LAMINATED MAT WITH ENDCAP

Abstract

An improved laminated mat is disclosed and includes a plurality of layers and end caps. The plurality of layers may be formed of wood, synthetic materials, wood, metal, or a combination of such materials. The end caps may form longitudinal edges of the laminated mats, and may have an outer region having a thickness equal to a total thickness of the plurality of layers. The outer region of the end caps may provide improved performance of the laminated by reducing wear and tear of the laminated mat. In an additional aspect, the laminated may include attachment means recessed within the plurality of layers, and may include a cover plate that overlies the attachment means and is flush with a top surface of the laminated mat.

Description

TECHNICAL FIELD

The present disclosure is generally related to laminated mats, and more specifically to systems and methods for providing endcaps for laminated mats.

BACKGROUND

Laminated mats are in broad use in many industries. However, presently available laminated mats have several deficiencies that affect their performance and reduce their useful life. For example, many laminated mats are constructed from layers of wood, such as an untreated wood. During use, wooden laminated mats come in contact with the ground and moisture, which may cause the wooden laminated mats to begin deteriorating or rotting. Typically, the deterioration or rotting of wooden laminated mats begins at the edge, where the layers of the wooden laminated mat are directly exposed to the moisture. As the edges rot, the layers of the laminated mat may begin to separate, which may increase the rate at which the wooden laminated mat rots. Further, the separation of the layers may cause the wooden laminated mats to warp, creating an uneven surface, which may introduce tripping hazards to persons working in areas where such wooden laminated mats are present. Additionally, the rotting of the wooden laminated mat may significantly decrease their useful lifespan. For example, the useful life of wooden laminated mats is often less than 1 year, and may be significantly shorter (e.g., 6 months) due to the deficiencies described above. Thus, replacing the wooden laminated mats once or twice a year imposes significant costs to industries (e.g., the oil and gas industry) where such laminated mats may be deployed.

In addition to deficiencies (e.g., rotting) caused by weather elements (e.g., moisture, extreme heat, etc.), wear from continued use and/or damage from heavy equipment used in the field can cause individual pieces of wood used to construct the wooden laminated mats to disintegrate and fall from the mats over time. This disintegration causes loss of compression and torque of the bolts and/or nails holding the mat together, which may cause the wooden laminated mat to be no longer useable or to lose its structural integrity. Additionally, the wear from continued use and/or damage from heavy equipment may increase the likelihood that rot occurs, and may increase the rate at which the layers of the wooden laminated mat separate. This may also cause the useable life of the wooden laminated mat to decrease.

Another type of mat may be referred to as a synthetic mat. While synthetic mats generally do not have the same rotting problems as wood mats, synthetic mats are not in wide use due to various disadvantages. For example, in the event that there is rain at a location where the synthetic mats are deployed, water tends to stay on top of the laminated synthetic mats, thereby causing slippery conditions. Synthetic mats also tend to be more labor intensive to deploy. Moreover, synthetic mats generally have continuous top surface and a hollow core. Because of this, if the mat is ever pierced, water fills into the core and causes the synthetic mat to be much heavier, which creates difficulties in transporting and deploying the mats. Further, if the synthetic mats are utilized in a cold environment, water expansion in the presences of freezing conditions further damages the mats. Another disadvantage of synthetic mats is that because they generally comprise one large piece of surface material, they generally are not repairable in a cost-effective manner in the event that the mat is damaged.

Another type of mat is a laminated synthetic mat. While laminated synthetic mats are not as susceptible to rot as wooden laminated mats, laminated synthetic mats remain susceptible to separation of the layers under normal wear and tear. Such a separation reduces the useful life of the laminated synthetic mats. For example, forklifts are often used to transport the mats (e.g., both laminated synthetic mats and wooden laminated mats) to a location where the mats are to be deployed or stored. If the forklift operator inadvertently catches the edge of the mats with the forks of the forklift, the forks may slide between the layers of the laminated mats, damaging the areas immediately surround the impact zone and separating the layers of the laminated mat.

