ECOLOGICALLY FRIENDLY TRACTION MAT

Abstract

A system and method of an operating surface for vehicles in a roadless area is provided. More specifically, a mat that provides a vehicle operating surface in a roadless area is provided. The mat includes pockets forming ridges with a predetermined orientation. A variety of materials may be positioned within the pockets to provide a predetermined thickness and rigidity to the pockets. The pockets of a first portion of the mat alternate with pockets of a second portion of the mat. In this manner, the mat may be folded for transport, handling, and storage.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/159,023 filed May 8, 2015, U.S. Provisional Patent Application Ser. No. 62/244,500 filed Oct. 21, 2015, and to U.S. Provisional Patent Application Ser. No. 62/159,033 filed May 8, 2015 which are each incorporated herein in their entireties by reference.

FIELD OF THE INVENTION

Embodiments of the present invention are generally related to mats for temporary roads and access areas. More specifically, the present invention relates to mats that provide a temporary surface for vehicles in a roadless area, such as a construction site.

BACKGROUND

Vehicles frequently operate in construction sites and must cross open fields to access work areas. Such areas rarely include adequate roads that can accommodate heavy equipment which causes several problems. Vehicles operating in roadless areas can damage top soil and vegetation which may require expensive remediation by the vehicle operator. In addition, heavy vehicles can create ruts and render areas more susceptible to erosion. Vehicles can also be damaged when crossing roadless areas. For example, roadless areas may not provide a stable surface for vehicles, increasing the risk of loads shifting within vehicles or vehicles overturning. Vehicles may also become stuck when crossing roadless areas due to lack of traction. In addition, vehicles and vehicle tires may accumulate rocks, soil (or mud), and other foreign objects in the roadless area. These foreign objects can damage the vehicles.

When the vehicle enters an improved road after operating in a roadless area, foreign objects that have accumulated on the vehicle can be dropped onto the road, which can be a hazard to other vehicles. Foreign objects may also contribute to water contamination by migrating into drainage systems and streams. Because of these and other problems, many systems have been developed to provide temporary surfaces for vehicles operating in roadless areas.

One system of providing a temporary vehicle surface in a roadless area is described in U.S. Patent Application Publication No. 2006/0034652 by Sanders, which is incorporated herein by reference in its entirety. Sanders describes the use of removable, pre-cast concrete planks. Several pre-cast planks are placed end-to-end to form a temporary driveway. One obvious drawback is the pre-cast planks are heavy and must be lifted and positioned with a lifting rig. in addition, the rigidity of concrete planks may cause problems on uneven or unstable terrain, such as on uneven sand or soil. That is, when unevenly supported, concrete planks may tip back and forth. The planks may also fracture and break when installed over a depression.

Another system is described in PCT Publication No. WO 2007/072034 by Marsh, which is also incorporated by reference herein in its entirety. Marsh generally describes a ground cover mat comprising a first face spaced from a second face. First and second reinforcing components are positioned between the first face and the second face and include a plurality of cavities. The reinforcing components provide stiffness to the mat, but may prevent folding or rolling the mats for storage and transport. Also, similar to the concrete planks described by Sanders, the stiff mat of Marsh may cause problems on uneven or unstable terrain.

Another system is a rubber access mat described in U.S. Patent No. 8,039,082 by Fowler, which is incorporated herein by reference in its entirety. The rubber access mat described by Fowler includes a rigidifying grid of reinforcing wire embedded within a rubber slab. The rigidity of the rubber mats of Fowler may prevent folding or rolling of the mats when not in use. Accordingly, these mats may be difficult to transport and handle and may take up a large amount of storage space.

Due to these and other limitations associated with known systems and methods, there is an unmet need for a temporary operating surface for vehicles.

SUMMARY OF THE INVENTION

The present invention provides a temporary surface for vehicle use. One aspect of the present invention is to provide a temporary surface that may be folded for storage and transportation. In one embodiment, the temporary surface may be folded along a median axis generally parallel to a length of the temporary surface. Optionally, the temporary surface may be rolled before or after it has been folded. Accordingly, in one embodiment the temporary surface is sufficiently flexible for rolling along one or more of a length and a width. In another aspect, the temporary surface is comprised at least partially of a geo-textile material.

