Abstract:
A component mat combines with similar mats to form a vehicle tracking pad assemblage, with juxtaposed ends joined by mechanical interlock. Optional turnout mats are interlocked to sides of the component mat. A top mat surface carries a finish formed of an array of upstanding mud removal elements of effective height. Mud removal element heights may be uniform among spaced apart elements or may vary among juxtaposed elements. The intermat interlock may carry the top finish to establish continuity over the junction. Suitable mud removal elements include cylinders, pyramids, ribs, and simulated rock patterns.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The invention generally relates to process or apparatus for road structure. More specifically, the invention relates to preformed modules or blocks of the portable mat type for pavement. Further, the invention relates to interfitting modules or blocks for pavement. A reusable mat provides a durable surface at tracking areas as typically found at construction sites. The mat configuration cleans the tires of trucks crossing the mat. 
         [0003]    2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
         [0004]    Regulatory bodies frequently implement tracking control at construction sites. Tracking control is used to prevent or reduce off-site vehicle tracking from entering a storm drain or watercourse. A first type of tracking control is to provide stabilized construction approaches. A stabilized construction approach is a constriction site ingress/egress point that is stabilized to reduce the tracking of mud and dirt onto public roads by construction vehicles. This type of construction approach is utilized at sites where dirt or mud can be tracked onto public roads; where the site is adjacent to water bodies; where poor soils are encountered; and where dust is a problem during dry weather conditions. 
         [0005]    Tracking control measures include a variety of standards and specifications, including but not limited to limiting points of ingress/egress; limiting vehicle speeds; properly grading each ingress/egress to prevent runoff onto paved roads; routing runoff through sediment traps; and designing stabilized ingress/egress points to support the heaviest equipment that will use it. A common specification requires a gravel pad at ingress/egress points. A filter fabric under liner often is required to line the bottom of the pad. In one location, a gravel pad specification calls for 1 inch rough diameter, clean, well graded gravel and crushed rock, commonly known as Class 150 Riprap Bedding. Another location requires coarser aggregate, such as two to three inch stone. Another system requires four to six inch rock. In different locations, specifications are known to require gravel pads to be twelve to twenty feet wide, six to eight inches deep, and fifty to seventy feet long and sometimes longer, yet. Standards further require continued re-screening, washing, or application of additional rock to maintain effectiveness. In practice, heavy construction trucks and equipment almost inevitably will press the gravel into the underlying mud, requiring that the gravel pad be reestablished by application of fresh bedding rock. Reestablishing the gravel pad may be required any number of times, according to need. 
         [0006]    In addition to requiring stabilized entrances and exits with gravel pads, tracking control measures further include street sweeping to prevent sediment from leaving the site; dust control during working hours; and cleaning trackout from paved surfaces each day or each shift. Other specifications are known to require that all materials spilled, dropped, washed, or tracked from vehicles onto roadways or into storm drains must be removed immediately. In practice, the method of removal may require special street cleaning equipment or manual labor. Some methods of cleaning a highway, such as the use of water trucks to remove materials dropped, washed, or tracked onto roadways are prohibited under any circumstances. 
         [0007]    Where gravel pads are not adequate to control trackout, regulations may require resort to a second type of tracking control: installation of wheel shakers, which are steel plates with ribs or corrugations extending across the entrance/exit. Typically wheel shakers are installed in the stabilized construction approach at the full width of the gravel pad over a substantial length, such as twenty-four feet. Of course, these wheel shakers must be manufactured and installed to support all expected loads. The addition of wheel shakers to a gravel pad adds both the basic cost of the additional features and the associated costs of operation, inspection, maintenance and repair. 
