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[0001]    This application claims the benefit of and priority to U.S. Provisional Patent application Serial No. 60/371,118 filed Apr. 10, 2002, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to flooring for cattle operations and in particular relates to soft flooring provided for cattle operations.  
         BACKGROUND OF THE INVENTION  
         [0003]    Presently, in cattle and dairy operations, concrete flooring is often used. Anyone who has stood for even a few minutes on a concrete floor knows about aching feet and numb legs. Cows often spend 10 hours a day standing and walking on concrete. Many farmers feel that a major reason for culling is lameness associated with walking on hard floors. Experts in the field have indicated that flooring for cattle should provide comfort and confident footing for cows and unfortunately, concrete is not the most comfortable flooring for cows to be walking on.  
           [0004]    In this regard, some dairy operations have used rubber belting and others have tried various forms of rubber mats, both of which having there own problems associated with installation and maintenance of these flooring systems. Farmers are looking for ways to improve flooring conditions for their cows. Anecdotal evidence has shown that cows prefer walking on materials which are closer to pasture like conditions and some evidence suggest that cows give more milk when their walking conditions and standing conditions have been adjusted to be as close as possible to pasture like conditions.  
           [0005]    Therefore, there is a need for flooring systems in cattle and dairy operations which most closely simulates pasture like conditions and provides cattle with dry comfortable and sure footing.  
         SUMMARY OF THE INVENTION  
         [0006]    The present invention a cattle flooring apparatus comprises:  
           [0007]    (a) interlocking mats including mat sections, inter connected with interlocking webs defined at mat edges.  
           [0008]    (b) a means for connecting adjacent mat sections and maintaining said mat edges flush and flat in a horizontal plane.  
           [0009]    Preferably further comprising a means for anchoring said interlocking mats to a concrete slat floor having slat openings.  
           [0010]    Preferably wherein said anchoring means includes a slat anchor including a dome member for securing said mat together with said slat anchor to a slatted floor by urging said dome member of said slat anchor through a mat opening and into a slat opening.  
           [0011]    Preferably wherein said slat anchor includes a lattice structure including at least one vertical member connecting a cap to said dome member, such that said vertical members substantially span said mat thickness and said cap covering over said mat opening and urging downwardly on a top surface of said mat.  
           [0012]    Preferably wherein said anchor further including a horizontal member connecting said vertical members with said dome member, wherein said horizontal member including shoulders on each side for engaging with a bottom surface of said mat.  
           [0013]    Preferably wherein said dome member including a wedge area for contacting with a slat opening contour.  
           [0014]    Preferably wherein said connecting means includes mat connectors forming a mat connection such that a connection is made across a mat edges by placing one mat connector adjacent a top surface of said mats and a second mat connector placed adjacent a bottom surface of said mats such that said top and upper and lower mat connectors are adapted to interlock though mat holes in said mats thereby connecting together adjacent mat sections and clamping onto said mats.  
           [0015]    Preferably wherein said mat connector further including a strap including a male connector proximate one end and a female connector proximate the other end, said male and female connectors adapted for cooperating with each other by interconnecting a male connector form above with a female connector from below and vice versa.  
           [0016]    Preferably wherein said male connector further including a cylindrical plug defining a rod aperture there through and said female end including a outer sheath and a central rod defining a plug aperture there between, said plug aperture for receiving said cylindrical plug and said rod aperture for receiving said central rod in concentric fashion.  
           [0017]    Preferably wherein said interlocking webs including mat tongues and corresponding interlocking mat grooves, wherein said tongues having a length L and a depth D, and said mat having a thickness of T and a first radius R1 defining a first shoulder and a second radius R2 defining a second shoulder.  
           [0018]    Preferably wherein the ratio of said first radius to said second radius being substantially 1:1.  
           [0019]    Preferably wherein the ratio of said first radius to said second radius being 1:≦1.5 or 1.5≧:1.  
           [0020]    Preferably wherein the ratio of T:L being substantially 1:3-5.  
           [0021]    Preferably wherein the ratio of D:L being substantially 1:1.5-2.5.  
