics, elastomers, thermosetting plastics, metal, or of coated
or encapsulated
components, so that the correct mats can be selected and provided to a jobsite
for use by the
customer. This would be necessary whether the mats are being purchased by the
customer or
whether the mats are being leased for use. There are a number of ways to
identify the
different core or internal construction of a mat depending upon the specific
type of
identification means that are applied to the mat. The preferred types of
identification means
include an external color code, a radio frequency identification (RFID) tag,
or an
alphanumeric indicator applied to an outer surface of the mat or that is
provided upon a plate
that is applied to an outer surface of the mat.
The easiest identification means to use is an external color code that is
placed upon
the mat, preferably in an area that does not receive much abrasion or wear.
Different colors
or strips or color combinations can be used to identify the different core
constructions of the
mat. And it is highly useful to apply the color code to the same relative
positions on each mat
for easy identification. For example, placing the external color code along a
longitudinal side
of each mat allows the color coding to be visible when the mats are stacked
upon each other.
This simple visual confirmation can be used to make sure that the proper mats
are selected:
even when the mats are just stacked in the work yard, one can see which ones
have the
correct color code for the desired core construction.
Another use of color can be to identify mats for a particular customer. This
would
assist in making sure that the mats are properly collected and delivered. This
color can be an
additional color beyond that which is used to identify the mat core, or the
mats can have a
single unique color or color pattern (e.g., stripes, dots etc.) that
identifies both the customer
and the mat core. And further, the color can be provided in a particular
location or area to
confirm who the customer is to assist in quality control regarding the correct
shipping and
delivery of the mats.
44
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
Another type of identification means comprises a RFID tag that is attached to
the mat
and that can be scanned to identify the core or internal construction of the
mat. One example
of such a tag is seen in Figure 17. This tag can be read by a scanner so that
the mat core
construction can be identified prior to shipping of the mat to the customer.
A simpler type of identification means is one that comprises an external
alphanumeric
indicator that is applied to an outer surface of the mat or that is provided
upon a plate that is
applied to an outer surface of the mat. These can be carved, burnished or
stamped into or
onto the mat again is a location that is not expected to experience severe
abrasion or wear.
This can also be used to identify a particular customer.
And as noted herein, in addition to the mat identification means, each mat can
further
be provided with a surface color that indicates a potential use or non-use of
the mat. This can
assist in allowing personnel to properly operate on the mat and to promote
safety. These
colors can include, for example, red to indicate that portions of the mat need
to be kept free of
equipment, yellow for indicating that caution is needed, green to indicate
portions of the mat
that are designed to accommodate travel or movement by trucks or heavy
equipment over the
mat.
It is also possible to include in the paints or coatings additives that can
facilitate
movement upon the mat, such as fine particles or grit that can impart slip
resistance, or
greater sized particles of materials that can provide bumps similar to a
rumble strip that
would indicate to a moving vehicle that it is approaching the end of the mat.
And the
different sized particles can be provided in different colored paints or
coatings.
Of course other colors can be used in any of the foregoing embodiments
according to
a particular code or correspondence of each color to a specific use or
prohibited use. These
colors can be tailored to the mat user's particular requirements so that work
operations upon
or around the mats can be optimized for safety, efficiency and expediency.
Coloring can also
be used to define certain areas of the worksite or to help the mats blend into
surrounding
areas, so that the jobsite can look as clean and undisturbed as possible. For
these reasons to
use of conventional paints and other surface coatings enhance the usefulness
of the mats for
any particular application.
A software application and related technology directed to assisting those that
provide,
install, or use the mats illustratively described herein can be provided. For
example, with
reference now to FIG. 28, system 2800 is provided that includes a plurality of
mats 2802,
server 2804, and client devices 2806. FIG. 28 can be a representation of a
field installation of
a set of mats in a particular geographic location for a particular customer
application (e.g.,
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
support for a crane, oil rig equipment, etc.). Mats 2802 are configured and
arranged in a
particular geographic location for the current customer application. System
2800 can involve
mats that are installed, currently housed in inventory, are in transit, or
under repair.