         [0008]    Where tracking pads and wheel shakers are inadequate to control trackout, regulations may require resort to a third type of tracking control: wheel washers. The contractor may have to install a wash rack or wash station where the wheels and undercarriages of exiting vehicles are washed. Wheel wash stations can be located at stabilized construction egress points to remove sediment from tires and under-carriages, and to prevent dirt, mud, and other sediment from being transported onto public highways. The wheel wash station should be installed on level ground, on a grid or pad of coarse aggregate, with a drainage ditch leading to an approved settling area or sediment trapping device. Where a wash rack is built, it often must be constructed of reinforced concrete with transverse concrete ribs for permitting drainage. A drainage underpass is required where water might pool on one side of the wash rack structure. The wash rack, like all other portions of a construction approach, must be built to withstand anticipated traffic loads. The wash rack, ditch, and sediment trapping device require frequent inspection, sediment removal, and repair to maintain system performance. A maintenance specification may simply provide that the entrance must be maintained in a condition that will prevent tracking or flow of mud onto public rights-of-way. 
         [0009]    In addition, tire wash stations require a supply of wash water. Where available, the contractor might obtain water from existing water service connections or fire hydrants. Where local water supply is not available, the contractor may have to bring in temporary water storage tanks. When a wash rack is installed, a turnout or doublewide exit is needed to avoid having entering vehicles drive through the wash area. 
         [0010]    The variety of standards and specifications that have been described, above, are examples taken from known regulations but are not exhaustive of all such requirements. These regulations indicate the seriousness of the trackout problem. Contractors are in need of improved technology that prevents or adequately controls trackout from construction sites. When a tracking pad can adequately control trackout, then the contractor may avoid having to install additional tracking control devices such as wheel shakers and tire washers. Similarly, the contractor may avoid having to construct and maintain ditches and sediment trapping devices. However, regardless of which types of tracking control are needed, it would be desirable for the contractor to have a stabilized construction entrance that is both durable and effective to remove mud from equipment tires. Similarly, it would be desirable for the contractor to be able to recover at least some of the costs of building and maintaining a stabilized construction entrance/exit. 
         [0011]    Mats are known for their ability to serve as load supporting, good traction surfaces. Interlocking mat systems are used to form temporary roadways and to provide large area coverage with improved traction over soft and uneven ground. U.S. Pat. No. 5,807,021 to Aaron shows a ground cover mat with a high traction surface on both faces, to interact with both the underlying ground and with vehicles traveling over the mat. U.S. Pat. No. 6,695,527 shows an interlocking mat system for construction of load supporting surfaces providing good traction. These surfaces can be used as temporary roadways and equipment support surfaces. A company known as Newpark Resources, Inc., currently on the Internet at www.NewparkMats.com, provides a mat system that can cover a wide area and provide a supporting work surface. A company known as Pathway Mats, Inc., currently on the Internet at www.pathwaymats.com, provides a mat system that forms a portable platform, walkway or roadway for outdoor and indoor events and construction sites. While these known mats and mat systems are designed to provide a stable surface with good traction, they do not address the problem of controlling trackout from construction sites. Therefore, a mat system that controls trackout is desirable, but it is not yet known. 
         [0012]    To achieve the foregoing and other objects and in accordance with the purpose of the present invention, as embodied and broadly described herein, the method and apparatus of this invention may comprise the following. 
       BRIEF SUMMARY OF THE INVENTION 
       [0013]    Against the described background, it is therefore a general object of the invention to provide a mat suited to control trackout from off-road sites onto paved roads. 
         [0014]    According to the invention, a vehicle tracking pad controls trackout of mud from vehicle tires onto roadways from off-road sites. The tracking pad is formed of a mat body configured in a regular geometric shape of predetermined length, having top and bottom major faces, defining first and second opposite longitudinal end edges suited for mating with like mat bodies when arranged in series therewith to establish an egress path of greater length than the predetermined length, and formed of flexible material accommodating irregular ground surface. A finish on the top surface of the mat body defines a plurality of spaced apart, upstanding structures for removing mud from vehicle tires rolling over the upstanding structures. At least some of the upstanding structures have a height in the range from four to six inches. 
         [0015]    The upstanding structures are selected from the group consisting of cylinders, pyramids, rock shapes, ribs, and combinations thereof. The upstanding structures are of predetermined thickness in the longitudinal direction of the mat and are longitudinally spaced apart by at least the dimension of the predetermined thickness of the upstanding structures. 