BRIEF SUMMARY

Systems, apparatuses and methods which provide for an improved laminated mat comprised of synthetic material, wood, or other materials are provided for herein. Such mats may include a plurality of inventive features. For example, in some embodiments the laminated mat may include one or more end caps configured to reduce the likelihood that layers of the laminated mat are separated during movement, use, and transport, and may reduce the wear and tear of the laminated mate, and may increase the useful life of the laminated mat.

In an additional or alternative embodiment, the laminated mat may comprise a cover plate that may reduce a likelihood that persons working in areas where the laminated mat may be deployed are injured. For example the laminated mat may include attachment means that may be recessed with respect to the top surface of the mat. Such attachments means may present a potential hazard that persons working in the area of the laminated may trip on. The cover plate may overlie the attachment means and substantially fill the recessed area where the attachment means is located, and may be seated flush with the top surface of the laminated mat, thereby eliminating the potential tripping hazard.

The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the embodiments will be described hereinafter which form the subject of the claims of the present disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the present disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a laminated mat in accordance with an embodiment of the present application;

FIG. 2 is an expanded perspective view of a laminated mat in accordance with an embodiment of the present application;

FIG. 3A illustrates a cross-sectional view of a laminated mat in accordance with an embodiment of the present application;

FIG. 3B illustrates a perspective view of an end cap for a laminated mat in accordance with an embodiment of the present application;

FIG. 3C illustrates a cross-sectional view of an end cap for a laminated mat in accordance with an embodiment of the present application;

FIG. 4A illustrates a cover plate for a laminated mat in accordance with an embodiment of the present application;

FIG. 4B illustrates a perspective view of a cover plate for a laminated mat in accordance with an embodiment of the present application;

FIG. 4C illustrates a profile view of a cover plate for a laminated mat in accordance with an embodiment of the present application;

FIG. 4D illustrates a top view of a cover plate for a laminated mat in accordance with an embodiment of the present application; and

FIG. 5 is a flow chart of a method for creating or using a laminated mat in accordance with an embodiment of the present application.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a perspective view and an expanded view of a laminated mat in accordance with an embodiment of the present application is shown as a laminated mat 100. In an embodiment, the laminated mat 100 may be constructed from wood. In an additional or alternative embodiment, the laminated mat 100 may be constructed from a synthetic material, such as rubber. In yet another additional or alternative embodiment, the laminated mat 100 may be formed of both wood and synthetic materials. As shown in FIGS. 1 and 2, the laminated mat 100 includes a plurality of layers. For example, in an embodiment, the plurality of layers may include a first layer 120, a second layer 130, and a third layer 140. In additional or alternative embodiments, the laminated mat 100 may include more than three layers or less than three layers. In an embodiment, the third layer 140 may be a bottom layer of the laminated mat 100 and the first layer 120 may be a top layer of the laminated mat 100. During deployment of the laminated mat 100, the third layer 140 may be in contact with the ground, and the layer 120 may be facing towards the sky (or a ceiling if deployed in a covered environment), and the second layer 130 may be an intermediate layer that is disposed between the first layer 120 and the third layer 140, as shown in FIGS. 1 and 2. Additionally, as shown in FIG. 1, the laminated mat 100 includes one or more attachment means 150 that may be used to lift the laminated mat 100, such as during placement, storage, loading for transport, etc. In an embodiment, the attachment means 150 may be a D-ring, as described in more detail below. In an embodiment, the attachment means 150 may be secured to the second layer 130 at a region 162, and may reside within an opening 160 of the first layer 120, as shown in FIG. 2. In an embodiment, the attachment means 150 may reside within the opening 160 and be recessed from the top surface of the first layer 120. By recessing the attachment means 150 from the top surface of the first layer 120, cover plates may be secured over the attachment means 150, as described in more detail below with reference to FIGS. 4A-4D.