Each mat 2802 includes an identification means that can be an electronic
device,
printed circuit board, or electronic circuit configured to provide certain
characteristics or
capabilities to the mat 2802 and to the overall system 2800. Mat 2803 is
configured to house
the identification means, e.g., such that it is enclosed within the mat 2803
(e.g., in order to
protect the identification means from physical damage or weather conditions).
The
identification means in each mat 2802 can be configured to be the same or
substantially the
same or can vary between mats.
Server 2804 is implemented at a location separate and typically remote from
mats
2802. Server 2804 includes a database (internal or external) for supporting
the operation of
server 2804. Computer executable instructions are implemented and stored in
server 2804
that is configured to communicate with mats 2802 and communicate with client
devices 2806
to provide certain features. Server 2804 can be implemented in a cloud service
and will in
general have associated protections such as a firewall or other equipment that
protects server
2804 from unauthorized security access or other online attacks. Server 2804
communicates
with client devices 2806 to provide certain services and interactive features
to software
running on client devices 2806. Server 2804 is configured to implement secure
connections
with client devices 2806. Certain information is collected, maintained, and
updated by server
2804.
For example, server 2804 collects, stores, and updates the following
information for
each mat to server 2804: the weight of the mat, load capabilities of the mat,
the markets that
mat is to be used in, the style and type of mat, the maximum load limits, the
age of the mat by
quarter (e.g., 2.25 years since first deployed), alerts or flag for the mat
(e.g., do not use,
damaged), color coding of mat to specify the mat is configured for a
particular type of use in
the field (e.g., the type of equipment it can be used with), color coding to
determine the
maximum weight that can be on the mat, material sources, manufacturing team
for that mat,
materials used, date of manufacture, date of each installation (and return),
length of each
installation, notes, structural wear, operational flags (e.g., suggesting
maintenance) and
potentially other information. The database may also store for each mat the
current or last
obtained location of the mat, an identifier for the mat, history information
for the mat, data
from a sensor on or in the mat (e.g., that provides actual usage
characteristics, level of
46
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
vibration), and a network address for the mat. The information is preferably
provided with
color coding for ease of viewing and interpretation.
A software application, computer executable instructions stored on computer
readable
medium, on client devices 2806 is configured to communicate with the server
2804. The
software application generates a graphical user interface that displays to the
user information
and interactive options related to the mats installed or used for that
customer. The software
application can also be configured to provide information and interactive
visual options to
others such as the owner or distributor of mats (e.g., view inventory
information). The
software application can be configured to receive information from server 2804
in connection
with mats and is configured to apply a visual color scheme based on the type
of mat. This
permits quick differentiation and understanding of the relevance of the mat.
For example,
mats with a steel core can be identified with the color blue and mats while
those with a plastic
core identified with the color red. The graphical interface on client device
2806 maintains
this color scheme when displaying frames, icons, or identifiers for each mat
and does so in a
consistent way whenever a mat is identified or selected in the interface.
Circuitry included as part of the identification means can include
communications
circuitry that configures the identification means to be able to (a)
communicate with other
mats such as by direct mat to mat wireless communications or through an
intermediary such
as a server, (b) communicate with server 2804, and/or (c) operate as a relay
or router that
sends or transmits communications (e.g., messages) from a first mat to a
second mat or server
2804 through an intermediary mat. The identification means can be configured
to be able to
communicate with nearby mobile telephone base stations and to transmit and
receive
messages over the wireless mobile telephone network (which implicitly includes
data
communications capability) using the base stations. This is primarily for the
purpose of
establishing a communication path for communicating with server 2804. Other
network
communications arrangements are also contemplated. Server 2804 can be
configured to
establish communications connections with client devices 2806 using the
Internet or other
network connection and can use wired, wireless, or combination thereof to
establish
communications.