It is another aspect of the present invention to provide a temporary surface including a plurality of ridges. The ridges comprise sleeves filled with a separate material. The fill material is selected to provide a predetermined level of stiffness and flexibility. In one embodiment, the ridges comprise pockets filled at least partially with a rubber material. The rubber material may be ground to a predetermined size to form a loose aggregate. In one embodiment, the rubber material is loose fill. The ends of the ridges may be sewn closed to retain the rubber material. Alternatively, a binding agent may be added to the rubber material to form a contiguous or semi-contiguous rubber member. Optionally, the rubber material comprises a recycled tire rubber.

Alternatively, each pocket may be filled with at least one cylinder. In one embodiment, each pocket is filled with an inner cylinder positioned within a bore of an outer cylinder. The outer cylinder may comprise rubber or recycled rubber. The inner cylinder may comprise flexible tubing. Optionally, the inner cylinder may include a hollow bore.

Additionally, in another embodiment, the pockets may be at least one of perpendicular and transverse to a longitudinal edge of the temporary surface. The orientation of adjacent pockets may be the same or different. Further, a first portion of the mat may have pockets that are perpendicular to one lateral edge and the second portion of the mat may have pockets angled relative to the second lateral edge.

One aspect of embodiments of the present invention is to provide a temporary surface comprising a mat. In one embodiment, the mat includes a first portion, a median portion, and a second portion. The first portion and the second portion include a plurality of tubular pockets or sleeves. In one embodiment, the pockets are formed by selectively joining a first sheet to a second sheet. The pockets may have any desired length and cross-sectional profile. In one embodiment, the pockets have one of a generally circular and an elliptical cross-sectional profile.

In one embodiment, the pockets are aligned substantially perpendicular to a lateral edge of the mat. Optionally, the pockets have a length that is transverse to lateral edges of the mat. Alternatively, the length of the pockets may be substantially perpendicular to the lateral edges. In another embodiment, a length of first pockets of the first portion is substantially parallel to a length of second pockets of the second portion. In one embodiment, the first pockets alternate with the second pockets. In some versions the pockets are not continuous along one or more portions of the pocket length such that a portion of the fill material is partially exposed when secured within the pocket. State otherwise, each pocket may be formed of two or more individual segments aligned axially.

Alternatively, in one embodiment, the first pockets are aligned at a first angle with a first lateral edge of the mat. The second pockets are aligned at a second angle with the first lateral edge. Optionally, the first angle and the second angle are supplementary angles that add up to about 180°. Accordingly, when the mat is folded along a length of the median portion generally parallel to the first lateral edge, the first pockets and the second pockets will at least partially intermesh with each other.

The median portion may optionally be devoid of pockets. In one embodiment, the median portion is formed only of the second sheet. In another embodiment, the first portion and the second portion are interconnected to the median portion such as by sewing or by a mechanical fastener such as a staple or rivet. Optionally, the median portion may be formed at least partially of the first sheet and the second sheet. In one embodiment, the median portion is thinner than the first and second portions. Additionally, a seam or crease may be formed along a longitudinal axis of the median portion. The seam or crease may improve folding of the mat. Optionally, retention elements may be formed in the median portion. In one embodiment, the retention elements comprise apertures formed through the median portion that facilitate folding.

The mats of some embodiments of the present invention provide a temporary surface for vehicle use. The contemplated mats also help prevent vehicles from carrying dirt and debris from job sites onto public road ways (such as, but not limited to, construction sites, parks, etc).

The mats may be constructed of a first piece and a second piece of Geo-Textile material sewn together. Examples of Geo-Textile materials that can be used are provided below. Pockets (also known as “sleeves”) are provided between the upper and lower pieces at predetermined intervals.

The mats may be of any size and shape. In one embodiment of the present invention, the mats are about 12 feet wide by about 15 feet long. Approximately 2 inch wide pockets are provided between the Geo-Textile material layers about every 9 inches to 18 inches starting from one end at about 9 inches to 12 inches. Additionally or alternatively, each matt may have a minimum of 8 pockets.

In one embodiment, the first and second portions of the mat form two traction areas. The first and second portions are each about 4 feet wide by about 14 feet long. The median portion between the first and second portions is about 1 foot to about 3 feet wide. In one embodiment, the first and second portions are separately formed and subsequently joined to form the median portion. The median portion may accommodate a stitch, or other fastening means, so the first and second portions may be interconnected. Further, the median portion, which is devoid of pockets or sleeves, allows for mat folding.

An about 4 inch to 6 inch perimeter area may optionally be provided around one or more peripheral edges of the mat. The perimeter area provides staking points to receive a fastener that can be driven into the soil or other surface beneath the mad. Alternatively, the perimeter area may accommodate grommets or folding tabs that receive stakes. In one embodiment, the mat weighs between about 75 pounds and 85 pounds. More preferably, the mat weight about 80 pounds.