           [0022]    Preferably wherein the ratio of T:D being substantially 1:1.5 to 2.5. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    The invention will now be described by way of example only, with references to the following drawings in which:  
         [0024]    [0024]FIG. 1 is a schematic top representation of two interconnected mat sections showing the present invention the cattle flooring method and apparatus.  
         [0025]    [0025]FIG. 2 is a schematic top plan view of a component of a mat connector.  
         [0026]    [0026]FIG. 3 is a schematic side elevational view of the strap.  
         [0027]    [0027]FIG. 4 is a schematic side elevational view of the assembled mat connector.  
         [0028]    [0028]FIG. 5 is a schematic bottom plan view of the mat connector.  
         [0029]    [0029]FIG. 6 is a schematic side elevational view of a fastener which is part of the mat connector.  
         [0030]    [0030]FIG. 7 is a schematic bottom plan view of the fastener which is used with the mat connector.  
         [0031]    [0031]FIG. 8 is a schematic top plan view of the fastener head which is part of the mat connector.  
         [0032]    [0032]FIG. 9 is a schematic side elevational view of the fastener which is part of the mat connector.  
         [0033]    [0033]FIG. 10 is a schematic side cross sectional schematic view of the mat connector shown diploid together with two mat sections, indicating how mat connector connects the two mat sections together.  
         [0034]    [0034]FIG. 11 is a schematic top plan view of a slat anchor.  
         [0035]    [0035]FIG. 12 is a schematic side elevational view of a slat anchor.  
         [0036]    [0036]FIG. 13 is a schematic side elevational view of a slat anchor.  
         [0037]    [0037]FIG. 14 is a schematic cross-sectional schematic view of the slat anchor diploid together with a mat in a slatted concrete floor.  
         [0038]    [0038]FIG. 15 is a schematic perspective view of the cattle flooring method and apparatus  90  showing two mat sections being joined together with a mat connector and anchored with a slat anchor having a textured surface and mounted on an underlay.  
         [0039]    [0039]FIG. 16 is a schematic top plan view of a presently preferred mat connector.  
         [0040]    [0040]FIG. 17 is a schematic side cross-sectional view of the presently preferred mat connector.  
         [0041]    [0041]FIG. 18 is a schematic side cross sectional view of the mat connector deployed with two mat sections showing the interconnection and the mat connectors in the locked position.  
         [0042]    [0042]FIG. 19 is a schematic partial view of a portion of a inter-locking web showing the dimensional proportions of a mat tongue. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0043]    The present invention shown in FIGS. 1 and 15 is a cattle flooring method an apparatus shown generally  90  and includes the following major components, namely interlocking mats  100 , mat connectors  200 , slat anchors  300 , underlay  400  and a presently preferred mat connector  500 .  
         [0044]    A cattle flooring method and apparatus  90  is comprised of a number of interlocking mats  100  having a top surface  131 , bottom surface  133  which are comprised of, a number of mat sections  108  which are connected via interlocking webs  112  having mat tongues  110 , mat grooves  121  on the connecting edges of interlocking mats  100 . Interlocking mat  100  is preferably manufactured of 100% revulcanized rubber and each section can be shaped and cut to the particular application it is to be applied to. For example, mat sections  108  may be rectangular in configuration for feed alleys and/or stalls and/or may be pie shaped for milking parlours in order to produce a circular configuration when mat sections  108  are connected together.  
         [0045]    Preferably interlocking mats  100  have a textured top surface  114  and mat channels  112  defined on the bottom surface. For additional comfort and moisture protection, an underlay  400  can be also installed prior to placing interlocking mats  100 . Underlay  400  includes a moisture barrier  410  adjacent the bottom of interlocking mat  100  and a particle layer  412  preferably made of rubber and/or neoprene particles which are rigidly connected to moisture barrier  410 . The interlocking webs  112  as shown in FIGS.  15  as well as in FIG. 1, may be defined on all mat edges  162  of interlocking mat  100  or may only be defined on some mat edges  162  of mat section  108  again depending upon the application.  
