TRACTION MAT SYSTEM AND A METHOD OF MANUFACTURING THEREOF

Abstract

A traction mat system and a method of manufacturing comprising a mat having a grip layer adhered to or mate integral to the surface of the mat. The grip layer can be a textured material foil sheet combined to a top surface and/or a bottom surface of the mat system. The texture of the grip layer is retained when the mat is contoured with a raised pattern to give the entire surface of the mat a texture to improve traction and grip. A method of manufacturing comprises a traction mat system wherein the traction mat can comprise of manufacturing step for placing a grip layer on the mat surfaces, for placing the foil sheet and/or aggregate on the mat. Each operation can be performed for both surfaces simultaneously or can be its own operation such as one surface at a time, or both surfaces at once.

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. 62/782,104 filed Dec. 19, 2018. The U.S. Provisional Patent Application Ser. No. 62/782,104 is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present specification relates to a mat system, more particularly an anti-skid mat system for providing traction to vehicles and construction equipment.

BACKGROUND

Constructions sites, oil and drilling operations and other industrial sites typically involve a significant amount of activity involving vehicles, construction equipment and other support equipment. To provide a smooth, clean, all-weather working condition, all year round, over environmental sensitive areas, or areas that would typically be hard for driving, a construction mat is typically laid down on the area for providing support to the construction vehicles. Typically, these types of areas are in wet areas such as bogs, wetlands, or fens where construction vehicles can become stuck without a solid, clean driving surface. Since, the areas are wet or can become wet during operations a construction mat with good traction for the vehicles is needed.

Current mats such as that provided in U.S. Pat. No. 6,511,257 provide a surface with raised portions on the mats that allow the tire to grip onto. The conventional mat system comprises traction promoting elements such as raised strips extending outwardly from the planar surface. This type of mat only provides limited traction due to the surface still being slick on both the mat surface and the raised strips. For example, the traction promoting elements give the mat a contour that improves tire grip, but the contours themselves remain a smooth, uniform surface that can become slick when the mat is wet or exposed to dust or other particles which are frequently present at a work site. In addition, these elements eventually wear out under the pressure of the vehicle and only provide limited traction on the mat surface once worn out causing an even slicker surface for the trucks to drive over.

It would be advantageous to provide traction mat system that provides traction elements over the entire surface of the mat system, and that allows construction vehicles to safely and efficiently drive over areas that are wet that could otherwise become stuck, or to protect environmental areas from heavy construction equipment.

SUMMARY

A traction mat system comprising a mat contoured with at least one raised pattern on at least one surface of the mat and a grip layer on at least one of the at least one surface. The at least one surface can be a bottom surface or a top surface. The grip layer can be a textured material foil sheet or it can be an aggregate material wherein the aggregate material can be pressed into at least one surface of the mat. The mat can have a top surface and a bottom surface, wherein the top surface and the bottom surface can be mirror copies of each other. The grip layer can be the same material as the mat. The mat can be composed of a mat material and wherein the aggregate material can be at least one of the same as the mat material, or it can be a high strength plastic particle, or metal particles. The texture of the grip layer is retained when the mat is contoured with a raised pattern to give the entire surface of the mat a texture to improve traction and grip.

In other embodiments, the grip layer may be an aggregate material wherein the aggregate material can be pressed into the mat's top surface and the mat's bottom surface. The aggregate material can be the same as the mat material, such as a high a strength plastic material, or a granular element such as silica, metal, or other particles known by those having skill in the art. In yet another embodiment, the aggregate material can be placed between the mat surface and a textured or non-textured foil sheet that can be combined with the mat material to trap the aggregate between the mat surface, and the foil sheet.

Aspects disclosed herein comprise a method of manufacturing a traction mat system comprising providing a stand connected to a press by at least one support and moving a trolley that supports at least one mold having a raised pattern between the stand and beneath the press. Placing a mat material in the mold. Placing a grip layer composed of at least one of a foil sheets and an aggregate layer over the mat. Pressing the press to the mold forming the foil sheet or aggregate material onto the mat material. The traction mat system can further comprise a second mold attached to the press. Wherein the grip layer is placed over a surface of the mat and a second grip layer is placed over a second surface of the mat.

Aspects and applications of the invention presented here are described below in the drawings and detailed description of the invention. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that they can be their own lexicographers if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the Absent such clear statements of intent to apply a “special” definition, it is the inventor's intent and desire that the simple, plain, and ordinary meaning to the terms be applied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.

Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. § 112 (f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112 (f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112 (f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for”, and will also recite the word “function” (i.e., will state “means for performing the function of molding a fishing lure, without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of molding a fishing lure, step for performing the function of molding a fishing lure,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. § 112 (f). Moreover, even if the provisions of 35 U.S.C. § 112 (f) are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the invention, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.

Additional features and advantages of the present specification will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present specification will become better understood with regard to the following description, appended claims, and accompanying drawings where:

FIG. 1a is an isometric view of a traction mat system and a method of manufacturing thereof in accordance to one, or more embodiments;

FIG. 1b is a side view of a traction mat system and a method of manufacturing thereof in accordance to one, or more embodiments;

FIG. 2a is a side view of an additional embodiment of traction mat system and a method of manufacturing thereof in accordance to one, or more embodiments;

FIG. 2b is a side view of an additional embodiments of traction mat system and a method of manufacturing thereof in accordance to one, or more embodiments;

FIG. 3A—3F is an isometric view of example embodiments of traction mat system and a method of manufacturing thereof in accordance to one, or more embodiments;

FIG. 4A-4D is an isometric view of an example embodiments of traction mat system and a method of manufacturing thereof in accordance to one, or more embodiments;

FIG. 5A-5D is an example of materials and surface types that can be used in a traction mat system in accordance to one, or more embodiments; and

FIG. 6 is a method for manufacturing a traction mat system in accordance to one, or more embodiments.

DETAILED DESCRIPTION

In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. The full scope of the inventions is not limited to the examples that are described below.

Referring to FIG. 1a-1b, a traction mat system and a method of manufacturing comprising a mat 18 having a grip layer adhered to or made integral to the mat. The grip layer may be a foil sheet 22, 40 combined to a surface (not shown) of the mat 18. In one embodiment, the mat 18 can be comprised of high-density polyethylene (HDPE), a hard plastic, or any other material known by those having skill in the art. The surface (not shown) can be a top surface and/or a bottom surface, and the surfaces can be mirror copies of each other wherein the top surface can be the same as the bottom surface. In other embodiments, the mat's 18 top and bottom surface (not shown) can vary in texture and surface properties wherein the texture can vary in surface patterns as shown in FIG. 5. The grip layer may comprise a foil sheet 22, 40 of a textured material that can be a solid textured material for adding traction to the top surface and/or bottom surface of the mat 18. The foil sheet can comprise, for example, high-density polyethylene, low-density polyethylene, plastics, metals or the like. In particular embodiments, the foil sheet can be made of the same material as the mat. In another embodiment, a textured layer may be poured or sprayed over the mat material to adhere to the mat and give added texture to the mat as shown in FIG. 2a.

The grip layer can be a sheet of material with plastics or metals embedded into it, and then can be compressed onto the mat's 18 surfaces. In other embodiments, the grip layer using the foil sheet 22, 40 can be replaced with an aggregate material wherein the aggregate material 104 can be spread across the surface of the mat and depressed into the mat's top surface and/or the mat's bottom surface as shown in FIG. 2a-2b. In certain embodiments, the aggregate material 104 can be omitted from either the top surface or bottom surface. The aggregate material 104 can be high a strength plastic or a granular element such as high-density polyethylene, low-density polyethylene, sand, wire, rubber, steel cords, or the like. In yet another embodiment, the aggregate material 104 can be placed between the mat's top surface and the mat's bottom surface and then a foil sheet 22, 40 can be combined trapping the aggregate between the top and bottom surface, and the foil forming the grip layer 22.

A traction mat system 10 can comprise a press 12, at least one mold wherein the at least one mold can be a upper mold 16 and a lower mold 34. The traction mat system 10 can further comprise a stand 38 having at least one support, a trolley 28, at least one tension roller wherein the at least one tension roller can be a top tension roller 14 and a bottom tension roller 30, and a foil sheet 40 material and/or an aggregate material (not shown) that can form a grip layer wherein the grip layer can be put on the top side, bottom side, or both top side and bottom side. The stand 38 and the press 12 can be connected together by the at least one support 24 wherein the supports can be beams, rods, tubular steel, I-beam, box beam or the like which can be attached to both the stand and the press by at least one fastener. The foil sheet 22, 40 can be in a roll or a single sheet which can be attached to the at least one tension roller 14, 30 and can be stretched tight across the at least one mold 16, 34, the press 12, and/or trolley 28, wherein the tension roller can hold the foil sheet tight and on the opposing side a tension support wherein the at least one tension support can be a top tension support 20 and a bottom tension support 32. The press 12 and the at least one molds 16, 34 can form the mat 18 and through some combination of heat and pressure the foil sheet 22, 40 can be integrated into the surface of the mat forming the grip layer on the bottom surface and/or top surface. In certain embodiments the upper mold 16, or bottom mold 34 and top tension roller 14 or bottom tension roller 30, and top tension support 20 or bottom tension support 32 can be omitted. The at least one mold 16, 34 may also have a texture incorporated within at least one surface of the mold to give the mat traction promoting elements that extend beyond the plane of the mat surface to improve traction.