The pockets may be filled with recycled rubber. Preferably, the rubber is preferably at least about 90% free of steel and other textile products. In one embodiment of the present invention the rubber particles are less than about 3/8 inch in diameter. Indeed, some embodiments of the present invention contemplate using fines in the pockets. The fill material may not be mixed with binding products and, thus, will be a loose agglomeration of material. One of ordinary skill in the art will appreciate that other compliant or resilient materials may fill the pockets without departing from the scope invention. For example, in one embodiment, a glue or binding agent is mixed with the loose rubber particles.

It is one aspect of the present invention to provide a mat for vehicles including a plurality of ridges. The mat generally includes, but is not limited to: (1) an area defined by a first sheet selectively joined to a second sheet, the area having a predetermined length and width; (2) first pockets formed in a first portion of the area and second pockets formed in a second portion of the area, each of the first and second pockets defined by two generally parallel joints interconnecting the first sheet to the second sheet; (3) a filling member positionable within each of the first and second pockets, the filling member comprising a first cylinder with a first bore and a second cylinder positionable within the first bore; and (4) a median portion between the first and second portions, the median portion devoid of pockets such that the mat is foldable along a longitudinal axis of the median portion such that a first pocket of the first portion is arranged between two adjacent pockets of the second portion. In one embodiment, the first pockets alternate along the length of the area with the second pockets. Additionally or alternatively, the first pockets may be aligned at a first angle with the length of the area and the second pockets may be aligned at a second angle with the length of the area. In one embodiment, the first and second angles add up to about 180°.

Another aspect of the present invention is a mat for vehicles. The mat generally comprises: (1) an area defined by a predetermined length and width, the area comprising a first portion, a median portion, and a second portion; (2) pockets formed in the first and second portions; and (3) a filling member for the pockets, wherein the pockets have a predetermined orientation such that when the first portion is folded proximate to the second portion, a first pocket of the first portion contacts an area of the second portion between two adjacent pockets of the second portion. Optionally, first pockets of the first portion alternate width-wise with second pockets of the second portion.

In one embodiment, the pockets are substantially perpendicular to longitudinal edges of the first and second portions. Alternatively, in another embodiment, the pockets are transverse to longitudinal edges of the first and second portions.

In one embodiment, the filling material comprises a first cylinder configured to be positioned in a pocket. Optionally, the first cylinder may include a first bore. The filling material may further comprise a second cylinder configured to be positioned in the first bore. In one embodiment, the second cylinder includes a second bore. Alternatively, the second cylinder is devoid of a bore.

In another embodiment, the filling material comprises a rubber aggregate to be retained within a pocket. The rubber aggregate may comprise recycled tire rubber. In one embodiment, the rubber aggregate has an average particle size of less than about 3/8 inch in diameter. Optionally, a binding agent may be added to the rubber aggregate. In another embodiment, the rubber aggregate is devoid of binding agents.

In one embodiment of the present invention, the first and second portions comprise a first sheet selectively joined to a second sheet. The median portion may comprise at least one of the first and second sheets. In one embodiment, the first and second sheets comprise a geo-textile including a woven polypropylene material. The geo-textile of the first and second sheets may have a tensile strength of between about 315 pounds by about 315 pounds to about 350 pounds by about 450 pounds.

It is another aspect of the present invention to provide a method of using a mat to provide an operating surface for a vehicle. The method generally includes, but is not limited to: (1) at least one of unfolding the mat and unrolling the mat; (2) placing the mat on a surface; (3) securing a fastener to the mat with one of the plurality of retention elements; and (4) driving the fastener at least partially into the surface. In one embodiment, the mat comprises: (a) an area defined by a predetermined length and width, the area comprising a first portion, a median portion, and a second portion; (b) a plurality of retention elements; (c) pockets formed in the first and second portions; and (d) a filling member positioned in the pockets. In one embodiment, the filling member comprises a first cylinder with a first bore and a second cylinder positioned within the first bore.

In one embodiment, first pockets of the first portion form a first angle with a first edge longitudinal edge of the mat. Second pockets of the second portion for a second angle with the first edge longitudinal edge. In another embodiment, the first and second angles are supplementary angles.