         [0046]    In practise, interlocking mats  100  are generally {fraction (3/4)} of an inch thick and underlay  400  is generally {fraction (1/2)} inch thick. The purpose of interlocking mats  100  is to provide a soft comfortable and dry footing for cattle as they walk on the interlocking  100  mat surface. The present system attempts to simulate natural conditions. The texture surface  114  is so designed that when cattle place a hoof on the surface, the water below the hoof is channelled away from the foot print itself, thereby making the walking dryer and safer for the cattle. Generally speaking concrete flooring has been the floor used to date, and there has also been some application of rubber belting placed on the concrete flooring. The present invention provides an alternative to present flooring systems.  
         [0047]    Interlocking Webs  
         [0048]    Referring now to FIG. 19 which is a schematic top plan view of a portion of the inner locking webs  112  showing a single mat tongue  110  and the dimensional proportions of mat tongue  110 . The major dimensions of mat tongue  110  are the lengths L  162 , depth D  160 , thickness T  111  shown in FIG. 15, first radius R1  150 , and second radius R2  152 .  
         [0049]    First radius R1  150  shown in FIG. 19 defines first shoulder  154  of mat tongue  110  and secondly radius R2  152  shown in FIG. 19 defines second shoulder  156  of mat tongue  110 . Through experimentation and trial and error, the inventor has determined that in order to maximize the strength of the joint between two mat sections  108  shown as interlocking webs  112  is optimized when the dimensions of mat tongue  110  fall within a certain dimensional ranges as defined here below. These optimum dimensions not only maximize the interlocking web  112  strength, but also minimize the curling and/or the lifting of mat tongue  110  from the flat position. Optimally, first radius R1 shown as  150  is approximately equal to second radius R2 shown as  152 . However, the ratios between first radius R1 shown as  150  and second radius R2 shown as  152  can vary up to a ratio of 1:1.5, or 1.5:1.  
         [0050]    Furthermore, the length L shown as  162  in FIG. 19 optimally is two times the depth D shown as  160  in FIG. 19. However, the length can vary anywhere from 1.5 to 2.5 times the depth D  160 .  
         [0051]    Furthermore, it has been found that thickness T shown as  111  in FIG. 15 is optimally one half of the depth D shown as  160  in FIG. 19 and {fraction (1/4)} of the length L shown as  162  in FIG. 19. The optimal dimensional ratios between thickness T shown as  111 , length L shown as  162  and Depth D shown as  160  are summarized below in chart form showing both the optimal ratio and the outer limits of the ratios of these dimensions in order to obtain adequate performance.  
         [0052]    Note that when these dimensional proportions are not observed, the strength of the joint created by interlocking webs  112  is compromised and mat tongue  110  has a tenancy to lift creating problems and deterioration of the joint created by interlocking webs  112 .  
       Optimal Dimensional Ratio&#39;s  
       [0053]    T:D:L  
         [0054]    1:2:4  
       Outer Operating Limits  
       [0055]    T:D  
         [0056]    1:1.5-2.5  
         [0057]    D:L  
         [0058]    1:1.5-2.5  
         [0059]    T:L  
         [0060]    1:3-5  
         [0061]    Mat Connector  
         [0062]    Referring now to FIGS. 2 through 10 which depicts a mat connector shown generally as  200  in FIG. 10, and includes a strap  212  together with two fasteners  210  located at each distal end of strap  212 . Strap  212  includes apertures  250  at each end for receiving shank  216  of fastener  210  there through. A protecting ridge  252  defines a surface for placement of fastener head  214 . Fastener  210  includes a head  214  connected to a shank portion  216  and having a wedge anchor  218  as well as a tip  220  all intregally part of shank  216 . Wedge anchor  218  has a length  224  and width  222  making it oblong in shape as best shown in FIG. 7. This corresponds to the oblong aperture  250  shown in FIG. 2 such that wedge anchor  218  of fastener  210  passes through aperture  250  with some resistance, however it is very difficult to remove fastener  210  from strap  212  once it has been placed through aperture  250 .  
         [0063]    As shown in FIG. 4 and FIG. 10, a complete mat connector  200  includes one strap  212  and two fasteners  210  each located at a distal end through aperture  250  of strap  212 .  
