Patent Description:
More particularly, the invention relates to the repair of modular floor mats which provide increased strength, stability, and protection of the subsurface in heavy industrial applications.

Heavy duty modular flooring systems of various designs have been utilized for a significant period of time to provide a temporary and rigid surface in remote or inaccessible areas. More particularly, such systems are primarily utilized in settings where a firm and stable surface is temporarily needed, such as industrial or construction areas. With respect to industrial or construction areas, temporary flooring may be utilized to provide walkways, driveways, parking areas or other rigid surfaces for the transport of materials, vehicles, storage, or mounting of equipment.

The modular nature of such flooring is utilized to adapt the flooring to the particular topographic or geographic needs of the particular site and to also allow for the efficient storage and transport of the modular flooring.

An example floor mat used is the DURA-BASE® mat by Newpark Resources Inc. The mat is formed of two overlapping rectangular sections with a honey-comb internal design. Holes extend around the perimeter of the mat along the non-overlapping portions of the two sections. When two of these mats are placed next to each other, the mats overlap and the holes along the common edge of these two mats line up such that a temporary locking pin can be placed through the holes of both mats to secure the two mats together. Given their shape and size, handling, placing, and removal of these mats has proved difficult. Due to the design of the perimeter of the mats, a decrease in durability occurs on the edges.

An example floor mat used is the MEGADECK® mat by Signature Systems. The mat is formed of two overlapping rectangular sections. Holes, having an attachment device, extend around the perimeter of the mat along the non-overlapping portions of the two sections. When two of these mats are placed next to each other, the mats overlap and the holes or attachment devices along the common edge of these two mats line up, such that a temporary locking pin can be placed through the holes or attachment devices of both mats to secure the two mats together. Such locking pins or devices are prone to failures that create a need for an improved connection apparatus.

Locking pins include a self-aligning locking mechanism that connect the overlapping flange of the mats. The connection includes a key or device to twist and lock the components. Such pins are made of cast aluminum. However, such pins commonly break or breaks occur to areas of the mats surrounding the pins. The pins also commonly detach and no longer connect the mats properly. Mats are commonly made up of a composite, thermoplastic, or similar material with varying flexibility. The locking pins, commonly made of an aluminum, steel, or metallic material have much less flexibility. This causes the connection between the floor mats and the locking pins to fail and detach when a heavy load or force is applied to the floor mats near the locking pin or attachment device location. The floor mat is able to flex or bend while the locking pin does not. This causes breaks in or around the hole locations under stress or heavy loading. Any successful fastening device must provide substantial holding strength to secure the mats and prevent separation. Particularly, when mats are used in roadway surfaces, extreme pressures are placed on the adjoining mats and on the locking mechanism.

In operation, the selection of the particular floor mat and its characteristics are primarily based upon the amount of load expected to be exerted on the modular flooring system, as well as the relative support characteristics of the underlying substrate, be it concrete, artificial turf, grass, dirt, or the like. Heavy construction applications commonly cause cracking and breaking, especially on the edges or sides of the flooring mats. Such breaks and damage render the modular floor mat unusable. Replacing a modular flooring mat is time consuming and expensive.

One method of repair, which has been used, includes removing the damaged section of the flooring mat to create sharp angles. Then adding a new section of flooring mat which has been shaped to fit in the removed space. The use of pegs or attachment points is then used to secure the added section of flooring mat. While this method is currently used, there are a number of issues and flaws which inhibit this solution: the added new section remains a weak point which will break with ease under common heavy construction applications; the attachment points are fragile and prone to breakage; and there is no seal between the added new section and the flooring mat allowing fluids and debris to penetrate. Therefore, there is a need for an improved repair method.

Additionally, the time and cost of replacing a flooring mat interferes with the construction project as a whole. While a flooring mat is being replaced, the area is unusable. Therefore, there is a need for an improved, quick on site repairing method.

Another method of repair is to add smaller flooring mats to cover up the broken area of the flooring mat. This solution also has a number of issues, such as an increased cost of purchasing additional flooring mats and increased waste because the broken sections must be disposed of.

Another common problem is the mats top layer detaches from the main body of the mat. This exposes the internals of the mat rendering the mat useless and vulnerable to more damage. Thus, there is a need for an improved attachment means of the top layer to the body or bottom layer of the mats.

Examples of prior art can be found in documents <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

The present invention relates to an improved method for repairing the flooring mats on site.

Further preferred embodiments are defined by the features of dependent claims <NUM>-<NUM>, <NUM>-<NUM>.