         [0016]    The first and second opposite longitudinal end edges of the mat define a mechanical interlock. The mechanical interlock on the first end edge is an extending upper panel and the mechanical interlock on said second end edge is an extending lower panel. The upper panel and lower panel each are of a thickness less than one-half the thickness of the mat. The upper and lower panels are overlapped to establish the mechanical interlock. A bolt or other securing device is inserted through the upper and lower panels to secure the interlock. 
         [0017]    According to a further aspect of the invention, a vehicle tracking pad is formed of first and second mat bodies. Each mat body is configured in a regular geometric shape of predetermined length, having top and bottom major faces defining first and second opposite longitudinal end edges carrying interlock elements for interlocking a first end of the first mat body with a second end of said second mat body when said first and second mat bodies are arranged in series, establishing an egress path of greater length than the predetermined length. The mats are formed of flexible material accommodating irregular ground surface. A finish on the top surface of each mat body defines a plurality of spaced apart, upstanding structures for removing mud from vehicle tires rolling over the upstanding structures. At least some of the upstanding structures have a height in the range from four to six inches. 
         [0018]    The interlock elements define an overlap panel extending from a first end edge of each mat body and an underlap panel extending from a second, opposite end edge of each mat body. The overlap panels carry a portion of the finish on the top surface thereof for extending the finish between first and second mat bodies when interlocked with an overlap panel of one mat body overlapping the underlap panel of the other mat body. 
         [0019]    Joined mats may form an egress path with a turnout. A turnout mat is arranged at a side edge of the first mat establishing the egress path. A mechanical interlock operates between the turnout mat and the first mat to maintain the turnout mat at the egress path. 
         [0020]    The accompanying drawings, which are incorporated in and form a part of the specification, illustrate preferred embodiments of the present invention, and together with the description, serve to explain the principles of the invention. In the drawings: 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0021]      FIG. 1  is a top plan view of a typical layout of tracking mats assembled to form a tracking pad. 
           [0022]      FIG. 2  is a top plan view of a vehicle tracking mat according to a first embodiment of the present invention employing cylinders as mud removing elements, and showing optional lateral edge panels in phantom. 
           [0023]      FIG. 3  is a cross-sectional view taken at the plane of line  3 - 3  in  FIG. 2  and showing bolts in assembly positions. 
           [0024]      FIG. 4  is a fragmentary isometric view of the first embodiment, showing the pattern of surface structures. 
           [0025]      FIG. 5  is a top plan view of a vehicle tracking mat according to a second embodiment of the present invention employing pyramids in a square configuration as mud removing elements. 
           [0026]      FIG. 6  is a cross-sectional view taken at the plane of line  6 - 6  in  FIG. 5 , and showing bolts in assembly positions. 
           [0027]      FIG. 7  is a fragmentary isometric view of the second embodiment, showing the pattern of surface structures. 
           [0028]      FIG. 8  is a top plan view of a vehicle tracking mat according to a third embodiment of the present invention employing pyramids in a staggered configuration as mud removing elements. 
           [0029]      FIG. 9  is a cross-sectional view taken at the plane of line  9 - 9  in  FIG. 8  and showing bolts in assembly positions. 
           [0030]      FIG. 10  is a fragmentary isometric view of the third embodiment, showing the pattern of surface structures. 
           [0031]      FIG. 11  is a top plan view of a vehicle tracking mat according to a fourth embodiment of the present invention employing a simulated aggregate configuration as mud removing elements. 
           [0032]      FIG. 12  is a cross-sectional view taken at the plane of line  12 - 12  in  FIG. 11 , and showing bolts in assembly positions. 
           [0033]      FIG. 13  is a fragmentary isometric view of the fourth embodiment, showing the pattern of surface structures. 
           [0034]      FIG. 14  is a top plan view of a vehicle tracking mat according to a fifth embodiment of the present invention employing a configuration of transverse ribs and grooves as mud removing elements. 
           [0035]      FIG. 15  is a cross-sectional view taken at the plane of line  15 - 15  in  FIG. 14 , and showing bolts in assembly positions. 