In an embodiment, the layers 120, 130, 140 of the laminated mat 100 may be constructed from a plurality of individual boards, as shown in FIGS. 1 and 2. Further, the individual boards of each of the layers 120, 130, 140 may be in a cross-hatched orientation with respect to an immediately adjacent layer. For example, as shown in FIG. 2, the boards of the first layer 120 and the third layer 140 are oriented parallel to a longitudinal axis 102 of the laminated mat 100, while the boards of the second layer 130 oriented perpendicular to the longitudinal axis 102. Configuring the boards of the layers 120, 130, 140 in a cross-hatched orientation may increase the durability and strength of the laminated mat 100. In an embodiment, the layers 120, 130, 140 may be held together by bolts, as described with reference to FIG. 3. The bolts may be countersunk into the laminated mat 100, such that bolts are flush with, or slightly recessed from top surface of the first layer 120.

In an additional or alternative embodiment, the layers 120, 130, 140 may each be formed as single continuous sheet, rather than as a plurality of individual boards. For example, the first layer 120 may be formed from a first continuous sheet of material, the second layer 130 may be formed from a second continuous sheet of material, and the third layer 140 may be formed from a third continuous sheet of material. The sheets may then be attached (e.g., bolted, nailed, glued, etc.) to form the laminated mat 100.

It is noted that constructing the laminated mat 100 from individual boards, rather than layers of sheets, may provide advantages. For example, the individual boards may be spaced apart to allow water to drain through the laminated mat 100, whereas the continuous sheets may not allow water to drain through the laminated mat 100. Thus, when single continuous sheets are used to form the laminated mat 100, additional work may need to be completed prior to deployment of the laminated mat 100, such as to create slight gradient in the area where the laminated mats are to be deployed so that the water will run off the top surface of the layer 120. Further, by forming the laminated mat 100 from individual boards, rather than continuous sheets, individual boards of a particular layer of the laminated mat 100 may be replaced without requiring replacement of the entire particular layer.

In an embodiment, the third layer 140 may include metal channels 142, as shown in FIG. 4. The metal channels 142 may be used to add strength to the laminated mat 100, and to prevent the laminated mat 100 from warping. The metal channels 142 may be configured such that the height of the legs of the metal channels 142 are flush with a lower surface of the third layer 140. In some cases, the height of the legs may be slightly smaller such that the metal channels 142 do not contact the ground. In an embodiment, the metal channels 142 may extend along the length of the laminated mat 100 where attachment means 150 are located. Such a placement may provide for additional strength to hold the weight of the laminated mat 100 and any other load when the mat is being lifted using the attachment means 150. While not shown, it is appreciated that the metal channels 142 may be bolted with one or more of the layers 120, 130, 140.

Additionally, as shown in FIGS. 1 and 2, the laminated mat 100 includes end caps 110. The end caps 110 include a channel configured to receive one or more of the layers 120, 130, 140 of the laminated mat 100. In an embodiment, and as illustrated in FIGS. 1 and 2, the end caps 110 may be positioned along the longitudinal edges (e.g., the edges parallel to the longitudinal axis 102) of the laminated mat 100. In an additional or alternative embodiment, end caps 110 may be placed on all edges of the laminated mat 100. It is noted, however, that the longitudinal edges of the laminated mat 100 are high impact edges due to the way the laminated mat 100 is oriented during use. For example, during deployment and use, a plurality of laminated mats 100 may be placed adjacent to one another along their respective longitudinal edges to form a road upon which equipment (e.g., tractors, trucks, etc.) may travel in a direction perpendicular to the longitudinal axis 102. Because direction of travel is perpendicular to the longitudinal edges of the laminated mats, the longitudinal edges of the laminate mat 100 experience more wear and more frequent high impact from the heavy equipment that traverses the laminated mats. This additional wear creates more strain between the layers 120, 130, 140 along the longitudinal edges than in other areas, such as the edges perpendicular to the longitudinal axis 102. Thus, the longitudinal edges of the laminated mat 100 are more likely to break down or become damaged than the edges perpendicular to the longitudinal axis 102. The end caps 110 may reduce the wear and tear of the laminated mat 100 along the longitudinal edges.