Accordingly, the present invention includes features and advantages which are believed to enable it to advance repair load-support surface technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of various embodiments and referring to the accompanying drawings.

Moreover, in the figures, like-referenced numerals designate corresponding parts throughout the different views.

<FIG> is a top down view of the flooring mat with a nut fixed to the bolt.

Before any independent embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The use of "including", "comprising", or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

Unless specified or limited otherwise, the terms "mounted", "connected", "supported", and "coupled" and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation such as, terms like "central", "upper", "lower", "front", "rear", etc. are only used to simplify description of embodiments of the present invention and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as "first" and "second" are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.

Referring initially to <FIG>, an exemplary floor mat <NUM> is comprised of a main body <NUM> and edges <NUM>. The floor mat <NUM> has a top surface <NUM> and a bottom surface <NUM>. The top surface <NUM> is designed to contact heavy machinery and support commercial construction sites. Examples of the floor mat <NUM> include the DURA-BASE® mat by Newpark Resources Inc. The floor mat <NUM> may be made of high-performance thermoplastics, high density polyurethane, or similar material. The internal structure of the mat <NUM> may be a honey-comb design, common in the structure of such mats <NUM>. Floor mat <NUM> may have engagement apertures <NUM> for transportation and connection means. The engagement apertures <NUM> allow for access through the floor mat <NUM> and attachment to additional floor mats <NUM>. The floor mat <NUM> may have angled or additional edges <NUM> for attachment means. The mats <NUM> can be attached together to form a load bearing site to make a stable ground or flooring for construction equipment.

Referring to <FIG>, the preferred embodiment of the floor mat <NUM> of the present invention comprises a plurality of uniform mats having upper section <NUM> and lower section <NUM>. Upper section <NUM> has upper work surface <NUM>, while lower section <NUM> has lower work surface <NUM>. Although upper work surface <NUM> and lower work surface <NUM> are depicted as being substantially smooth, minor indentations or raised portions may be added to said work surfaces to increase traction characteristics. Such indentations or raised portions aid in forming a non-slip work surface. Upper section <NUM> and lower section <NUM> are mutually offset relative to each other, which results in upper peripheral extension <NUM> and lower peripheral extension <NUM>. In the preferred embodiment, outer edges of upper section <NUM> and lower section <NUM> are beveled along the full extent of said edges.

Further an upper section <NUM> and lower section <NUM>, as well as upper peripheral extensions 160a and 160b and lower peripheral extension 170a and 170b are present. When two mats of the preferred embodiment are laterally placed together for purposes of constructing a roadway or other support surface, lower peripheral extension 170a is received under upper peripheral extension 160a of an adjacent mat. Similarly, when two mats are placed together in longitudinal fashion, lower peripheral extension 170b is received under upper peripheral extension160b.

When a plurality of floor mats <NUM> are joined together, the floor mats <NUM> form a continuous and substantially smooth roadway or other support surface. Further, the overlap/underlap relationship shared by adjacent floor mats <NUM> provides strength for load support purposes. Additionally, the overlap/underlap relationship also provides increased friction contact between mats to prevent separation of the floor mats <NUM> in tandem with the locking pins through apertures <NUM>. The engagement apertures <NUM> allow for access through the floor mat <NUM> and attachment to additional floor mats <NUM>. The floor mat <NUM> may have angled or additional edges <NUM> for attachment means. The engagement apertures <NUM> of one floor mat <NUM> align with the engagement apertures <NUM> of another floor mat <NUM> to allow for removable coupling between the floor mats <NUM>.

Although it is possible that the floor mats <NUM> can be constructed of solid material, in the preferred embodiment said mats are comprised of two mirror-image components which are affixed together to form a single mat. <FIG> depict lower section <NUM>, having area of reduced material <NUM>. While an area of reduced material <NUM> is depicted as a row configuration in <FIG>, it is possible that the area could have any number of configurations. Beveled ridge walls <NUM> extend along the inner edges of the area of reduced material <NUM>. Lower peripheral extension 170a and 170b are constructed of solid material.

In the preferred embodiment, lower section <NUM> is joined with and affixed to a mirror-image section. The sections are oriented such that area of reduced material <NUM> is aligned with the area of reduced material of the upper mirror-image section, and so that only these sections of reduced material overlap. This orientation results in forming lower peripheral extensions 170a and 170b. Similarly, the solid edges of the mirror-image section form upper peripheral extensions 160a and 160b.

