CA2440932C - Mat assembly for heavy equipment transit and support - Google Patents
Mat assembly for heavy equipment transit and support Download PDFInfo
- Publication number
- CA2440932C CA2440932C CA002440932A CA2440932A CA2440932C CA 2440932 C CA2440932 C CA 2440932C CA 002440932 A CA002440932 A CA 002440932A CA 2440932 A CA2440932 A CA 2440932A CA 2440932 C CA2440932 C CA 2440932C
- Authority
- CA
- Canada
- Prior art keywords
- support member
- beams
- flanges
- outwardly facing
- adjacent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000945 filler Substances 0.000 claims abstract description 22
- 239000000463 material Substances 0.000 claims abstract description 20
- 239000004033 plastic Substances 0.000 claims abstract description 14
- 229920003023 plastic Polymers 0.000 claims abstract description 14
- 238000001125 extrusion Methods 0.000 claims abstract description 9
- 210000002105 tongue Anatomy 0.000 claims description 20
- 238000000034 method Methods 0.000 abstract description 3
- 238000000465 moulding Methods 0.000 abstract description 3
- 238000010276 construction Methods 0.000 abstract 1
- 239000002131 composite material Substances 0.000 description 7
- -1 aluminum) Chemical class 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 238000003466 welding Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 230000000712 assembly Effects 0.000 description 3
- 238000000429 assembly Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 239000003733 fiber-reinforced composite Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000004800 polyvinyl chloride Substances 0.000 description 2
- 229920000915 polyvinyl chloride Polymers 0.000 description 2
- 241000609240 Ambelania acida Species 0.000 description 1
- 241001155433 Centrarchus macropterus Species 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000010905 bagasse Substances 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000012447 hatching Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 238000004021 metal welding Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000004023 plastic welding Methods 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C9/00—Special pavings; Pavings for special parts of roads or airfields
- E01C9/08—Temporary pavings
- E01C9/086—Temporary pavings made of concrete, wood, bitumen, rubber or synthetic material or a combination thereof
Abstract
A mat assembly particularly suited for heavy equipment transit and support, such as roadway construction and the like. The mat assembly is made up of a number of structural members preferably having a "double I-beam" cross-sectional shape. Each I-beam has spaced apart flanges with edges preferably formed in tongue and groove profiles. When butted together, the tongue and grooves of adjacent I-beams mesh. Filler blocks are disposed in the cavities between the webs of the I-beams. Tension members extending through the webs and filler blocks tie multiple I-beams together to form the mat assembly. Preferably, both the I-beams and filler blocks are formed of a plastic material, via extrusion or other molding methods. The resulting mat is capable of bearing very high loads bet is decay resistant.
Description
_ ~ 02440932 2003-09-16 ._ .
Pstent Applicafton of Meyissa B. l2ogers on Mat .Assembly fair ~feavy ~quipment'I'ransit and Sup~sort Eaclkground - Field o:f Art This invention rebates to structural members and assemblies thereof, used in.
various fabrication purposes. With more particularity, tl-~is invention relates to structural members preferably (but not exclusively) formed from plastic or camposite rz~.aterials, and a support mat 1o assembly fabricated therefrom.
Background - Related Art Structural members of many different varieties are old an the aa-t, In particular, so-called °'Z-beams," bearing tlaat name because the cr~ss-sectional shape of the structtu-al merr~ber resembles the letter "I," have been used for mazcy, ~ire.any years in building fabrication and the ><5 like. Such I-beams were primarily re~.ade 0f iron or steel. The typical I-beam, well ktaow~a in the art, has two spaced-apart parallel Flanges connected by a central web. A key advantage to use of an I-beam, as opposed to a solid beam having the same outer dimensions, is that the I-beam is much more structurally '°effacient_" By that is meant that a tremendously reduced volume and weight of material is needed to yield a structural member having nearly the same rigidity a~s a 2o solid beam. This is because the greatest rigidity is contributed by material a.t the most distant F~PRESS I1IIAIL#EF190853836US
_ _ ..._. _. ~ -02440932 P003-09-16 . .. . _ _ .....
paints from the bending axis of the beam. In a solid beast, the large volume of material relatively close to the beudzng axis contributes relatively little to rigidity_ In addition, due to their geometry, I-beams have high vettica.l or con~.pressive load capacity (that is, loads perpendicular to the face of the flange}. 'Thereby, I-bEam slruetural s .rtaembers are suitable and desirable for support sa~rfaces.
A drawback to I-bearrxs is relatively low torsional (t~risting) rigidity. This results, in part, ~xom the absence of t6.e material adjacent the centeal web.
These properties of I-beam structural rr~embers make them suitab)e for buildixxg transit and support areas for heavy equipment, especially on relatively soft terrs~in.