           [0036]      FIG. 16  is a fragmentary isometric view of the fifth embodiment, showing the pattern of surface structures. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0037]    The invention is a mat  10  that serves as a component of a vehicle tracking pad assemblage. The mat  10  is able to serve as a sole pad and, in addition, is configured to define a component of a multi-unit assemblage of similar mats, together establishing a temporary, stabilized construction approach. Each mat is formed of a flexible material so that the mats are capable of following the contours of the underlying support, which may be bare ground. Thus, suitable materials for forming a mat  10  include rubber, elastomer, plastic, and reinforced varieties of rubber, elastomer, and plastic. 
         [0038]    In the drawings, the same numbers will be applied to the same or substantially similar elements in all embodiments. 
         [0039]    With reference to  FIGS. 2 ,  5 ,  8 ,  11 , and  14  of the drawings, a single vehicle tracking mat  10  is configured in a regular geometric shape such as a rectangle. In this context, a regular shape refers to a shape that fits together with other mats of similar shape to form a continuous surface. In addition to being of a regular shape, the mat  10  is scaled to conveniently combine with other similar mats  10  to define a construction approach  12 , shown in  FIG. 1 . Thus, the width of a mat  10  may be approximately the width of a single lane construction approach  12  for ingress/egress. A mat width of seven to eight feet is suitable. The length of a mat  10  may be the greatest length that can be conveniently handled for installation. A mat length of twelve to fifteen feet is suitable. 
         [0040]    Mats having the suggested dimensions can be combined both in length and in width. For example, a construction approach that is required to be twenty feet wide is easily established and slightly exceeded by three mats, each seven to eight feet wide, in side-by-side array. The mats can be assembled lengthwise to substantially any required length. Thus, a construction entrance that must be at least seventy feet long can be established and slightly exceeded by a series of six mats, each twelve feet long, assembled lengthwise. 
         [0041]    Where a turnout  14  is required at a junction with a roadway, mats  10  can be laid, either transversely or longitudinally, at each side of the central path established by the mats. Where  FIG. 1  shows a turnout  14  that is approximately six feet by six feet on each side of the central path, turnout mats  16  can be supplied, or the regular mats  10  can be cut as required to create these turnout mats  16  of slightly smaller configuration than the regular mats  10 . Turnout mats  16  may carry elements of a mechanical interlock system at least at one end, for attachment to the main pathway of a construction approach  12 . The mats  10  forming the main pathway of the construction approach  12  may carry mating elements of a mechanical interlock system on their side edges for mating with the turnout mats  16 . 
         [0042]    With reference to  FIGS. 2-16 , mat  10  is configured to clean mud from equipment tires passing over the mat. Each mat is formed of a main body  18  of predetermined thickness that may be termed “full thickness.” The main body carries a working surface with a top side finish configured with mud removal structures for direct contact with equipment tires. The mud removal structures are characterized by a height and spacing that causes mud to be removed from vehicle tires rolling over the mud removal structures. 
         [0043]    The main body  18  of mat  10  includes at least two opposite end edge panels, which typically will be the end edges at the longitudinal ends of a mat  10 . The end edges carry means for mechanically interlocking two similar mats  10  arranged end-to-end. The longitudinal side edges of a mat  10  also may carry elements of a mechanical interlock system, as mentioned in reference to the use of turnout mats  16 . The mechanical interlock can be an overlap and underlap system. 
         [0044]    In an overlap and underlap system, one of the end edge panels  22 , which can be called the underlap panel, extends beyond the main body  18  and working surface by a predetermined distance, such as one foot. The opposite end edge panel  24 , which can be called the overlap panel, is topped by a portion of the working surface and extends from the main body  18  by a similar distance, such as one foot. The underlap end edge panel  22  is a low or bottom panel, and the overlap panel, which is the second and opposite end edge panel  24 , is a high or top panel. The terms “low” and “high” refer to relative height positioning of the two panels  22 ,  24  with respect to the full thickness of the main body  18 . The low panel  22  may have about one-half the thickness or less of the full thickness of main body  18  and may extend from the bottom half of an edge of the main body  18 . The high panel  24  may have about one-half the thickness or less of the full thickness of main body  18  and may extend from the top half of the opposite edge of the main body  18 . In the described positions, the underlap and overlap system functions when the low panel of one mat  10  and the high end panel of another such mat  10  are overlapped when the two mats  10  meet and are suitably placed end-to-end. 