As illustrated in <FIG>, the floor mat <NUM>, when damaged, may include a broken section <NUM> including a broken edge <NUM>. The broken edge <NUM> may be rough and topographical. The broken edge <NUM> may be formed on an uneven section of the top surface <NUM> or bottom surface <NUM>. The broken edge <NUM> may include a portion of the engagement apertures <NUM>, not shown. The broken edge <NUM> may include rough or jagged edges common when thermoplastics are damaged or broken by force. Such breaks are common in the construction industry as floor mats <NUM> undergo various stresses and forces. The broken edge <NUM> may be such that the top surface <NUM> or bottom surface <NUM> extends further than the other.

As illustrated in <FIG>, the broken section <NUM> of the floor mat <NUM> may be cut to create a squared edge <NUM>. The squared edge <NUM> may be cut to approximately create a perpendicular, flat surface <NUM>. The flat surface <NUM> is arranged to be easily connectable to repair the floor mat <NUM>. The flat surface <NUM> may be arranged at approximately a <NUM> degree angle to the top surface <NUM> or bottom surface <NUM> or arranged so that an even surface is present. The internal beveled ridge walls <NUM> are exposed with the squared edge <NUM>. The lower peripheral extension 170a and 170b are exposed with the square edge <NUM>. The squared edge <NUM> may be cut to approximately create a saw-toothed or step-like surface. The squared edge <NUM> is advantageously cut to aid in connecting a new piece of mat.

As illustrated in <FIG> and <FIG>, the flat surface <NUM> may include holes 320a. Holes 320a may be drilled, dug, or created by another means. Holes 320a are at least large enough in diameter to fit a rebar wire or a similar support means. Holes 320a are at least long enough in depth so a rebar wire may be placed to create a support for secure attachment of a repair method. There may be multiple holes 320a, dependent upon the size of the broken section <NUM>. An increased size of the broken section <NUM> increases the number of the holes 320a. Holes 320a are preferably spaced approximately eight inches, approximately twenty centimeter, apart, but may be spaced more or less. Holes 320a are drilled to be parallel to one another, but may be angled as well. Holes 320a may be approximately perpendicular to the internal beveled ridge walls <NUM>. The Holes 320a are advantageously located to allow for bars <NUM> to be inserted to aid in support of the floor mat <NUM> and for any structure to be added.

Bars <NUM> are placed in holes 320a along flat surface <NUM>. Bars <NUM> are rebar or a similar material. Bars <NUM> may be approximately straight or angled. Bars <NUM> extend out of holes 320a at an approximately perpendicular angle to flat surface <NUM>. Bars <NUM> extend out to a user specified distance to provide support for future attachments. Bars <NUM> may be secured in holes 320a with a sealant <NUM>. Bars <NUM> may also be placed between the beveled ridge walls <NUM> and extend along the inner edges of the area of reduced material <NUM>. The sealant <NUM> may be injected into the beveled ridge walls <NUM> and extend along the inner edges of the area of reduced material <NUM> to secure the bars <NUM>.

As illustrated in <FIG>, the sealant <NUM> is applied to the holes 320a. The sealant <NUM> may be applied to partially or fully coat the internals of the holes 320a. The sealant <NUM> may be a polymer, concrete epoxy, or any material capable of sealing. The sealant <NUM> may also be applied to flat surface <NUM> of the squared edge <NUM> to aid in attaching. The sealant <NUM> may be applied to partially or fully coat the flat surface <NUM>. The sealant <NUM> is applied to fixedly attach the bars <NUM> to the holes 320a and aid in fixedly attaching a new piece <NUM> to the flat surface <NUM>.

The new piece <NUM>, or secondary piece, is attached to the squared edge <NUM>. The new piece <NUM> may be made of a similar thermoplastic or material like the floor mat <NUM>. The new piece <NUM> is attached using the bars <NUM> and sealant <NUM>. The new piece <NUM> is shaped to fit approximately seamlessly with the floor mat <NUM> after the squared edge <NUM> is cut. An outer edge <NUM> of the new piece <NUM> aligns with the outer edge of the floor mat <NUM>. The new piece <NUM> may have holes 320b which line up with holes 320a and allow for entrance of the bars <NUM>. When new piece <NUM> is attached with the sealant <NUM>, a liquid proof seal is made. This seal prevents liquid or debris from passing in-between the new piece <NUM> and floor mat <NUM>, while attaching the new piece <NUM> to the squared edge <NUM>. The new piece <NUM> advantageously increases the surface area of the mat <NUM> to its original unbroken form.