As used herein, a “geo-textile” shall mean a permeable fabric which has the ability to separate, filter, reinforce, protect or drain soil. In one embodiment, the geo-textile material comprises one or more of polypropylene and polyester. The geo-textile material may be woven, needle punched, and/or heat bonded. In one embodiment, the geo-textile is a woven polypropylene material comprising heavy woven monofilament and/or filibrated yarns. Optionally, the geo-textile material has a tensile strength of at least about 315 pounds by about 315 pounds. Alternatively, the tensile strength is at least about 450 pounds by about 350 pounds. In one embodiment, the geo-textile material is the same as, or similar to, Geotex® 2x2HF produced by Propex™. In another embodiment, the geo-textile material is the same as, or similar to, Geotex® 3x3HF produced by Propex™. However, it will be appreciated by one of skill in the art that suitable geo-textile materials are available from a variety of sources.

The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”

The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the Summary of the Invention, Brief Description of the Drawings, Detailed Description, Abstract, and Claims themselves.

The Summary of the Invention is neither intended, nor should it be construed, as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements or components. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the invention and together with the Summary of the Invention given above and the Detailed Description given below serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the present invention is not necessarily limited to the particular embodiments illustrated herein. Additionally, it should be understood that the drawings are not necessarily to scale.

FIG. 1 is a top perspective view of a mat of an embodiment of the present invention in a position of use proximate to a boundary of a road;

FIG. 2 is a top plan view of the mat of FIG. 1;

FIG. 3 is a side elevation view of the mat of FIG. 1;

FIG. 4A is a front elevation view of the mat of FIG. 1 illustrating an embodiment in which the mat is formed of a first sheet of material selectively joined to a second sheet of material;

FIG. 4B is another front elevation view of a mat of another embodiment of the present invention;

FIG. 4C is still another front elevation view of another embodiment of a mat of the present invention and also illustrating optional reinforced lateral edges of an embodiment of the present invention;

FIG. 5 is a partial cross-sectional view of the mat of the embodiment of FIG. 1 taken along line 5-5 of FIG. 2 and illustrating pockets filled with an inner cylinder positioned within a bore of an outer cylinder according to one embodiment of the present invention;

FIG. 6 is a partial cross-sectional view of a mat of another embodiment of the present invention illustrating pockets filled with a rubber aggregate according to another embodiment of the present invention;

FIG. 7 is a partial side elevation view of the mat of FIG. 1 wherein the mat has been folded along a longitudinal axis;

FIG. 8 is a view of the mat of FIG. 1 in a position of use proximate to a vehicle; and

FIG. 9 is a top plan view of a mat of another embodiment of the present invention.

Similar components and/or features may have the same reference number. Components of the same type may be distinguished by a letter following the reference number. If only the reference number is used, the description is applicable to any one of the similar components having the same reference number.

To assist in the understanding of one embodiment of the present invention the following list of components and associated numbering found in the drawings is provided herein:

#   Component
2   Road
4   Road boundary
6   Curb
8   Sidewalk
10  Mat
12  First portion
14  Median portion
16  Second portion
18  Pocket opening
20  Pocket filling
22  Pockets of first portion
24  Longitudinal edge of first portion
26  Pockets of second portion
28  Longitudinal edge of second portion
30  Longitudinal axis
32  Pocket length
34  Width of first and second portions
36  Length of mat
37  Width of mat
38  Width of medial portion
42  Reinforced portion
46  Reinforced portion
48  Width of reinforced portions
50  Retention elements
51  Retention elements
52  Fastener
54  First sheet
56  Second sheet
58  Joint or stitches
60  Medial edge of first portion
62  Medial edge of second portion
64  Reinforced lateral edge of first portion
66  Reinforced lateral edge of second portion
68  Pocket spacing
70  Pocket width
72  Inner cylinder
74  Optional bore of inner cylinder
76  Outer cylinder
78  Bore of outer cylinder
80  Rubber aggregate
82  Lateral extension
86  Lateral extension
88  Vehicle
90  Vehicle tires
92  Tire width
94  Exterior tire width
96  Tire separation distance
110 Mat
112 First portion
114 Median portion
116 Second portion
122 Pockets of first portion
124 Longitudinal edge of first portion
126 Pockets of second portion
128 Longitudinal edge of second portion
130 Longitudinal axis
134 Width of first and second portions
136 Length of mat
137 Width of mat
138 Width of medial portion
150 Retention elements
151 Retention elements
158 Joint or stitches
168 Pocket spacing
170 Pocket width
182 Lateral extension
186 Lateral extension

DETAILED DESCRIPTION

The present invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, may be modified in numerous ways within the scope and spirit of the invention.

Referring now to FIGS. 1-3, a mat 10 according to one embodiment of the present invention is illustrated. The mat 10 generally includes a first portion 12 and a second portion 16 joined by a median portion 14.