In embodiments, the temperature and pressure of the press 12 can be controlled to allow the at least one foil sheet 22, 40 to adhere to or be combined with the mat material but maintain the texture of the foil sheet. The at least one tension rollers 14, 30 can be attached to the press 12, and/or the trolley 28 and can keep the foil sheets 22, 40 tight as the mold's material is pressed forming the mat's shape with the textured surface. In certain embodiments, the press 12 can hold the upper mold 16 and the trolley 28 can hold the lower mold 34 wherein when the press is lowered the mat material can be injected into or the mat material can be placed onto the lower mold 34 or between the molds and the press can bring the molds together, at a specific heat and pressure to form the mat material into a specified shape with a textured surface formed into one of the mat's sides preferably the at least the top surface and/or the bottom surface of the mat. The press 12 and molds can have a heat source that heats up the molds when compressed together forming the mat 18 with a grip layer integrated within it. In certain embodiments, the foil sheet 22, 40 can be a separate operation from the molding process or the foil sheet can be integrated within the same operation as the mat forming process. The trolley 28 can move the lower mold 34 into place and locked into position, the upper mold 16 can be lowered down onto the lower mold 34 and then compressed to form the mat 18 with the integrated grip layer.

Referring to FIG. 2a, a side view of an embodiment of an aggregate layer of a traction mat system and a method of manufacturing. The mat 18 may have traction promoting elements already formed before this operation or traction promoting elements that can be formed within this operation, by, for example, impressions in by the roller 106 that can allow some of the mat material to extend beyond the plane of the mat when the mat is pressed between the trolley 28 and the roller 106. The trolley 28 or a dispenser 102 can move the mat 18 along an axis where the aggregate material 104 can be dispensed from the dispenser. The dispenser 102 can evenly or unevenly dispenses the aggregate 104 onto the surfaces of the mat 18. The roller 106 can be lowered onto the mat 18 and can compress the aggregate 104 material into the mat top and/or bottom surfaces. In certain embodiments, a roller can be heated and can heat up the mat 18 material as it rolls over the aggregate 104 material and the mat surface. The aggregate material 104 can be high a strength plastic or a granular element such as high-density polyethylene, low-density polyethylene, sand, wire, rubber, steel cords, or the like.

Referring to FIG. 2b, a side view of another embodiment of laying aggregate and foil sheet of a traction mat system and a method of manufacturing thereof. A mat 18 can be formed before this operation or can be formed within this operation, wherein the trolley 28 can move the mat 18 along an axis where the aggregate material 104 is dispensed from a dispenser 102. The dispenser 102 can evenly or unevenly dispense the aggregate material 104 onto the surfaces of the mat 18. The roller 30 can be lowered onto the mat 18 and can compress the aggregate material 104 into the mat surface, in certain embodiments this step can be omitted. Alternatively, the foil sheet 40 can be placed on the surfaces of the mat and then the press 12 can lower onto the mat 18 and foil sheet and compress the foil sheet and any aggregate material 104 onto and/or into the mat.

Referring to FIG. 3A-3F, shows different embodiments of a traction mat system and a method of manufacturing. At 3A, the foil sheet 40 or aggregate 104 can be compressed or combined to one or more surfaces of the mat 18. At 3B, the foil sheet 40 can be placed over the aggregate material 104 which can be compressed or combined with at least one surface of the mat 18. At 3C, the aggregate material 104 can be placed over the foil sheet 40 which can be compressed or combined to one or more surfaces of the mat 18. At 3D, the aggregate material 104 and/or foil sheet 40 can be compressed or combined to two or more surfaces of the mat 18. At 3E, the foil sheet 40 can be place over the aggregate 104 and then can be compressed or combined to two or more surfaces of the mat 18. At 3F, the aggregate material 104 can be placed over the foil sheet 40 then it can be compressed or combined to two or more surfaces of the mat 18. The foil sheet 40 and/or the aggregate material 104 can be interchanged within each operation, and one or the other can be omitted from each operation creating a solid textured surface.