For example, and referring to FIGS. 3A-3C, various views of the laminated mat 100 and end caps 110 are shown in accordance with an embodiment of the present application. In FIG. 3A, a cross-sectional view of the laminated mat 100 in accordance with an embodiment of the present application is shown. As explained above, the end caps 110 may be configured to receive one or more of the layers of the laminated mat 100. For example, in FIG. 3A, the second layer 130 is shown extending into the channel of the end caps 110. Further, the top surface of the first layer 120 and the top surface of the end caps 110 may be substantially flush, and the bottom surface of the third layer 130 and the bottom surface of the end caps 110 may be substantially flush, as shown in FIG. 3A. In an embodiment, the top surface of the first layer 120 and the top surface of the end caps 110 may be textured to provide improved grip for equipment and workers crossing the laminated mat 100, which may be beneficial in some operational conditions, such as when it is raining.

In additional or alternative embodiment, the channel of the end caps 110 may receive more than 1 layer of the laminated mat 100. For example, if the laminated mat 100 included 4 layers, the channel may be configured to receive the second and third layers (e.g., the middle layers). As another example, if the laminated mat 100 included 5 layers, the channel may be configured to receive the second and third layers (e.g., the middle layers). Further, the channel may receive less than all of the middle layers in some embodiments. For example, if the laminated mat included 4 layers, the channel may only receive the second layer, or the third layer, but not both, or may receive portions of the second and third layers. In yet another additional or alternative embodiment, the channel of the end caps 110 may receive only a portion of one or more layers of the laminated mat 100. For example, if the laminated mat 100 included two layers, the channel may receive a portion of the two layers, such as by milling the two layers along the longitudinal edges to form rabbets that are adjacent on each of the layers (e.g., form a tongue) that may be inserted into the channel while maintaining the top and bottom surfaces flush with the top and bottom surfaces of the end cap 110. The end caps 110 may reduce penetration of moisture between the layers 120, 130, 140. For example, because an outermost edge of the laminated mat 100 may correspond to the outer edge 310 of the end caps 110.

As can be seen in FIG. 3A, the longitudinal edges of the laminated mat 100 may be the end caps 110. By forming the longitudinal edges of the laminated mat 100 using the end caps 110, an outer edge of the laminated mat 110 may not expose the layers 120, 130, 140 of the laminated mat 100. For example, and referring to FIG. 3B, a perspective view of the end cap 110 is shown. As shown in FIG. 3B, the end cap 110 includes a channel 300, an outer edge 310, an upper portion 320, a lower portion 330, and an outer region 340. During placement, the longitudinal edges of the laminated mats 100 may be placed such that outer edges 310 of the laminated mats 100 are placed adjacent to one another. As can be seen in FIGS. 3A-3C, the outer edge 310 of the end cap 110 is formed as a single piece, meaning that the layers 120, 130, 140 are not exposed. Thus, the likelihood that equipment traversing the laminated mat 100 catches one or more of the layers 120, 130, 140 and causes the one or more layers to separate may be reduced.

As shown in FIG. 3C, the channel 300 may have a thickness 302 and a depth 304. The thickness 302 may be sized to receive the second layer 130 (or the boards that form the second layer 130). For example, in an embodiment, the thickness 302 may be the same as a thickness of the second layer 130. However, when the thickness 302 is the same as the thickness of the second layer 130, it may be difficult to insert the second layer 130 into the channel 300 of the end cap 110. Thus, in an additional or alternative embodiment, the thickness 302 may be sized to be slightly larger than the thickness of the second layer 130, which may make it easier to assemble the laminated mat 100. Furthermore, in embodiments of laminated mats comprising more than three layers, the thickness 302 may be sized to received one or more of the layers, and, in embodiments comprising two layers, the thickness 302 may be sized to receive the milled edges of the two layers, as described above. The depth 304 of the channel 300 may vary depending a particular configuration of the laminated mat 100. For example, a larger depth 302 may provide additional strength to the laminated mat 100. In an embodiment, the depth 304 may be determined based on a desired number of anchor points for securing the end cap 110 to the other layer(s) of the laminated mat 100. For example, a larger depth 302 may provide additional points at which the end cap 110 may be secured to the laminated mat 100.