         [0045]    As an example, the full thickness of the main body  18  may be four and one-quarter inches, while each of the panels  22 ,  24  may have a thickness of two inches. This example does not include the thickness of the contoured working surface, where it is carried on the top panel. Each panel  22 ,  24  in this example is less than one-half the full thickness of the main body  18 , establishing a clearance of one-quarter inch when panels  22 ,  24  of two juxtaposed mats  10  are overlapped. This clearance is useful to ensure that an overlapping top panel  24  remains at no greater height than the top of the overlapped panel  22  of the juxtaposed mats  10 . Thus, the top panel is less exposed to the tires of passing vehicles and is less prone to damage. The clearance also accommodates residual mud between the overlapped panels. 
         [0046]    The overlapping panels  22 ,  24  form an interlock that is helpful for establishing an assemblage, as contrasted to an array of mats merely placed in spatial proximity to one another. Another element of the interlock is a mechanical through-fastener that secures the overlapped panels in fixed relative positions. A fastener can be a bolt  26  passing through both panels. The top panel  24  and bottom panel  22  may define a plurality of bolt holes  28  positioned to be in alignment when panels of linearly arranged mats  10  overlap. The bolt holes in the bottom panels  22  may include built-in nuts or the like to engage with bolts  26  inserted through top panels  24 . 
         [0047]    The interlockable edge panels are primarily desirable on the longitudinal ends of a mat  10 , with the mat arranged for vehicle traffic to follow the longitudinal dimension of the mat. With reference to  FIG. 2 , an optional, similar arrangement may provide a high panel  30  and low panel  32  formed at the opposite lateral edges of a mat  10 . Lateral high and low panels  30 ,  32  are useful for interlocking parallel rows of longitudinally aligned mats  10  or for forming a wide row of laterally aligned panels  10 . The top panel  30  may carry a portion of the contoured working surface, while the bottom panel  32  typically would not. The lateral panels  30 ,  32  are optional additions to any embodiment of the invention, regardless of surface finish. 
         [0048]    The working surface is contoured with a configuration of structures serving as a means for removing mud from tires of passing trucks and other equipment. With reference to  FIGS. 2-16 , the working surface is a top finish formed of an array of upstanding mud removing elements. In a first embodiment of the top finish illustrated in  FIGS. 2-4 , the mud removing elements are upstanding cylinders  34 . As best shown in  FIGS. 3 and 4 , the mud removing elements may be of varying heights. For example and not as a limitation, the mud removing elements may be varied in four heights, with an incremental increase from the shortest to the tallest. In particular,  FIG. 3  shows a longitudinal row of mud removing elements with heights varying in relative dimensions rated from 1-4. The illustrated sequence is 4-1-3-2-4-2-3-1, which then repeats over the length of the row. This illustrated sequence can be termed a random sequence with the tallest elements separated by one or more shorter elements. Neighboring rows can be longitudinally shifted or otherwise varied from the illustrated sequence. 
         [0049]      FIG. 4  shows shifted row patterns such that transverse rows show random height variations. The transverse row variations may be similar to those of the longitudinal rows. Some of the illustrated transverse rows show sequences such as 4-1-4-, 2-4-2-, 3-1-3-, 1-3-1-, and 4-2-4-. Where the mud removing elements are cylinders  34 , the cylinders can be separated from one another both longitudinally and laterally. The distance of separation is greater than the diameter of each cylinder. The typical heights of each cylinder may be in the range from two to six inches with diameters of three to six inches, measured from the top face of the mat body  18 . 
         [0050]    Where the mud removing elements are configured as discrete members suitable for arrangement into longitudinal and transverse rows, various row arrangements are suitable. The longitudinal and transverse rows can be perpendicular to one another, as suggested by the arrangement of cylinders in  FIG. 2 . An optional arrangement shown in  FIG. 8  employs staggered neighboring rows such that a mud removing element in a second row is offset from transverse alignment with such elements in a first row. Rows may extend diagonally or at other non-square angles to the shape of a mat  10 . The staggered arrangement may be symmetrical, with the elements of one row near the middle of the distance between juxtaposed elements of the neighboring row, as shown in  FIG. 8 . A staggered arrangement also may be nonsymmetrical. The mud removing elements also can be arranged in arbitrary patterns, such as where the elements simulate stones or aggregate. 