Referring to FIG. 4A-4D, shows different examples of mats in which the foil sheet and/or aggregate can be adhered to or combined with different types of mats, and mat surfaces. A current mat system can have a molded structure 34 that can be combined with the foil sheet 40, and/or the aggregate material 104 on both its top surface and bottom surface to add extra traction to the surfaces.

Referring to FIG. 5A-5D, shows examples of different type of materials and textures or shapes that can be pressed into and/or integrated within the mat surfaces.

Referring to FIG. 6, the method of manufacturing a traction mat comprising at step 602 providing a stand connected to a press by at least one support and moving a trolley that supports at least one mold having a raised pattern between the stand, and into and/or beneath the press. The raised pattern can be a foil sheet which can comprise placing a foil sheet, above or below the mat in a press and compressing the foil sheet and mat to contour the mat and adhere or combine the foil sheet to the mat material. The foil sheet can be held into position by a tensioner or some other type of apparatus on the machine. At step 604, placing a mat material in the mold which can be for example high-density polyethylene, or other high strength plastics. At step 606, placing a grip layer composed of at least one foil sheet and/or an aggregate layer over the mat. At step 608, pressing the press to the mold forming the foil sheet or aggregate material onto the mat material.

In another embodiment, an aggregate can be placed and/or dispersed evenly on a foil sheet face opposite the surface of the foil sheet contacting the mat material, or in between the mat material and the foil sheet. The foil sheet and the aggregate can be pressed to adhere or combine the mat material, the foil sheet, and the aggregate into a mat with contours and a textured surface. In other embodiments a second mold can be attached to the press wherein a grip layer can be placed over the surface of the mat and a second grip layer can be placed over a second surface of the mat. The aggregate material can be placed on and/or dispersed evenly, in a pattern, or randomly on finished mat surface(s). The aggregate material can be pressed, rolled or forced into the finished mat tread surface(s) and the excessive/loose aggregate can be removed from the mat and reused for future mats.

It is to be understood that although aspects of the present specification are highlighted by referring to specific embodiments, one skilled in the art will readily appreciate that these disclosed embodiments are only illustrative of the principles of the subject matter disclosed herein. Therefore, it should be understood that the disclosed subject matter is in no way limited to a particular methodology, protocol, and/or reagent, etc., described herein. As such, various modifications or changes to or alternative configurations of the disclosed subject matter can be made in accordance with the teachings herein without departing from the spirit of the present specification. Lastly, the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present disclosure, which is defined solely by the claims. Accordingly, embodiments of the present disclosure are not limited to those precisely as shown and described.

Certain embodiments are described herein, including the best mode known to the inventors for carrying out the methods and devices described herein. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described embodiments in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

1. A traction mat system comprising:

a mat contoured with at least one raised pattern on at least one surface of the mat and a grip layer on at least one of the at least one surface.

2. The traction mat system of claim 1, wherein the at least one surface is a bottom surface or a top surface.

3. The traction mat system of claim 1, wherein the grip layer is a textured material foil sheet or an aggregate material wherein the aggregate material is pressed into at least one surface of the mat.

4. The traction mat system of claim 1, wherein the mat has a top surface and a bottom surface, wherein the top surface and the bottom surface are mirror copies of each other.

5. The traction mat system of claim 1, wherein the grip layer is the same material as the mat.

6. The traction mat system of claim 3, wherein the mat is composed of a mat material and wherein the aggregate material is at least one of the same as the mat material, or a high strength plastic particles or metal particles.

7. A method of manufacturing a traction mat system comprising:

providing a stand connected to a press by at least one support and moving a trolley that supports at least one mold having a raised pattern between the stand and beneath the press;

placing a mat material in the mold;

placing a grip layer composed of at least one of a foil sheet and an aggregate layer over the mat; and

heating and pressing the press to the mold forming the foil sheet or aggregate material onto the mat material.

8. The traction mat system of claim 7, comprising a second mold attached to the press.

9. The traction mat system of claim 7, wherein the grip layer is placed over a surface of the mat and a second grip layer is placed over a second surface of the mat.

10. The traction mat system of claim 9, wherein the grip layer is pressed into or integrated in the surface of the mat and the second surface of the mat.