With reference now to FIG. 29, an electronic device 2900 provides the
identification
functionality and other functionality. In this embodiment, electronic device
2900 comprises
processor 2902, communications circuitry 2904, antenna 2905, storage 2908,
sensor(s) 2910,
and battery 2912. Communication circuitry 2904 can be a combinations of
hardware or
physical circuits in combination with software that is executed on the
hardware or circuits.
47
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
Communications circuitry 2904 can be wireless communications modem such as one
that is
used to communicate in accordance with mobile telecommunications standards
such as
CDMA and GSM. Antenna 2904 is a separate circuit or devices from
communications
circuitry 2904 or is integrated into the communications circuitry 2904.
Antenna 2906 is used
by communications circuitry 2904 to transmit and receive messages in
accordance with a
wireless communications protocol. In some embodiments, there can be more than
one
antenna or communications circuitry to implement multiple communications
protocols or the
capability can be integrated into one antenna and communications circuitry.
Processor 2902 is a computer processor configured to provide programmed
functionality to device 2900. Computer processors are also generally referred
to as
microprocessors. Processor 2902 is configured to sends and received data from
storage 2908
and to received and execute computer readable instructions from storage 2908
(if processor
2902 is not an ASIC and is a general processor). Storage 2908 is computer
readable memory
and can comprise volatile and/or non-volatile memory (non-transitory memory).
Non-
volatile memory may be RAM, or solid state memory that is used by device 2900
to store
data and computer readable instructions for carrying out the functionality of
the device 2900.
Storage can include ROM or other transient memory for operational purposes.
Battery 2912
is integrated into device 2900 or can be connected to it via wires. Battery
2912 has the
capability to provide an extended operating life to device 2900 such that the
battery when
charged and installed can support the operation of the device for an extended
period of time
such as 90 to 180 days. Battery 2912 is for example a lithium battery. Sensor
2910 is
configured in device 2900 to provide operational information related to the
mat to the device
2900. Sensor 2910 can be a vibration sensor, load sensor, temperature sensor,
or other type
of sensor. Multiple sensors of different types can be implemented as sensors
2910.
In operation, device 2900 is installed when a mat is first manufactured.
Device 2900
provides a tool for the identification, tracking, and condition monitoring of
each mat. When
device 2900 is returned from usage, if needed battery 2912 is charged or
replaced and
information stored about its corresponding mat is maintained (without being
deleted).
Processor 2902 with the support of storage 2908 executes a software program
that stores
identification information such as a serial number and other details such as
those mentioned
above in connection with the data on the server. Processor 2902 also receives
sensor 2910
data overtime and stores the data in storage 2908. The sensor can be a
vibration sensor and
device 2900 can store a history or a representation of vibrations detected by
the sensor over
time (detected vibrations of the mat). Device 2900 can be configured to send
sensor data or
48
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
data representative of the output of a vibration sensor to server 2804. As
such, data from
sensor(s) 2910 can be stored remotely at server 2804 or can be stored only on
device 2900 for
that mat, or a combination can be implemented.
Sensor 2910 or communications received via circuitry 2904 can also be
configured as
a mechanism for checking the mat into and out of use by a particular customer
or premises
(e.g., inventor). A message can be sent over a wireless communications channel
to device
2900 to update this information and add the information to storage 2908. The
data can be
stored, tracked (historical log), and maintained in storage 2908, server 2804
or a combination
thereof
In one embodiment, device 2900 includes a printed circuit board that receives
circuitry such as semiconductor chips that are configured to implement
processor 2902,
communications circuitry 2904, storage 2908, and sensor(s) 2910. Other
configurations and
implementations are also contemplated.
Communications circuitry 2904 can include GPS circuitry for determining the
geographic location of device 2900 (and consequently its corresponding mat).
GPS location
data can be stored by processor 2902 in storage 2908 (stores the current
location and/or a
history of locations) or can be transmitted to server 2804 and stored in the
database.
Communication circuitry 2908 or sensors 2910 can include a gyro and related
circuitry that
configures device 2900 to be able to track and determine the orientation of
mat (based on
predetermined information about the location of the device 2900 within the
mat).