Such transit and 1~ support areas are frequently .needed in, for example, construetion, ~litary, axad oilfield applications. However, it is not feasible to use iron or steel I-beams for such applications, as they would be far too heavy and too expensive, arid further are subject to corrosion. While it may be passi.ble to form I-beams ou! of. lighter and less expensive materials such as wood, decay is a problem, since the application is often in a v~ret, soft terrain environment. Wooden members is therefore often turn out to be sinsle-use members due to rotting, breaking and splintering from high loads, etc.
It is desirable to form mat assemblies suitable for use in, soft terrain, wluch co~.nbine the favorable attributes olCrelatively law cost, lore weight, high load bearing capacity, and resistance to decay. The present invention combines certain favorable aspects of Z-beams (high rigidity, 2o high load bearing capability), while maintaining vertical load capacity and increasing torsional rigidity through the addition of filler blacks, and with highly decay_resrstant xo.ateriats (plastic or F~(PRESS MAlL #EF19085383f US
__.. ~ 02440932 2003-09-16 composite materials, or light weight metals such as aluminum), to form very strong gnat assemblies having a reasonable cost.
Sr~rnmary of the Invention The present invontxon is a generally I-beam, shaped structural member having spaced apart flanges connected by a central web, and a mat assembly formed tom such T-beams. The edges of the I-beam flanges are formed into repeating geometric profiles, such as tan~ue az~d groove profiles, which mesh with ire tongues and grooves o~ adjacent I-beams when butted together. A preferred embodiment of the T-beam of the present invention is a "double°' I-beam, that is, resembling Owo I-beams stacked one atop the other; thereby yielding tree flanges lo connected by a central web. Preferably, the I-beam is fabricatEd vi.a, ex~udirlg plastic or composite materials. A rnat asseanbly, according to a preferred errabodiment of the present invention, is comprised of a plurality of I-beams, disposed adjacent one another and butted togetlier so that the flange edge tongues and grooves mesh together. Fillax blocks are disposed in at least some o~the cavities between the webs of adjacent I-beams, and provide increased strength and torsional rigidity. The filler blocks also prevent distorrion or bending of the central webs, thereby preserving the load bearing capacity of the r-beams, and serve to seal the cavities betuveen the webs, to prevent liquids and solids from entering the cavities. A
means for connecting the I-beams is provided, which in the preferred embodiment is a tension member, such as a rod, cable, chain, oz~ other means. 'The tension membe~°
extends through th.e wvebs and zo the filler blocks, and holds the I-beams and filler bloelcs together to form the zz~at assera~bly.
Adhesives and/or welding may optionally be used to join the I-beaans.
Brief Description of the Drawings EXPRE58 MAIL#Ef1909538361JS
_ ~ 02440932 2003-09-16 ._. _ Figs. la and Ib are perspective and cross section views o~one embodiment of the I-ream support member of the present invention.
Figs. ?a - 2d are perspective grad section Views of one embodiment of the dyer block_ Fig. 3 is a perspective view of a mat assembly, partially exploded, with certain element numbers omitted for clarity.
Fig. 4 is a cross section view of a mat assembly.
Figs. 5a - Sc show another embodiment of the izwention, comprising end caps.
Fig. 6 is a cross section view of another embadimezri o~the I-beam.
Figs. 7a - 7c are perspective and cross section views of a rrtat assembly formed with the I-lo beam shorvii in Fig. 6.
Figs. 8a - 8c show alternative embodiments of the y-beam.
Fig. 9 shows another embodiment of the I-beam.
Descri.ptiou of Some Presently Preferred Embodiments While the present invention lends itself to Various embodiments, as will be recognized by I5 those having ordinary skill in this art held, with reference to the drawxz~gs some presently preferred embodimexits will be described.
Figs. I a and 1 b are perspective and cross section views of one embodiment of the I-beam structural member of the present invention. In this embodiment, beam 1Q
comprises three spaced apart flanges 20 connected by webs 30. In effect, a "double I-beam.'°
is formed. Faeh edge of ~o ranges 20 comprise a recurring geometric profile adapted to rr~esh together with azn adjacent I-bean, and in the preferred embodiment is either a tongue 40 or groove 50 profile. Freferabl,y, each flange 24 has a tongue 4~0 on one edge and a groove 50 on its other edge.
Further, tech DCPR~S: MAIL FIB0953836US
_ _ _ ~ 02440932 2003-09-16 _ (large on a single beam lies its tongue and groove on the same side as the tongues and grooves of the other ranges on the same beam.. Said mother way, all tongues 4.0 arc on the same side of beams 1~, and, all grooves 50 are on the same side of besr~n 10. This facilitates the meshir»g together of beams 10, one to the next to form the mat assembly of this invention, as later described_ Preferably, beann 10 is formed from a composite or plastic anaterial.