         [0064]    In use, mat connector  200  is used to connect two adjacent mat sections  108  together as shown schematically in FIG. 1 and in cross section in FIG. 10. Two holes, roughly the diameter of shank  216  or slightly smaller, are drilled and/or punched into adjacent mats sections  108 , such that fasteners  210  of mat connector  200  can align with these holes. Strap  212  together with two fasteners  210  are then forceable attached to mat sections  108  by forcibly urging each fastener  210  into the pre-drilled wholes in mat sections  108 . The shape of wedge anchor  218  enables fastener  210  to enter and penetrate into mat sections  108 , however makes removal in the reverse directions very difficult.  
         [0065]    Kindly note that a presently preferred embodiment of mat connector  200  is described here below as mat connector  500  as depicted in FIGS. 16, 17 and  18 .  
         [0066]    Slat Anchor  
         [0067]    Slat anchor shown generally as  300  and depicted in FIGS. 11 through 14 and in situ schematically in FIGS. 1 and 15 are used to anchor interlocking mats  100  onto slatted concrete floors  324  which are often used in the cattle industry. Slat anchor  300  provides a quick simple and removable method of anchoring interlocking mats  100  to the concrete slatted surface without introducing any unnecessary objects and/or dangers to the cattle walking over interlocking mats  100 .  
         [0068]    Referring now to FIGS. 11, 12 and  13 . Slat anchor shown generally as  300  includes cap  302  having a lattice structure  304  which includes vertical members  306 , a horizontal member  308  which also defines a shoulder  310  at each end, reinforcing rib  314  and a dome member  312  having a wedge area  330  which moves resiliently in the dome movement direction  332  shown by arrows in FIG. 13.  
         [0069]    Referring now to FIG. 14, anchor slat  300  is shown deployed in a concrete slatted floor  324  together with an interlocking mat  100 . In order to install anchor slat  300 , a mat opening  340  is created in interlocking mat  100  which aligns with the top of slat opening  320 . Slat opening  320  is normally flared out as shown in the profile in FIG. 14 and each side wall defines a slat opening contour  322  including a wedge contact area  340  as shown in FIG. 14. Cap  302  is dimensioned to cover over the mat opening  340  and the distance between the underside of cap  302  and the top of shoulder  310  is roughly the thickness T  111  of interlocking mat  100 . Slat anchor  300  is positioned into a slat opening  320  as shown in FIG. 14 by forcibly urging anchor slat  300  downwardly through mat opening  340  and further downwardly into slat opening  320  until anchor slat  300  is positioned as shown in FIG. 14. During the insertion of anchor slat  300  into slat opening  320 , wedge area  330  of dome member  312  makes contact with the narrowest point of slat opening  320  namely slat constriction  338 . The contact of dome member  312  with slat constriction  338  causes the dome member to squish resiliently together particularly at wedge area  330  in the dome movement direction  332  as shown in FIG. 13. In practise the distortion of dome member  312  when placed into slat opening  320  is somewhat more complicated then as depicted in FIG. 13, however for the purpose of this application, it is enough to understand that wedge area  330  moves resiliently inwardly and outwardly in dome movement direction  332  as it is being forcibly urged past slat constriction  338 .  
         [0070]    Dome member  312  is dimensioned such that when anchor slat  300  is in the locked position as shown in FIG. 14, wedge area  330  as shown in FIG. 13 as well as in FIG. 14, is biased against wedge contact area  340  of slat opening contour  322 . In this position it is difficult to extract anchor slat  300  from slat opening  320 .  
         [0071]    A person skilled in the art will realize that the installation of slat anchors  300  is very straight forward that once mat openings  340  have been created, one simply needs to take a hammer and forcibly urge anchor slat  300  into slat opening  320  thereby firmly anchoring interlocking mat  100  to concrete slatted floor  324 . A person skilled in the art will also see that anchor slats  300  are reusable in that they can be extracted without permanently damaging anchor slat  300  by prying upwardly on anchor slat  300  out of slat opening  320 .  
         [0072]    Preferably anchor slat  300  is injection molded out of a pliable resilient plastic which is suitable for this application and the cap  302  portion of slat anchor  300  is designed to provide minimal interference with animals walking on interlocking mats  100 .  
         [0073]    Presently Preferred Mat Connector  500   
         [0074]    Referring now to FIGS. 16 through 18 which show generally mat connector  500  which is a presently preferred design over the one previously described above as mat connector  200 .  
