Connector assembly for modular ground covering panels

A system for constructing a load bearing surface includes a plurality of modular ground covering panels. Along at least one first side edge of each of the panels, the lower surface projects beyond the upper surface to define a lower peripheral tab. Along at least one second side edge of each of the panels, the upper surface projects beyond the lower surface to define an upper peripheral tab. The lower peripheral tab of one of the panels and the upper peripheral tab of another one of the panels overlappingly engage so that the upper surfaces of the panels are in adjoining relation to form the load bearing surface. A connector assembly includes a first connection element fixed to the lower peripheral tab, and a second connection element that releasably fastens the upper peripheral tab to the first connection element to secure the panels together.

FIELD

The present disclosure relates generally to modular ground covering panels that are constructed to form a load bearing surface.

BACKGROUND

U.S. Pat. No. 6,511,257 describes a reusable mat system for the construction of load bearing surfaces, such as temporary roadways and equipment support surfaces, over unstable or unsubstantial terrain, comprising durable, interlocking individual mats which can be quickly and easily installed in a single application, and which can thereafter be easily removed and stored until needed again. The individual mats interlock on all sides to form stable and continuous load bearing surfaces, and exhibit favorable traction characteristics.

U.S. Pat. No. 6,652,183 describes a road mat that includes a body having a first end, a second end, a first face and a second face. A first coupling is positioned at the first end has an outwardly extending portion extending outwardly from the first end adjacent to the second face, an angled portion extending from a remote end of the outwardly extending portion toward but not past the first face, and an inwardly extending retaining lip extending from a remote end of the angled portion back toward the first end. A second coupling is positioned at the second end is similarly configured with an outwardly extending portion extending outwardly from the second end adjacent to the first face, an angled portion and an inwardly extending retaining lip. The retaining lip of the second coupling engages the retaining lip of the first coupling preventing separation.

U.S. Pat. No. 7,413,374 describes a portable overlapping secured mat system with uniformly sized plastic mats joined together to form structural support surface for use by persons or equipment. The mats' edges have recessed upper and lower lips with finger projections extending from the upper lips sized to fit into holes of adjacent mats' lower lips securing the mats together when the front edge of the finger projections are moved into a recesses of the back wall of the hole.

INTRODUCTION

The following is intended to introduce the reader to the more detailed description that follows and not to define or limit the claimed subject matter.

According to an aspect of the present disclosure, a system for constructing a load bearing surface may include: at least first and second modular ground covering panels, each of the panels including upper and lower surfaces, wherein along at least one first side edge of each of the panels the lower surface projects beyond the upper surface to define a lower peripheral tab, wherein along at least one second side edge of each of the panels the upper surface projects beyond the lower surface to define an upper peripheral tab, and wherein the lower peripheral tab of one of the panels and the upper peripheral tab of another one of the panels are adapted to overlappingly engage so that the upper surfaces of the panels are in adjoining relation to form the load bearing surface; and at least one connector assembly including a first connection element fixed to the lower peripheral tab, and a second connection element that releasably fastens the upper peripheral tab to the first connection element to secure the panels together.

The second connection element may be fastened to and unfastened from the first connection element generally from above the upper surfaces of the panels. The upper peripheral tab may include at least one aperture, and the second connection element may include a bolt that extends through the aperture. A head of the bolt may be accessible from above the upper surfaces of the panels. The first connection element may include a nut configured to receive the bolt, and the nut may be retained in position relative to the lower peripheral tab so that rotation of the nut about a bolt axis is not permitted. The lower peripheral tab may include a first flange surface, and the upper peripheral tab may include a second flange surface, and tightening the bolt relative to the nut may cause the flange surfaces to bear against one another in opposed relation. The flange surfaces may be generally parallel to a plane defined by the upper surfaces of the panels.

The connector assembly may include at least one brace plate for distributing forces to at least one of the peripheral tabs. The second connection element may include a first brace plate arranged between the head of the nut and the upper peripheral tab. The upper peripheral tab may include a recess generally surrounding the aperture, and the first brace plate may be received within the recess. The first connection element may include a second brace plate that is mounted to the lower peripheral tab. The lower peripheral tab may include a recess generally surrounding the first connection element, and the second brace plate may be received within the recess. The first connection element may include a third brace plate that is mounted to the first flange surface. The first flange surface may include a recess generally surrounding the first connection element, and the third brace plate may be received within the recess. Tightening the bolt relative to the nut may draw the second and third base plates towards the first base plate, thereby securing the peripheral tabs together.

The first connection element may include a body housing the nut in secure arrangement. An interior of the body may be complementary in shape to an exterior of the nut. The nut may be removable from the body. The first connection element may include a clip adapted to retain the nut in the body. A plurality of the connector assemblies may be spaced apart along the adjoined side edges of the panels.