         [0051]    In a second illustrated embodiment of the top finish shown in  FIGS. 5-7 , the mud removing elements are pyramid shaped structures  36  in a square pattern of transverse and longitudinal rows and columns. The heights of the pyramids are selected for effectiveness in removing mud from vehicle tires. Heights in the approximate range from four to six inches are suitable. All pyramids may be of the same height, such as six inches, or the heights of successive pyramids in a row or series may be varied, as suggested by the disclosed sequences of heights for cylinders  34 . 
         [0052]    In a third illustrated embodiment of the top finish shown in  FIGS. 8-10 , the mud removing elements are pyramid shaped structures  36  in a staggered pattern. While the drawings illustrate a regular or symmetrical staggered pattern, an alternative arrangement might be nonsymmetrical or irregular. 
         [0053]    In a fourth illustrated embodiment of the top finish, the mud removing elements are simulated rock or aggregate shaped structures  38  as shown in  FIGS. 11-13 . An aggregate pattern can be irregular and nonsymmetrical, as would be the case with real aggregate; although as a practical matter, a molded aggregate pattern would be expected to repeat certain portions of the pattern. An arrangement that is regular and symmetrical is acceptable. The height of the aggregate finish is arranged for effectiveness in removing mud from vehicle tires. Suitable heights for the simulated aggregate elements are in the approximate range of from four to six inches. As described for the cylinder finish, the heights of the aggregate elements may range over other heights, as well. The feature of arranging the mud removing elements in square or staggered pattern can be employed not only for pyramid shaped structures  36  but also for cylinders  34  and aggregate  38 . 
         [0054]    In a fifth illustrated embodiment of the top finish, the mud removing elements are transverse ribs  40  and grooves  42  as shown in  FIGS. 14-16 . The ribs may taper upwardly to an apex. A spacing between juxtaposed ribs  40  establishes each groove  42 . The spacing may be approximately one-half the thickness of a rib. The height of the ribs is selected for effectiveness as mud removing elements, with a suitable height being in the approximate range from four to six inches. 
         [0055]    Regardless of pattern, the mud removing elements of each type are spaced apart and present height variations sufficient that the elements act against tires rolling over the mat  10  to cause mud to be removed from the tires. One of the chief mechanisms from removing mud from tires is to deform the tires as they pass over the mud removing elements. Where the mud removing elements are of different heights, the variation should be frequent enough to locally deform a tire. The height variations shown in  FIG. 3  provide guidance, showing approximately two mud removing elements and two gaps per foot. If the two mud removing elements are unequal in height, a taller element and a shorter element are arranged in spaced, longitudinal series. Each element of  FIG. 3  is spaced apart from the next in longitudinal series by a gap distance similar to the thickness of a mud removing element. 
         [0056]    Similarly, where the pyramids of  FIGS. 6 and 9  are of uniform height, the distance between pyramids in series is a significant factor for deforming tires. The distance between the apexes of pyramids in series is similar to or greater than the thickness of a pyramid element. Viewed in longitudinal series, approximately two pyramids and two gaps define each foot. The staggering between two longitudinal rows influences the lateral deformation induced in a tire. 
         [0057]    Mud removing elements with a configuration simulating aggregate function similarly to cylinders and pyramids. The randomness of an aggregate pattern presents a varied series of high and low mud removing elements, coupled with varied lateral heights. 
         [0058]    Ribs and grooves can be sized and spaced similarly to pyramids. The uniformity of a rib that extends transversely across a mat induces an additional shaking effect. 
         [0059]    It is possible for a mat to carry more than one type of finish. Thus, cylinders, pyramids, irregular rock shapes, and ribs can be integrated into the finish of a single mat. 
         [0060]    The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be regarded as falling within the scope of the invention as defined by the claims that follow.