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US-12618201-B2 - Modular mat system

US12618201B2US 12618201 B2US12618201 B2US 12618201B2US-12618201-B2

Abstract

A module mat system with first layer that is joined to a second layer by fusion welding, hot welding, hand welding, seam welding, heat pressing, or other methods know to those having skill in the art. Each layer has a central core with a first cellular structure formed from ribs extending from the interior surface. The cross section of the ribs in the central core of the first layer matches the cross section of the ribs in the central core of the second layer such that when fusion welded together the ribs of the central core of the first layer weld to the ribs of the central core of the second layer.

Inventors

  • Justin Thelin
  • Aaron Allen
  • Brian SCHENK

Assignees

  • SPARTAN MAT LLC

Dates

Publication Date
20260505
Application Date
20201024

Claims (13)

  1. 1 . A module mat system comprising: a first layer and a second layer, each layer having an interior surface and an exterior surface, the interior surface comprising a central core with a first cellular structure formed from core ribs extending from the interior surface wherein the cells of the first cellular structure have a first rib pattern; a first band extending from at least one side of the central core, wherein the first band has a second cellular structure formed from first band ribs extending from the interior surface of the first band, wherein the cells of the second cellular structure have a second rib pattern; wherein each core rib that abuts the first band has a corresponding first band rib that aligns with the core rib; and the second rib pattern is smaller than the first rib pattern such that the cell density of the second rib pattern is more dense than the cell density of the first rib pattern.
  2. 2 . The module mat system of claim 1 , wherein the first band has a first portion that is proximal to the central core and a second portion distal to the central core, wherein the second portion has a third cellular structure formed from ribs extending from the interior surface of the first band, wherein the third cellular structure has a third rib pattern and the third rib pattern is smaller than the second rib pattern such that the cell density of the third rib pattern is more dense than the cell density of the second rib pattern.
  3. 3 . The module mat system of claim 1 , wherein the first band includes at least one guide hole in the first band.
  4. 4 . The modular mat system of claim 2 , further comprising a guide hole in the first portion of the first band.
  5. 5 . The module mat system of claim 1 , wherein the exterior surface of at least one layer comprises a plurality of traction elements raised from the exterior surface.
  6. 6 . The module mat system of claim 2 , comprising a second band extending peripherally from at least one side of the central core, wherein the second band is vertically offset from the first band.
  7. 7 . The module mat system of claim 6 , wherein the second band connects to the central core at a peripheral wall, and wherein the peripheral wall is taller than the cell ribs that contact the peripheral wall.
  8. 8 . The module mat system of claim 7 , wherein the cell ribs have a height, and wherein the height of the second band ribs is lower than the height of the core ribs.
  9. 9 . The module mat system of claim 1 , wherein the first layer and the second layer are welded together.
  10. 10 . The module mat system of claim 1 , wherein the cell ribs of the first layer are welded to the cell ribs of the second layer.
  11. 11 . The module mat system of claim 6 , wherein the first band of the first layer is welded to the second band of the second layer.
  12. 12 . The module mat system of claim 7 , wherein the second band has a third portion that is proximal to the central core and a fourth portion distal to the central core, wherein the third portion has the fourth cellular structure with the fourth rib pattern and whrein the fourth portion has a fifth cellular structure formed from ribs extending from the interior surface of the second band forming a fifth rib pattern, wherein the fifth rib pattern is smaller than the fourth rib pattern such that the cell density of the fifth rib pattern is more dense than the cell density of the fourth rib pattern.
  13. 13 . The module mat system of claim 12 , wherein the second and the fourth rib patterns are the same and wherein the third and the fifth rib patterns are the same.

Description

CROSS REFERENCE TO RELATED APPLICATIONS The present application claims the benefit under 35 U.S.C. 119 of U.S. Provisional Patent Application Ser. No. 62/926,132 filed Oct. 25, 2019. The U.S. Provisional Patent Application Ser. No. 62/926,132 is hereby incorporated by reference in its entirety. TECHNICAL FIELD The present specification relates to a modular mat system, more particularly a modular mat system with uniform construction with an enforced flange which provides increased strength, protection and durability for heavy industrial environments. BACKGROUND Heavy duty modular mat systems have been designed and utilized to provide temporary and rigid driving surfaces in remote and inaccessible areas. Such modular mat systems are primarily used where the natural environment provides unstable and soft surfaces for heavy construction equipment to drive across and operate. Heavy duty modular mat systems may be utilized to provide driveways, parking areas, walkways, platforms, or others rigid surfaces for vehicles, or other equipment. The modular mats can be adapted to the particular topographic or geographic needs of the particular work site. In operation, the choice of a mat system is primarily based upon the amount of load expected to be exerted on the mat, and the condition of the environment that the mat will be placed on which can be rock, dirt, concrete, grass, mud, water, mud, rock, or other such underlying substrates. Heavier construction equipment requires that the mats be resistant to cracking and breaking while under load, which can result in mats that are heavy and more cumbersome for the user. Since most construction sites are in undeveloped or remote areas, installation and removal of the mats are very expensive and time consuming. Because of the high costs associated with installation and removal of a modular mat the process must be done quickly and efficiently. Traditional mats generally use modular mat tiles that are linked together by a plurality of connectors which can be some mechanical mechanism. The mechanical mechanisms can be bolts or multiple piece cams that lock the mats together. Complex interactions between the mats causes stress between the mats and the connection points. In addition, this type of method requires the use of a large number of mats with bolts or multiple piece cams that lock the mats together in a side-by-side fashion, which can be tedious and time consuming when dealing with large areas. These mats are connected at one or more flanges that extend beyond the main body of the mat. These flanges are either part of the top main body, bottom main body, or both wherein the flanges are usually a solid piece which can decrease the structural strength when attached to the opposing mat when bending or flexing while under load. Current mats such as that provided in U.S. Pat. No. 9,506,255 provides for a modular mat having two layers wherein the layers have a central portion and flange that extends outwardly from the central portion. The two layers have at least one fitting receiver and a locking pin that connects the mats together. This type of mat design is limited in structural strength because it adds stress risers to the points within the central portion of the mat where the fitting receivers are located, and where the mats are connected together by a mechanical mechanism. These stress risers prohibited the mat to freely extend or flex when a heavy vehicle is driving across or stored on the mat. At the points where the stress risers are located these types of mats become brittle and crack under load and will eventually lose structural integrity. In addition, this mat design comprises apertures that extend through the first flange and the second flange wherein the apertures can have as much as quarter inch difference in size between the plurality of apertures causing for loose fitting receivers. It would be advantageous to provide a modular mat system which maintains it structural integrity under high loads and is durable for heavy industrial applications. There is also a need for a modular mat system that can quickly be assembled and disassembled. SUMMARY A module mat system with first layer that is joined to a second layer by fusion welding, hot welding, hand welding, seam welding, heat pressing, or other methods know to those having skill in the art. Each layer has a central core with a first cellular structure formed from ribs extending from the interior surface. The cross section of the ribs in the central core of the first layer matches the cross section of the ribs in the central core of the second layer such that when fusion welded together the ribs of the central core of the first layer weld to the ribs of the central core of the second layer. In one embodiment, the central core has a first band extending from at least one side of the central core, and the first band has a cellular structure with a cross-section that is substantially smaller than the cross section