The first and second portions 12, 16 include pockets or sleeves 22, 26. Each pocket 22, 26 includes at least one opening 18. In one embodiment, the openings 18 are positioned proximate to the longitudinal edges 24, 28 of the first and second portions 12, 16. Alternatively, the openings 18 are positioned proximate to the median portion 14. A predetermined filling 20 (described in more detail in conjunction with FIGS. 5-6) is inserted through the openings 18 and retained within an interior of the pockets 22, 26.

The pockets 22, 26 and filling 20 are configured to provide, or improve, traction to tires of a vehicle. For example, in one embodiment, the filling 20 at least increases the thickness of the mat 10. Additionally, in one embodiment, the arrangement and orientation of the pockets 22, 26 is selected to cause tires on a left side of a vehicle to contact the pockets 22 at a different time than the tires on a right side of the vehicle contact the pockets 26. The alternating contact of the left tires with the pockets 22 and the right tires with the pockets 26 will cause the vehicle to shake or vibrate transverse to a direction of travel of the vehicle. In this manner, foreign objects, such as dirt and rocks, may be dislodged from the vehicle and fall onto the mat 10 before the vehicle enters an improved road 2. This may beneficially decrease the amount or frequency of vehicle washing required for vehicles operating in roadless areas.

The mat 10 is illustrated in FIG. 1 positioned proximate to a boundary 4 of a road 2. In one implementation, the boundary is a concrete curb 6. A longitudinal axis 30 of the mat 10 is preferably orientated generally perpendicular to the boundary 4. Optionally, at least a portion of the mat 10 may extend past the boundary 4. Accordingly, the mat 10 may be arranged to provide protection to surfaces, such as the curb 6, that are not adapted to receive and support vehicle traffic. It will be appreciated that the mat 10 may be positioned proximate to other structures. For example, in FIG. 3, the mat 10 is illustrated positioned proximate to a sidewalk 8. Although only one mat 10 is illustrated in FIG. 1, it will be appreciated by one of skill in the art that a plurality of mats 10 may be aligned longitudinally to provide a larger temporary surface for vehicles.

Referring now to FIG. 2, the mat 10 also has a predetermined length 36. In one embodiment, the mat length 36 is between about 14 feet and about 16 feet. More preferably, the mat length 36 is about 15 feet. In one embodiment, the mat 10 has a width 37 of between about 10 feet to about 15 feet. More preferably, the width 37 is about 12 feet.

The medial portion 14 may have any predetermined width 38. In one embodiment, the medial width 38 is between about 4 inches and about 38 inches. More preferably, the medial width 38 is about 36 inches.

In one embodiment, the pockets 22 of the first portion 12 alternate width-wise with the pockets 26 of the second portion 16. Accordingly, as described in more detail in conjunction with FIG. 7, in one embodiment when the first portion 12 is folded along the longitudinal axis 30, the each pocket 22 fits between adjacent pockets 26 of the second portion 16. In this manner, the mat 10 can be folded to take up less space during storage and handling.

The pockets 22, 26 may also have any predetermined orientation with respect to the longitudinal edges 24, 28 of the first and second portions 12, 16. In one embodiment, the pockets 22, 26 are substantially perpendicular to the longitudinal edges 24, 28.

The pockets 22, 26 may have any predetermined length 32. The length 32 of the pockets 22, 26 may be substantially equal to, or greater than, a width 34 of each of the first and second portions 12, 16. In one embodiment, the length 32 of the pockets 22, 26 is about 36 inches. Optionally, the width 34 of portions 12, 16 is greater than 36 inches. In another embodiment, the width 34 is between about 32 inches and about 72 inches.

In one embodiment, a portion 42, 46 of each of the first and second portions 12, 16 is reinforced. The reinforced portions 42, 46 may be formed from additional layers of one or more of the first and second sheets 54, 56 (described in more detail in conjunction with FIG. 5). The reinforced portions 42, 46 may be positioned in the first and second portions 12, 16 to align with tires of a vehicle as described in more detail in conjunction with FIG. 8. In embodiment, reinforced portions 42, 46 of the first and second portions 12, 16 have a width 48 of about 36 inches.

In one embodiment, retention elements 50 extend from one or more portions of the mat 10. Fasteners 52, such as stakes or soil nails, may be secured to the mat 10 by the retention element 50 and then driven into the ground. In this manner, the retention elements 50 and fasteners 52 prevent inadvertent or unintended movement of the mat 10, such as when vehicles drive over the mat 10.