As additionally shown in FIG. 3C, the upper portion 320 may have a thickness 322, and the lower portion 330 may have a thickness 332. In an embodiment, the thickness 322 may be the same as, or substantially equal to a thickness of the first layer 120, and the thickness 332 may be the same as, or substantially equal to a thickness of the third layer 140. Further, the end cap 110 may have an overall thickness 342. The overall thickness 342 of the end cap 110 may be equal to, or substantially the same as the sum of the thickness of the layers 120, 130, 140. Thus, when assembled, the end cap 110 may be substantially flush with the upper surface of the first layer 120 and the lower surface of the third layer 140. Because the longitudinal edges of the laminated mat 100 are constructed as the end caps 110, the longitudinal edges are a single homogeneous piece, which may be more resistant to wear and tear, and may more easily withstand impact in high traffic/impact areas, as is common to the longitudinal edges of the laminate mat 100.

Furthermore, and as illustrated in FIG. 3C, the outer region 340 of the end cap 110 may have a width 344. The width 344 of the outer region 340 may be configured to reduce or minimize impact from forks of a forklift. For example, the end cap 110 may be formed of rubber, and the width 344 of the outer region 340 may be sufficient to withstand impact from forks of a forklift without allowing the forks to penetrate to the layer(s) within the channel 300 or the remaining portions of the laminated mat 100. For example, as the forks penetrate the outer region 340, the forks may penetrate into the outer region, but due to the softness (or elasticity) of the outer region 340, the forks may eventually begin to push the laminated mat 100, rather than continue to penetrate through the laminated mat 100 and separate one or more of the layers 120, 130, 140. In an embodiment, the outer region 340 of the end cap 110 may include a strip of metal extending from the lower surface of the end cap 110 toward the upper surface of the end cap 110, where the strip of metal may engage the forks if they penetrate the end cap 110 to a threshold depth, and may prevent the forks from penetrating further into the end cap 110, so as to protect the portion of the second layer 130 inserted into the channel, and the remaining layers of the laminated mat 100.

Referring to FIGS. 4A-4D, various views of a cover plate for a laminated mat in accordance with an embodiment of the present application are shown as a cover plate 400. FIG. 4A illustrates the cover plate 400 as installed on the laminated mat 100 of FIGS. 1-3C. As shown in FIG. 4A, the cover plate 400 includes a first opening 410 and a second opening 420. The first opening 410 may be dimensioned to allow a retention member of the attachment means 150 to protrude through the first opening 410. It is noted that the attachment means 150, and the retaining member in particular, may be flush with the top surface of the first layer 120 when installed. As shown in FIG. 4A, the cover plate 400 may be secured to the laminated mat 100 using a screw 422 that is inserted through the second opening 420. The screw 422 may be recessed from, or may be flush with the top surface of the first layer 120

By using the cover plate 400 in conjunction with the laminated mat 100, work place injuries caused by workers tripping while walking through a work site where the laminated mat 100 is deployed. For example, as explained above, the attachment means 150 may be recessed within the first layer 120 of the laminated mat 100 by securing the attachment means 150 to the second layer 130 (e.g., at a region 162 of FIG. 2) such that the attachment means 150 resides substantially within an opening (e.g., the opening 160 of FIG. 2) of the first layer 120 of the laminated mat 100. When the cover plate 400 is not used, the attachment means 150 and the opening in which the attachment means 150 resides may pose a hazard, whereby workers may step into the opening or on the attachment means 150 and trip or twist their ankle. Thus, the cover plate 400 may reduce the likelihood that workers trip or are injured while walking across the laminated mat 100.