According to an aspect of the present disclosure: a first panel includes upper and lower surfaces and side edges, and along at least one first side edge the lower surface projects beyond the upper surface to define a lower peripheral tab; a second panel includes upper and lower surfaces and side edges, along at least one second side edge the upper surface projects beyond the lower surface to define an upper peripheral tab, the upper peripheral tab including an aperture, and the upper peripheral tab is adapted to overlappingly engage the lower peripheral tab of the first panel so that the upper surfaces of the first and second panels are in adjoining relation to form a load bearing surface; and a connector assembly including a nut retained in position relative to the lower peripheral tab so that rotation of the nut about a bolt axis is not permitted, and a bolt that extends through the aperture of the upper peripheral tab, the nut being adapted to receive the bolt to releasably fasten the upper peripheral tab of the second panel to the lower peripheral tab of the first panel to secure the panels together.

According to an aspect of the present disclosure: a first panel includes upper and lower surfaces and side edges, and along at least one first side edge the lower surface projects beyond the upper surface to define a lower peripheral tab; a second panel includes upper and lower surfaces and side edges, along at least one second side edge the upper surface projects beyond the lower surface to define an upper peripheral tab, the upper peripheral tab adapted to overlappingly engage the lower peripheral tab of the first panel so that the upper surfaces of the first and second panels are in adjoining relation to form a load bearing surface, and the upper peripheral tab includes an aperture; and a connector assembly including a first connection element fixed to the lower peripheral tab, and a second connection element that releasably fastens the upper peripheral tab to the first connection element to secure the panels together, the connector assembly including at least one brace plate for distributing forces to at least one of the peripheral tabs.

Other aspects and features of the teachings disclosed herein will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific examples of the present disclosure.

DETAILED DESCRIPTION

Various apparatuses or methods are described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses and methods that differ from those described below. The claimed inventions are not limited to apparatuses and methods having all of the features of any one apparatus or method described below or to features common to multiple or all of the apparatuses or methods described below. It is possible that an apparatus or method described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or method described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicant(s), inventor(s) and/or owner(s) do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.

In general, the concepts described herein pertain to a load bearing surface formed by a plurality of modular ground covering panels having upper surfaces arranged in adjoining relation. Each of the panels may include at least one peripheral tab that overlapping engages a peripheral tab of at least one adjacent panel. A plurality of connector assemblies secures the panels together. Each of the connector assemblies includes a first connection element that is fixed to a peripheral tab of one of the panels, and a second connection element that releasably fastens the corresponding peripheral tab of the adjacent panel to the first connection element.

Referring toFIGS. 1 and 2, an example of a modular ground covering panel is shown generally at reference numeral10. The panel10includes an upper surface12, and a lower surface14arranged spaced apart from the upper surface12and generally parallel thereto.

The panel10may be formed of plastic material, for example but not limited to, low-density polyethylene (LDPE). The panel10may be hollow, and may be manufactured using a rotational molding process. Optionally, the upper surface12may include traction features, such as a repeating diamond plate pattern or the like. The panel10may be configured according to various sizes and shapes, and the present teachings should not be limited to the particular configuration illustrated in the drawings. In some examples, the panel10may be produced to have dimensions of about 85″×180″×6″.

In the example illustrated, the panel10includes first, second, third and fourth side edges16,18,20,22. The first side edge16extends between bevel corners40,42; the third side edge20extends between bevel corners42,44. The first and second side edges16,18extend generally in parallel in a longitudinal direction between the third and fourth side edges20,22. The third and fourth side edges20,22extend generally in parallel in a lateral direction between the first and second side edges16,18.

In the example illustrated, along the first side edge16, the lower surface14projects beyond the upper surface12to define a lower peripheral tab24(FIG. 1). The lower peripheral tab24presents an elongate flange surface26generally along a longitudinal extent of the panel10between the third and fourth side edges20,22. Furthermore, along the third side edge20, the lower surface14projects beyond the upper surface12to define a lower peripheral tab28(FIG. 1). The lower peripheral tab28presents an elongate flange surface30generally along a lateral extent of the panel10between the first and second side edges16,18. The flange surfaces26,30may be generally parallel to a plane defined by the upper surface12.

Conversely, along the second side edge18, the upper surface12projects beyond the lower surface14to define an upper peripheral tab32(FIG. 2). The upper peripheral tab32presents an elongate flange surface34generally along a longitudinal extent of the panel10between the third and fourth side edges20,22. Moreover, along the fourth side edge22, the upper surface12projects beyond the lower surface14to define an upper peripheral tab36(FIG. 2). The upper peripheral tab36presents an elongate flange surface38generally along a lateral extent of the panel10between the first and second side edges16,18. The flange surfaces34,38may also be generally parallel to a plane defined by the upper surface12.

Given two of the panels10arranged next to one another in a side-by-side relationship, the tabs24,32are sized and shaped for overlapping engagement, with the flange surfaces26,34in opposed relation. Similarly, given two of the panels10arranged next to one another in an end-to-end relationship, the tabs28,36are sized and shaped for overlapping engagement, with the flange surfaces30,38in opposed relation. Other arrangements for the panel10may be possible.