Referring now to FIG. 4A, the first and second portions 12, 16 may be formed of a first sheet 54 of material interconnected to a second sheet 56 of material at joints 58. The joints 58 have a predetermined orientation. As illustrated in FIGS. 1-2, at least some of the joints 58 form generally parallel lines that define the pockets 22, 26.

The joints 58 may be formed in any suitable manner. In one embodiment, the joints 58 comprise stitches of thread or wire sewn through the first and second sheets 54, 56. However, other methods of forming the joints 58 are contemplated. For example, in one embodiment the joints 58 comprise one or more of rivets, staples, bolts, glue, and fabric welds. As will be appreciated by one of skill in the art, fabric welding includes heat tape welding or using a welding tape to joint selected portions of the first and second sheets 54, 56 together.

In one embodiment, the median portion 14 is devoid of pockets. Additionally, in one embodiment, the median portion 14 comprises only the second sheet 56.

Referring now to FIG. 4B, the median portion 14A may alternatively include the first sheet 54. Accordingly, in one embodiment, the mat 10A generally comprises a generally continuous first sheet 54 selectively interconnected to a generally continuous second sheet 56. Referring now to FIG. 4C, in an optional embodiment, the mat 10B includes a first portion 12B and a second portion 16B that are individually formed. The individual first and second portions 12B, 16B are subsequently joined together along medial edges 60, 62 to form the mat 10B. Optionally, the medial edges 60, 62 may at least partially overlap to form the medial portion 14B.

Mats 10 of all embodiments of the present invention may also include reinforced lateral edges. Two embodiments of the optional reinforced edges 64, 66 are illustrated with the embodiment of mat 10B in FIG. 4C. The reinforced lateral edges 64, 66 are generally formed by provided one or more additional layers of at least one of the first sheet 54 and the second sheet 56. For example, in one embodiment, reinforced lateral edge 64 is formed folding at least one layer of the second sheet 56 over a portion of the first sheet 54. Additionally or alternatively, a reinforced lateral edge 66 may be formed by folding at least one layer of the first sheet 54 around a portion of the second sheet 56.

Optionally, the materials of the first and second sheets 54, 56 may be the same or different. For example, in one embodiment, the material of the first sheet 54 may be of a different type, thickness, and/or density than the material of the second sheet 56. In one embodiment, the material of at least one of the first and second sheets 54, 56 comprises a geo-textile.

Referring now to FIGS. 5-6, the pockets 22, 26 are formed by the joints 58 that selectively interconnect the first and second sheets 54, 56. The pockets 22, 26 may have any predetermined spacing 68, width 70, and cross-sectional profile. In one embodiment, the pockets 22, 26 have a spacing 68 of from about 9 inches to about 18 inches. In another embodiment, the spacing 68 is selected such that each of the first and second portions 12, 16 include at least 8 pockets.

In one embodiment, the pocket width 70 is between about 2 inches and about 6 inches. More preferably, the pocket width 70 is about 4 inches. In another embodiment, the pocket width 70 is about 4.5 inches. In one embodiment, the pockets 22, 26 have a generally symmetric cross-sectional profile. Optionally, the cross-sectional profile in one of circular and elliptical, but other cross-sectional profiles are contemplated.

As previously described, filling 20 may be positioned within the pockets 22, 26. In one embodiment, the filling 20 comprises an inner cylinder 72 positioned within a bore 78 of an outer cylinder 76. The inner and outer cylinders 72, 76 may comprise the same or different materials. In one embodiment, the outer cylinder 76 has a thickness greater than the inner cylinder 72. Optionally, in another embodiment, the pockets 22, 26 may be filled with only one of the inner cylinder 72 and the outer cylinder 76. Optionally, the openings are not sewn shut. In this manner, the filling 20 of the pockets 22, 26 may be replaced or changed for maintenance or to alter the stiffness or rigidity of the filled pockets 22, 26. Additionally, in one embodiment, the filling 20 may have a length that is greater than the length 32 of the pockets 22, 26. Accordingly, at least a portion of the filling 20 may extend at least partially from an opening 18 of a pocket 22, 26.

In one embodiment, the inner cylinder 72 comprises flexible tubing, such as a flexible plastic hose. Optionally, the inner cylinder 72 may include a hollow bore 74. The inner cylinder 72 with the bore 74 may be selected for use when a less rigid filling 20 is desired. Alternatively, the inner cylinder 72 may be generally solid without the bore. Accordingly, an inner cylinder 72 without the bore may form a portion of the filling 20 when a more rigid filled pocket 22, 26 is desired.