As illustrated in <FIG>, clamps <NUM> and other gripping member means may be used to secure the new piece <NUM> to the floor mat <NUM> while the sealant <NUM> is drying or solidifying. The clamps <NUM> are used to maintain an approximate level surface between the new piece <NUM> and the floor mat <NUM> while the sealant <NUM> is drying or solidifying. Clamps <NUM> may extend through the engagement apertures <NUM> to further secure the new piece <NUM> to the floor mat <NUM>. Clamps <NUM> are removed once the sealant <NUM> is sufficiently solidified. Various clamps <NUM> may be used in any amount to secure the new piece <NUM> and the floor mat <NUM>.

As illustrated in <FIG>, bars <NUM> may extend through the new piece <NUM>. This is to ensure there is proper support throughout the new piece <NUM>. Bars <NUM> are inserted through holes 320a, 320b. If the bars <NUM> are exposed, bars <NUM> are then altered or cut to be approximately even or flush with the outer edge of the new piece <NUM>. Bars <NUM> may extend all the way along the floor mat <NUM> or partially. The bars <NUM> may be spaced out to properly support the new piece <NUM> with the floor mat <NUM>.

To create the seal, the outer edge <NUM> of the new piece <NUM> and the outer edge of the floor mat <NUM> are altered to better adhere with the sealant <NUM>. The outer edge <NUM> may be ground down to expose an inner surface of the new piece <NUM>. The outer edge <NUM> of the floor mat <NUM> may be ground down to expose an inner surface of the floor mat <NUM>. Sealant <NUM> may then be applied to the exposed surfaces. A plastic weld may also be applied to the exposed surface. After the sealant <NUM> or the plastic weld is dried or solidified, another grinding process may occur to smooth out the dried area and create a flush surface with the dried area and the outer edge <NUM>.

As illustrated in <FIG>, the floor mat <NUM> may be damaged in another way so that an alternative repair method is needed. Such damage may result in a tear out <NUM>. The tear out <NUM> exposes the honey-comb design internals or the beveled ridge walls <NUM> of the mat <NUM>. The tear out <NUM> leaves an empty spacing in floor mat <NUM>, which compromises the strength and allows for a weak point of further damage. Filler <NUM> may be applied to at least partially fill the tear out <NUM>. Filler <NUM> may be beads or a similar material designed to fill or permeate an opening. Filler <NUM> also provides support for in the tear out <NUM> to add material strength and prevent the tear out <NUM> from being a weak point or flexing. The tear out <NUM> is fixed by cleaning the tear out <NUM> surface, adding filler <NUM>, welding over the tear out <NUM>, sealing it, and then cleaning the top of the welding.

Referring to <FIG>, the floor mat <NUM> is shown with lock devices <NUM> installed and with some of the holes <NUM> without the lock devices <NUM> installed. The holes <NUM> are at least large enough to fit the lock device <NUM>. Holes <NUM> may go through the floor mat <NUM> fully, providing access to both the top surface <NUM> and bottom surface <NUM>. The engagement aperture <NUM> is made up of at least the lock device <NUM> and a washer <NUM> which are placed within, or approximate, to the holes <NUM>.

Referring to <FIG> and <FIG>, the washer <NUM> is shown coupled to the top of hole <NUM>. The top of holes <NUM> or the area surrounding holes <NUM> are countersunk to allow for the fitting of the washer <NUM>. The washer <NUM> is placed in the countersunk area around the hole <NUM>. The countersunk area around the hole <NUM> is at least deep enough to allow for the washer <NUM> to be even or flush with the area around the holes <NUM> of the floor mat <NUM>. Preferably, the countersunk area around the hole <NUM> is deeper than the thickness of the washer <NUM> to allow for a margin of error or a future step of adding thermoplastic over the washer <NUM>. The countersunk area around the holes <NUM> is formed with a grinding or digging device. The washer <NUM> may include attachment points <NUM>. The attachment points <NUM> are spaced out along the washer <NUM> to provide at least a uniform connection when the washer <NUM> is attached via the attachment points <NUM>. The washer <NUM> may be attached to the area round the holes <NUM> by bonding, securing with pins, or any other attachment means.