In the example illustrated, the panel10includes a plurality of first connection elements50spaced apart along the tabs24,28. The panel10also includes a plurality of apertures52spaced apart along the tabs32,36, extending between the upper surface12and the flange surfaces34,38. The apertures52may be positioned in corresponding registration with the first connection elements50of an adjacent panel10, with either the flange surfaces26,34or the flange surfaces30,38being in opposed relation.

Optionally, as illustrated, the panel10may include protrusion elements46spaced apart along the tabs24,28. Complementary recess elements48are spaced apart along the tabs32,36, and receive the protrusion elements46to provide a means for quick positioning of panels10to be joined together, prior to being secured. A greater number of the recess elements48may be provided so as to allow options for a staggered arrangement of the panels10.

Referring now toFIG. 3, a system is shown consisting of four of the panels10, denoted by reference numerals10a,10b,10cand10d. The panel10ais arranged next to the panel10bin a side-by-side relationship, whereas the panel10ais arranged next to the panel10cin an end-to-end relationship, etc. A plurality of connector assemblies54secure the panels10a,10b,10c,10dtogether in adjoining relation, so that the upper surfaces of the10a,10b,10c,10dform a load bearing surface56. As illustrated, the connector assemblies54may be spaced apart along the side edges of the panels10a,10b,10c,10dat regular intervals.

Referring toFIG. 4, the connector assembly54may include the first connection element50, and a second connection element58. In the example illustrated, the second connection element58includes a bolt60having a head62, and the bolt60extends through a brace plate64. The first connection element50includes brace plates66,68, a body70arranged between the brace plates66,68, a nut72retained by the body70, and a clip74. The bolt60and the nut72include complementary threads that facilitate the second connection element58being releasably fastened to the first connection element50. The threads of the bolt60have an axial dimension84parallel to a bolt axis80, and the threads of the nut72have a height dimension86parallel to the bolt axis80. In the example illustrated, the axial dimension84is approximately three times larger than the height dimension86.

Referring now toFIG. 5, the second connection element58is shown received in the tab36ain the aperture52that extends between the upper surface12aand the flange surface38a. The brace plate64is shown mounted to a recess in the upper surface12aof the panel10aso that it is generally flush with the upper surface12a.

The first connection element50is shown received in the tab28cin an aperture82that extends between the lower surface14cand the flange surface30c. The brace plate66is shown mounted to a recess in the lower surface14cof the panel10cso that it is generally flush with the lower surface14c, and the brace plate68is shown mounted to a recess in the flange surface30cof the tab28cso that it is generally flush with the flange surface30c. Spacing between the brace plates66,68may be selected so that the tab28cis compressed therebetween. The brace plates64,66,68distribute forces between the connector assembly54and the tabs36a,28c. Accordingly, the first connection element50may be rigidly fixed to the tab28c, so that rotation of the first connection element50(including the nut72), e.g., about the bolt axis80, is generally not permitted.

In the example illustrated, the body70houses the nut72in secure arrangement, with an interior of the body70being complementary in shape to an exterior of the nut72(e.g., the nut72may have a square profile). The clip74may be secured to the interior of the body70(e.g., by interference fit) and retains the nut72in the body70. If the nut72becomes stripped or otherwise damaged, it may be removed from the body70by first releasing the clip74, and replaced with another one.

In use, tightening the bolt60relative to the nut72about the bolt axis80causes the brace plates66,68to be drawn toward the brace plate64. Accordingly, the flange surfaces38a,30cbear against one another, securing the panels10a,10ctogether. The bolt axis80may be generally orthogonal to a plane defined by the upper surfaces12a,12c, and the flange surfaces30c,38a,which may promote the flange surfaces38a,30cbearing against one another in a generally uniform manner about the connector assembly54.

Because the nut72is fixed in position, fastening the bolt60to the nut72is simplified because manipulation of the nut72is not required. Also, because the head62of the bolt60is accessible from above the upper surfaces12a,12c, the second connection element58may be installed relatively quickly, through the aperture52, and fastened to the first connection element50while the panels10a,10clie in adjoining position.

Referring again toFIG. 2, the panel10includes a plurality of cavities76, which as illustrated may be spaced apart across the lower surface14in a repeating pattern or array. The cavities76depend inwardly from the lower surface14. In the example illustrated, the cavities76are formed by sidewalls78(FIG. 5) that extend generally between the upper and lower surfaces12,14. The cavities76serve to reinforce the panel10by forming a generally rigid structure between the upper and lower surfaces12,14. Although the cavities76are shown to have a hexagonally shaped profile, other geometric shapes and configurations are possible.

While the above description provides examples of one or more apparatuses or methods, it will be appreciated that other apparatuses or methods may be within the scope of the accompanying claims.