Additionally, the outer cylinder 76 may comprise a rubber material. In one embodiment, the rubber material comprises recycled tire material. Optionally, the exterior diameter of the outer cylinder 76 is between about 2.5 inches and about 3.5 inches. More preferably, the exterior diameter is about 3 inches. Optionally, the pocket openings 18 are not sewn shut. In this manner, the filling 20 of the pockets 22, 26 may be replaced or changed for maintenance or to alter the stiffness or rigidity of the filled pockets 22, 26.

Referring now to FIG. 6, pockets 22, 26 of the mat 10 may include a filling 20A of another embodiment. The filling 20A comprises rubber particles or aggregate 80. In one embodiment, the aggregate 80 has an average diameter of less than about ⅜ inches. Preferably, the diameter of substantially all of the aggregate 80 is less than about ⅜ inches. Optionally, the aggregate 80 is loosely packed into the pockets 22, 26. In one embodiment, the aggregate 80 is not mixed with a binding material or glue. Thus, the aggregate 80 may form a loose agglomeration of material. In this embodiment, the pocket openings 18 are sealed after the pockets 22, 26 are filled with the aggregate 80. Alternatively or additionally, a glue or binding agent may be mixed with the aggregate 80.

Referring now to FIG. 7, the pockets 22, 26 in all embodiments of the present invention may be staggered. Thus, when the first portion 12 is folded into proximity with the second portion 16 along the longitudinal axis, the pockets 22, 26 at least partially mesh together. Said another way, a pocket 22A of the first portion 12 generally contacts the first sheet 54 of the second portion 16 between adjacent pockets 26A, 26B of the second portion 16. Thus, the mat 10 may be folded to decrease the width of the mat 10. Further, because of the alternating arrangement of the pockets 22, 26 the mat 10 has a decreased thickness when folded compared to a similar mat without the staggered pockets 22, 26. Optionally, after the mat 10 is folded, a user may roll the mat 10 from one narrow end along the longitudinal axis toward the other narrow end.

Referring now to FIG. 8, a mat 10 of the present invention is illustrated with optional lateral extensions 82, 86 adjacent to the first and second portions 12, 16. The lateral extensions 82, 86 are optionally formed of a different material or have a different thickness than the first and second portions 12, 16. Optionally, the lateral extensions 82, 86 may be integrally formed with the respective first and second portions 12, 16.

Optional retention elements 51 of another embodiment of the present invention are arranged in the extensions 82, 86. The retention elements 51 may also be formed in the median portion 14. In one embodiment, the retention elements 51 of the median portion 14 are arranged such that they do not intersect the longitudinal axis 30. In this manner, the median retention elements 51 do not interfere with folding of the mat 10 along the longitudinal axis 30. The retention elements 51 are configured to receive a fastener 52 (illustrated in FIG. 1). In one embodiment, the retention elements 51 comprise apertures through at least one of the extensions 82, 86 and the median portion 14. The apertures may include a reinforced edge formed of additional seaming or a grommet interconnected to the mat. The grommet may be formed on any material, including without limitation metal, plastic, rubber, and wood. Retention elements 51 may be used with, or instead of, retention elements 50.

The mat 10 is illustrated in a position of use proximate to a vehicle 88. The first and second portions 12, 16 of the mat 10 generally align with tires 90 of the vehicle 88. More specifically, the width 34 of the first and second portions 12, 16 is at least equal to, and preferably greater than, the width 92 of the vehicle tires 90. Additionally, the mat width 37 is at least equal to, and preferably greater than, the exterior width 94 of the vehicle tires. Optionally, the width 38 of the medial portion 14 is less than an interior separation 96 of the vehicle tires 88.

Optionally, in an embodiment, the first and second portions 12, 16 have a greater material thickness or more layers of material than the medial portion 14 to accommodate repeated contact by vehicle tires. This may decrease the relative weight of the mat 10 compared to other known systems with a uniform thickness.

Referring now to FIG. 9, a mat 110 of another embodiment of the present invention is illustrated. The mat 110 is similar to the mat 10. Accordingly, the mat 110 is made of the same or similar materials and has the same or similar dimensions 134, 136, 137, 138. Pockets 122, 126 of the mat 110 may have the same spacing 168, width 170, and fill as the pockets 22, 26 of mat 10. However, the pockets 122, 126 have a different orientation compared to the pockets of mat 10. More specifically, the pockets 122, 126 are aligned transverse to longitudinal edges 124, 128. Pockets 122 are aligned at a first angle with respect to longitudinal edge 124. Pockets 126 are aligned at a second angle with respect to longitudinal edge 124. In one embodiment, the first and second angles are supplementary angles. Accordingly, the sum of the first and second angles is 180°. In this manner, when the mat 110 is folded along longitudinal axis 130, the pockets 122 will substantially align with a space between adjacent pockets 126 similar to the folded mat 10 illustrated in FIG. 7.