         [0075]    The major advantages over the previous mat connector  200  is that mat connector  500  is manufactured from a single continuous part making manufacturability less expensive, more reliable and providing for a more positive connection.  
         [0076]    Mat connector  500  shown in FIGS. 16 and 17 includes the following major components, namely strap  502  having at a one distal end, a male end  506  and at the other distal end a female end  504 . Strap  502  is preferably a thin planar member.  
         [0077]    Female end  504  preferably includes an outer cylindrical sheath  512 , central rod  514 , disposed concentrically to outer sheath  512 , whereby the space between the central rod  514  and the inner diameter of out sheath  512  defines a plug aperture  518  as shown in FIG. 17. Outer sheath  512  also defines sheath outer diameter  530  and all of these components make up female connector  510 . Female connector  510  is designed to interlock with male connector  508  disposed at male end  506 .  
         [0078]    Male connector  508  includes a cylindrical plug  516  the interior of which defines a rod aperture  520 . FIG. 18 shows two mat connectors  500  deployed in situ together with mat sections  108 .  
         [0079]    In use a person skilled in the art will recognize that two mat connectors  500  are necessary in order to create mat connection  501  as shown in FIG. 18. One connector is located underneath mat  100  and the other above.  
         [0080]    Mat connectors  500  are used to traverse the connection between two mat sections  108  namely over interlocking webs  112 . Over time interlocking webs  112  which include mat tongues  110  tend to lift and this is particularly troublesome when alley scrapers or other devices are used to clean the matting material. It is desirable to have a system in place which will keep mat tongues of interlocking webs  112  flush with the surface of interlocking mats  100 . In other words, interlocking webs  112  are maintained flush with horizontal plane  164 .  
         [0081]    Mat connectors  500  are attached to adjacent mat sections  108  by firstly creating mat holes  190  in each adjacent mat section  108  which is large enough to accommodate the sheath outer diameter  530  of mat connector  500 . The lower mat connector  500  is inserted into mat holes  190  and cooperates with and is interlocked with an upper mat connector  500  which is oriented in reverse fashion. Female end  504  of the upper mat connector interlocks with male end  506  of the lower mat connector  500 . At the other end in similar fashion, the male end  506  of the upper mat connector  500  interlocks with female end  504  of the lower mat connector.  
         [0082]    The cylindrical plug  516  of male connector  508  is slightly tapered from top to bottom such that as cylindrical plug  516  is inserted into plug aperture  518  of female connector  510 , it interferingly enters into plug aperture  518  and progressively becomes a tighter and tighter fit as the upper and lower mat connectors  500  are brought closer and closer together. In addition, the central rod  514  of female connector  510  is also slightly tapered and it as well fits interferingly into rod aperture  520  of male connector  508  thereby also creating a tighter fit as upper and lower mat connectors  500  are brought together. In the locked position  580  shown in FIG. 18, the lower surface  570  of mat connector  500  contacts the textured surface  114  of mat section  108  as well as the bottom surface of mat sections  108 . Adjacent mat sections  108  are sandwiched between the two mat connectors  500  with strap  502  located adjacent the upper and lower surfaces of mat section  108 . In this manner tongues  110  of interlocking webs  112  are kept flush with the upper surface of mat sections  108 .  
         [0083]    It should be apparent to persons skilled in the arts that various modifications and adaptation of this structure described above are possible without departure from the spirit of the invention the scope of which defined in the appended claim.

Summary:
The present invention a cattle flooring method &amp; apparatus comprises interlocking mats including mat sections, inter connected with interlocking webs defined at mat edges; and mat connectors forming a mat connection such that a connection is made across a mat edges by placing one mat connector adjacent a top surface of said mats and a second mat connector placed adjacent a bottom surface of said mats such that said top and upper and lower mat connectors are adapted to interlock though mat holes in said mats thereby connecting together adjacent mat sections and clamping onto said mats. The cattle flooring apparatus further includes a slat anchor including a dome member for securing said mat together with said slat anchor to a slatted floor by urging said dome member of said slat anchor through a mat opening and into a slat opening.