Software implemented on server 2804 and/or client devices 2806 can be
implemented
and configured to provide an interactive site planning and status tool.
Information about a
plurality of mats can be collected and used in the software to allow a user to
plan a site
installation based on mat dimensions, designated application, and other
information stored by
server 2804 and/or client devices 2806. The software (referring to a set of
computer
executable instructions adapted to provide certain features when executed) is
also configured
to allow a user of the system to view information about a mat at an
installation such as age,
history, vibration sensor data, and other information (including recently
sensor collected data)
and use that information to determine the physical state and it continues to
have sufficient
structural integrity for the site application.
In some embodiments, device 2900 may have different implementations or states.
One can be a configuration in which device 2900 is configured to communicate
(establish a
network) with other devices 2900 in mat that are nearby. A mesh network or
similar network
protocol can be configured using devices 2900 that provides the devices 2900
the capability
49
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
to communicate with other mats through each other and to collect data (from
its own mat and
other mats) and transmit to other devices 2900 or other types devices over the
network.
Another implementation or state can be one in which device 2900 is configured
to connect to
other networks such as a mobile telecommunications network or other wireless
network. A
particular device 2900 can be capable of both and configured to be operating
in both
networks. For example, a first mat (by way of device 2900) can transmit
identification
information or other data to a second mat (to device 2900 in that mat) and the
second mat is
configured to transmit the received data to server 2804 over a wide area
network (which
includes a data network of a mobile telephone network such as Verizon). The
transmission
can be in response to sever 2804 transmitting a request to the first mat
(which may be
transmitted through the second mat) and services by the first mat.
In some implementations, device 2800 is configured to determine that a first
type of
connection (e.g., mobile telecommunication network) is unavailable and selects
to transmit or
establish communications using a second type of connection (e.g., local mesh
network with
another mat). For example, if a mat determine that it does not have a good or
sufficient
signal on the mobile telecommunications network, it can communicate with one
or more
other mats and use that mat's better reception on the mobile
telecommunications network to
communicate with server 2804.
System 2800 is preferably configured to provide real time tracking of mats by
way of
devices 2900. Real time means the system is configured to provide accurate
information
(e.g., current location) that may be delayed only by about 10 milliseconds or
less. System
2800 is configured to request and receive or in general receive locations
information from
GPS sensors or stored GPS location information from mats (via devices 2800)
and store the
information for transmission to users such as users on client devices. A real
time database
can be implemented on sever 2800 to be able to provide the required
performance in serving
real time data to users.
Device 2800 can be installed inside a mat and have a cover or door on the
exterior of
the mat that permits a user to open and gain access to device 2900 (e.g., to
replace the battery
or for maintenance).
Functional components illustrated in FIG. 29 can be individual physical
elements such
as individual semiconductor chips. Multiple components can be integrated
together into
same chip or circuit. An application specific integrated chip can be developed
and used for
the overall design or components.
CA 03090704 2020-08-06
WO 2020/014156
PCT/US2019/040877
It is understood that different combinations of features are contemplated
including
device 2900 with few elements or additional elements.
Therefore, in sum, it is to be realized that the optimum dimensional
relationships for
the parts of the invention can include variations and tolerances in size,
materials, shape, form,
function and use are deemed readily apparent and obvious to the skilled
artisan, and all
equivalent relationships to those illustrated in the drawings and described in
the specification
are intended to be encompassed by the claims appended hereto.
Unless defined otherwise, all technical and scientific terms used herein have
same
meaning as commonly understood by one of ordinary skill in the art to which
this invention
belongs. Also, as used herein and in the appended claims, the singular form
"a", "and", and
"the" include plural referents unless the context clearly dictates otherwise.
All technical and
scientific terms used herein have the same meaning.
The foregoing detailed description is considered as illustrative only of the
principles
of the invention. Further, since numerous modifications and changes will
readily be apparent
to those having ordinary skill in the art, it is not desired to limit the
invention to the exact
constructions demonstrated. Accordingly, all suitable modifications and
equivalents may be
resorted to falling within the scope of the invention.
51