The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described and shown in the figures were chosen and described to best explain the principles of the invention, the practical application, and to enable those of ordinary skill in the art to understand the invention.

While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. For example, aspects of the inventions disclosed in U.S. Pat. No. 4,244,841, U.S. Pat. No. 5,653,551, U.S. Pat. No. 6,380,309, U.S. Pat. App. Pub. No. 2004/0005430, PCT Pub. No. WO 2001/092638, PCT Pub. No. WO 2006/002507, PCT Pub. No. WO 2007/072034, all of which are incorporated by reference herein, may be incorporated into embodiments of the present invention.

Claims

1. A mat for vehicles including a plurality of ridges, comprising:

an area defined by a first sheet selectively joined to a second sheet, the area having a predetermined length and width;

first pockets formed in a first portion of the area and second pockets formed in a second portion of the area, each of the first and second pockets defined by two generally parallel joints interconnecting the first sheet to the second sheet, wherein the first pockets alternate along the length of the area with the second pockets;

a filling member positionable within each of the first and second pockets, the filling member comprising a first cylinder with a first bore and a second cylinder positionable within the first bore; and

a median portion between the first and second portions, the median portion devoid of pockets, wherein the mat is foldable along a longitudinal axis of the median portion such that a first pocket of the first portion is arranged between two adjacent pockets of the second portion.

2. The mat of claim 1, wherein the first pockets are aligned at a first angle with the length of the mat area and the second pockets are aligned at a second angle with the length of the mat area.

3. A mat for vehicles, comprising:

an area defined by a predetermined length and width, the area comprising a first portion, a median portion, and a second portion;

pockets formed in the first and second portions; and

a filling member for the pockets, wherein the pockets have a predetermined orientation such that when the first portion is folded proximate to the second portion, a first pocket of the first portion contacts an area of the second portion between two adjacent pockets of the second portion.

4. The mat of claim 3, wherein the pockets are substantially perpendicular to longitudinal edges of the first and second portions.

5. The mat of claim 3, wherein the pockets are transverse to longitudinal edges of the first and second portions.

6. The mat of claim 3, wherein the filling material comprises a first cylinder configured to be positioned in a pocket.

7. The mat of claim 6, wherein the first cylinder includes a first bore.

8. The mat of claim 7, wherein the filling material further comprises a second cylinder configured to be positioned in the first bore.

9. The mat of claim 8, wherein the second cylinder includes a second bore.

10. The mat of claim 3, wherein the filling material comprises a rubber aggregate to be retained within a pocket.

11. The mat of claim 10, wherein the rubber aggregate comprises recycled tire rubber.

12. The mat of claim 10, wherein the rubber aggregate has an average particle size of less than about ⅜ inch in diameter.

13. The mat of claim 12, wherein a binding agent is added to the rubber aggregate.

14. The mat of claim 12, wherein the rubber aggregate is devoid of binding agents.

15. The mat of claim 3, wherein the first and second portions comprise a first sheet selectively joined to a second sheet, and wherein the median portion comprises at least one of the first sheet and the second sheet.

16. The mat of claim 15, wherein the first and second sheets comprise a geo-textile including a woven polypropylene material.

17. The mat of claim 16, wherein the geo-textile of the first and second sheets has a tensile strength of between about 315 pounds by about 315 pounds to about 350 pounds by about 450 pounds.

18. The mat of claim 3, wherein first pockets of the first portion alternate width-wise with second pockets of the second portion.

19. A method of using a mat to provide an operating surface for a vehicle, comprising:

at least one of unfolding the mat and unrolling the mat;

placing the mat on a surface, the mat comprising: an area defined by a predetermined length and width, the area comprising a first portion, a median portion, and a second portion; a plurality of retention elements; pockets formed in the first and second portions; and a filling member for the pockets;

securing a fastener to the mat with one of the plurality of retention elements; and

driving the fastener at least partially into the surface.

20. The method of claim 19, wherein first pockets of the first portion form a first angle with a first edge longitudinal edge of the mat and second pockets of the second portion for a second angle with the first edge longitudinal edge, and wherein the first and second angles are supplementary angles.