FIG. 4B illustrates a perspective view of the cover plate 400 of FIG. 4A. As shown in FIG. 4B, the cover plate 400 may include a member 402. In an embodiment, the member 402 may be perpendicular to the cover plate 400, and may project downward from the cover plate 400 towards the attachment means 150. In such an embodiment, the member 402 may be configured to maintain the top surface of the cover plate 400 in a substantially parallel orientation with respect to the first layer 120 of the laminated mat 100 so as to prevent the cover plate 400 from resting at an angle when secured to the laminated mat 100. This may prevent the cover plate 400 from being lower on the edge of the cover plate 400 opposite the first opening 420, which would pose a risk of workplace injury by workers tripping on the edge of the first layer 120 proximate the lowered edge of the cover plate 400. In an additional or alternative embodiment, the member 402 may be a latch configured to be inserted into an opening (not shown) in the attachment means 150 or the laminated mat 100. For example, instead of being substantially planar, as shown in FIG. 4B, the member 402 may include a curved or angled portion that may be inserted into an opening in the laminated mat 100 or the attachment means 150, where the opening is configured to receive at least a portion of the member 402 and to prevent the edge of cover plate 400 proximate the member 402 from lifting up. Thus, when the cover plate 400 is secured to the mat 100, the member 402 may need to be inserted into the opening of the laminated mat 100 or the attachment means 150 prior to securing the screw 422 to the laminated mat 100.

FIG. 4C illustrates a profile view of the cover plate 400. As shown in FIG. 4C, the attachment means 150 may reside below the cover plate 400 when secured to the laminated mat 100. FIG. 4D illustrates a top view of the cover plate 400. In addition to reducing the likelihood of work place injuries, the cover plate 400 may also protect the attachment means 150 from damage caused by machinery (e.g., trucks, tractor treads, etc.) that may traverse the laminated mat 100. Thus, using cover plates, such as the cover plate 400, may improve the laminated mat 100 by reducing the likelihood of injury and by reducing wear and tear on the attachment means 150.

Referring to FIG. 5, a flow chart of an exemplary embodiment of a method for creating or using a laminated mat is shown as a method 500. At 510, the method 500 includes providing a first plurality of boards (e.g., the plurality of boards comprising the first layer 120 of FIGS. 1 and 2), and, at 520, the method 500 includes disposing the first plurality of boards adjacent to one another along a first axis (e.g., the longitudinal axis 102 of FIGS. 1 and 2). At 530, the method 500 includes providing a second plurality of boards (e.g., the plurality of boards comprising the second layer 130 of FIGS. 1 and 2), and, at 540, the method 500 includes disposing the second plurality of boards adjacent to one another along a second axis that is perpendicular to the first axis (e.g., an axis perpendicular to the longitudinal axis 102 of FIGS. 1 and 2). At 550, the method 500 includes providing a third plurality of boards (e.g., the plurality of boards comprising the third layer 140 of FIGS. 1 and 2), and, at 560, the method 500 includes disposing the third plurality of boards adjacent to one another along the first axis (e.g., the longitudinal axis 102 of FIGS. 1 and 2). At 570, the method 500 includes providing end caps (e.g., the end caps 110 of FIGS. 1-3C) along longitudinal edges of the laminated mat, and, at 580, attaching the first plurality of boards, the second plurality of boards, the third plurality of boards, and the end caps to form the laminated mat. The end caps may include a channel (e.g., the channel 300 of FIG. 3.

In an embodiment, the method 500 may include additional steps (not shown in FIG. 5). For example, the method 500 may include disposing one or more of the second plurality of boards within the channel, as described above. As another example, the method 500 may include disposing one or more metal channels (e.g., the metal channels 142 of FIG. 2) between select ones of the third plurality of boards. As yet another example, the method 500 may include providing one or more attachment means, securing the one or more attachment means to at least one board selected from among the first plurality of boards, the second plurality of boards, and the third plurality of boards, providing a cover plate for each of the one or more attachment means, and securing each cover plate in an orientation that overlies one of the one or more attachment means and is flush with a top surface of the laminated mat.