The lock devices <NUM> are releasably securable through corresponding holes <NUM>. The lock devices <NUM> may have any suitable form, construction, or configuration. In a preferred embodiment, the lock devices <NUM> have a top section which extend through the corresponding hole <NUM> and bottom section with a larger diameter. In this embodiment, the illustrated floor mat <NUM> includes a plurality of lock devices <NUM>, each configured to accept a releasable locking pin there-through. Each illustrated floor mat <NUM> may include, for example, a total of <NUM> locking devices <NUM>. In some embodiments, the locking devices <NUM> may form a liquid-tight seal around, or in, the holes <NUM> within which they are engaged. Some examples of locking devices <NUM> may be circular or oval shaped, but are not limited to such shapes.

Referring to <FIG>, the locking device <NUM> is shown installed in the hole <NUM>. The locking device <NUM> may include a lock frame <NUM> structured to engage and lock with a rotatable pin and a body <NUM> shaped to securely fit in the holes <NUM>. The lock frame <NUM> may also have an attachment means or a section for installing attachment means. The locking device <NUM> may be installed into the hole <NUM> directionally from the bottom surface <NUM> of the floor mat <NUM> using a hammer or other means of force. Once the locking device <NUM> is installed securely in the hole <NUM>, pins or another attachment means are installed or used to fix the locking device <NUM> to the floor mat <NUM> from the bottom surface <NUM>. Preferably, the bottom section with a larger diameter is fixed to the area around the hole <NUM> using pins or another attachment means.

Once the locking device <NUM> and washer <NUM> are installed, both surround the area around the hole <NUM> from the top surface <NUM> and bottom surface <NUM> directions. Additional filing may be done to the washer <NUM> and locking device <NUM> to make all surfaces flush with the area surrounding the holes <NUM>. The locking device <NUM> preferably does not extend past the top of the washer <NUM>.

Referring to <FIG>, a bonding agent <NUM> is shown formed over the washer <NUM>. The bonding agent <NUM> may be formed over or around the washer <NUM> and area surrounding the holes <NUM>. The bonding agent <NUM> may be a polymer, plastic welding material, concrete epoxy, or any material capable of sealing. The bonding agent <NUM> acts as a weld to hold the washer <NUM> in place to the top of the area around the hole <NUM>. After the bonding agent <NUM> is sufficiently dry, a step of grinding or sanding may be applied to make the surface flush again with the surrounding area of the floor mat <NUM>. The flush surface aids in the attachment of one floor mat <NUM> to another by allowing even surfaces to be stacked on one another. The bonding agent <NUM>, when solidified, increases the strength of the connection between the installed locking device <NUM> and hole <NUM>. The solidified bonding agent <NUM> may fully cover the washer <NUM> adding the properties of the thermoplastic and adding an increased bond between the mat <NUM> and the locking device <NUM>. This allows for an increased protection, where the mat <NUM> may be able to sustain an increased force to the area around the locking device <NUM> without damage occurring. The locking device <NUM> advantageously increases the durability of the floor mat <NUM> at the connection points.

Claim 1:
A method of repairing a mat (<NUM>), comprising:
cutting an irregular open section (<NUM>) of the mat (<NUM>) to an approximately perpendicular edge (<NUM>);
cutting the approximately perpendicular edge (<NUM>) to an approximately perpendicular, flat surface (<NUM>);
drilling holes (320a) into the perpendicular, flat surface (<NUM>);
drilling holes (320b) into a secondary piece (<NUM>);
inserting bars (<NUM>) into the holes (320a,320b) of the secondary piece (<NUM>) and of the perpendicular, flat surface (<NUM>);
applying a sealant (<NUM>) to the approximately perpendicular, flat surface (<NUM>);
conjoining the secondary piece (<NUM>) to the perpendicular edge (<NUM>), wherein the secondary piece (<NUM>) covers the open section;
clamping the secondary piece (<NUM>) to the perpendicular edge (<NUM>) temporarily:
and fixing the secondary piece (<NUM>) to the perpendicular edge (<NUM>);
wherein the mat (<NUM>) is configured to support the weight of people, vehicles and equipment thereupon and undergo movement relative to one or more other mats (<NUM>) without disengaging from another, and the mats (<NUM>) comprise at least four sides and an edge extending along each side, the first and second sides of each mat (<NUM>) having a lower lip extending horizontally outwardly below the edge thereof and the third and fourth sides of each mat (<NUM>) having an upper lip forming the edge thereof, the respective upper and lower lips of different mats (<NUM>) being interconnectable with locking pins releasably securable through corresponding apertures formed therein and wherein the secondary piece (<NUM>) is fixedly attached to the mat (<NUM>) to repair the mat (<NUM>) and the bars (<NUM>) are inserted for secure attachment.