Laminated mats constructed according to the method 500 may provide improved laminated mats. For example, because the laminated mats include end caps along the longitudinal edges (e.g., high impact, high traffic areas), the laminated mats may be more resistant to wear and tear. Additionally, by providing cover plates in some embodiments, a likelihood of injury to workers that are working in areas where the laminated mats are deployed may be reduced or eliminated.

Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein. without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

1. A laminated mat comprising:

a plurality of layers, the plurality of layers including at least a top layer and a bottom layer, the top layer having a first thickness, a first width, and a first length, and the bottom layer having a second thickness, a second width, and a second length; and

one or more end caps, wherein the one or more end caps form longitudinal edges of the laminated mats, and wherein the end caps have an outer region having a thickness equal to a total thickness of the plurality of layers.

2. The laminated mat of claim 1, wherein the one or more end caps include a channel sized to receive at least a portion of one of the plurality of layers.

3. The laminated mat of claim 1, wherein the plurality of layers includes an intermediate layer disposed between the top layer and the bottom layer, and wherein each of the one or more end caps includes a channel sized to receive a portion of the intermediate, the portion of the intermediate layer extending beyond the top layer and the bottom layer.

4. The laminated mat of claim 3, each of the plurality of layers includes a plurality of boards, and wherein boards of adjacent layers of the plurality of layers are disposed in a cross-hatched manner with respect to each other.

5. The laminated mat of claim 1, wherein each of the one or more end caps is formed as a single homogeneous piece.

6. The laminated mat of claim 1, further comprising one or more attachment means.

7. The laminated mat of claim 6, wherein the one or more attachment means are recessed within the plurality of layers such that the one or more attachment means are substantially flush with a top surface of the laminated mat.

8. The laminated mat of claim 6, further comprising one or more cover plates.

9. The laminated mat of claim 8, wherein the one or more cover plates are configured to be secured to one or more of the plurality of layers.

10. The laminated mat of claim 9, wherein each of the one or more cover plates is secured to one or more of the plurality of layers in an orientation that overlies one of the one or more attachment means, and wherein each of the one or more cover plates is seated flush with a top surface of the laminated mat.

11. The laminated mat of claim 8, wherein each of the one or more cover plates includes a member protruding perpendicular to a surface of the one or more cover plates.

12. The laminated mat of claim 8, wherein each of the one or more cover plates includes a member protruding from a surface of the one or more cover plates, wherein the member is configured to be inserted into an opening in one of the plurality of layers.

13. The laminated mat of claim 1, wherein the plurality of layers are formed of wood.

14. The laminated mat of claim 1, wherein the plurality of layers are formed of a synthetic material.

15. The laminated mat of claim 1, wherein the plurality of layers are formed of wood, a synthetic material, or a combination thereof.

16. The laminated mat of claim 1, wherein the bottom layer includes one or more metal channels.

17. A method for forming a laminated mat, the method comprising:

providing a first plurality of boards;

disposing the first plurality of boards adjacent to one another along a first axis;

providing a second plurality of boards;

disposing the second plurality of boards adjacent to one another along a second axis that is perpendicular to the first axis;

providing a third plurality of boards;

disposing the third plurality of boards adjacent to one another along the first axis;

providing end caps along longitudinal edges of the laminated mat; and

attaching the first plurality of boards, the second plurality of boards, the third plurality of boards, and the end caps to form the laminated mat.

18. The method of claim 17, further comprising disposing one or more metal channels between select ones of the third plurality of boards.

19. The method of claim 17, wherein the end caps include a channel, and wherein the method includes disposing one or more of the second plurality of boards within the channel.

20. The method of claim 19, wherein the method includes:

providing one or more attachment means;

securing the one or more attachment means to at least one board selected from among the first plurality of boards, the second plurality of boards, and the third plurality of boards; and

providing a cover plate for each of the one or more attachment means; and

securing each cover plate in an orientation that overlies one of the one or more attachment means and is flush with a top surface of the laminated mat.