Preferred materials for fabrication of the bearer. are various plastics, composite materials, fiber-reinforced composites, etc., including (by way of examQle only) filled and unfilled polyethylene, poly propylene, and polyvinyl chloride (PVC)_ JFillers vrhich may be used in the present invention include fiberglass, to minerals, organic materials, silk, bagasse, and other na~,ura.l anal synthetic ~boz~s. resins knowvn in the art and suitable for the beam nay have tensile strengths of 12,0100 t~
20,0U0 psi. Beam 10 is preferably fo~nrned via extrusion, although it is understood that other forming moans known in th.e art could be used, including but not limited to pour molding, injection molding, compression zr~olding and the like. Other suitable materials for beann 10 are lightweight metals, such as p.5 alurnirtum and aluminurta alloys.
Beam, 10 may be made am many different dimensions to suit particular app~.cations.
Ho~vev~r, one exemplary ennbodiment suitable for many applications has x height H ~of approximately 8 inches, width W of approximately ~ iuzcltes, and a thicl~.ness of the flanges and web of approximately I inch_ When in these approximate crossmsection dimensions, most 2o materials yield a beam weigl~iug approximately 7 lb./linear foot_ Beam I O
m.ay be made iz~
waz-ious lengths, by way of example up to 3t3 to 4.0 feet long; however, longer or shorter lengths may be trade as desired, for easy handling in assembly arid of flee assembled mats, as described EXPRESS MAIL #EF190953836US
02440932 2003-09-16 - _.. .
later. IIowe~er, it is understood that the scope of the invention is not limited to any particular dimension or combination of dimealsions_ As gill be later described in more detail, the ~.nat assembly of the present inwe~ntion also comprises filler blocks 60, showc~ in Figs. 2a - 2d, which fill a portion of the cavities between s webs of adjacent beams 10, as shown in Figs. 3 and 4. Filler blocky 60 are elongated blocks having cross-sectional shapes and dimensions adapted to largely fill the cavities created bet~creen webs of adjacent beanns 10_ Approximate resulting dimensions are rounded rectangle approximately 3" high, 3" wide in cross section, and approximately 6" tong.
1'he embodinnent of filler blocks 60 shown fill only a portion of the beam cavity, adjacent to the tension member 1~ penetration (described later); however, it is tYnderstood that if desired Che entirety of the web cavity could be filled. Preferred materials for filler blocks 60 are -carious plastic and composite materials, arid may be formed from the same materials which bcatr~s 1. 0 are formed. 'Y'et another possible material for filler blocks 60 is urethane. In order to minimi~x the quantity of material used, and thus cost, filler blocks GO preferably h.awe a catacomb interior stzuctuze, as seen irx Figs.
~s 2a - 2d.
I=ig. 3 shows one embodiment of the maC assembly of the present invention. A
plurality of beams 10 are a~zanged adjacent oxie anothea~, and butted together, so that mating tongue 40 and groove 50 profiles of adjacent beams 10 mesh together. Filler blocks 60 are disposed in the cavities between the webs of adjacent lbearns 10_ Webs 30 and filler blocks 60 eomprisE holes 2o 30a and GOa, which are aligned with each other in the assembled rnat_ To assemble and hold together a desired number of beams 10 and flier blocks 60, a means for connecting the I-beams together is used. In one presently preferred embodiment, the means for connecting comprises EXPRESS MAIL itEF190953838US
. . . ~ 02440932 2003-09-16 . .. . _. _ . _. _.._ . . . .
tension member 70 run through beams 10 and fillex blocks 60 (Via holes ~Oa and GQa)_ End fasteners 70a are attached to apply tension to tension an.embers 70, and thereby force the plur~.lity of beams 10 tightly together to form mat assembly 80. In the presently preferred e~,bodxxrxent, tension member 70 comprises a steel "all thread." rod, ~ittt nuts sewing as end fasteners 70a.
s The nuts are simply made up on the all thread rods by wrenches, etc. as customary iwtlie art, to force beams 10 together. Alternative embodiments of tension member ?0 could be ropes of various materials, chain, plastic or composite rods, etc. It is fi~.rther understood that the means for connecting beams 10 to foam rnat assernbiy 80 may also comprise adhesives or welding (whether plastic welding or metal welding). The adhesives or welding to join I-beams 10 rr~ay be 1o in addition to tension me~mbez 70, or in lieu thereof.
The sequence of beg X 0 anal filler block 60 assembly can be varied_ One presently preferred method is to essentially "stack" the 1-beams 10 aad filler blocks 60 (if used) onto te~iom zrte;nbers 70, until the desired number of beams 10 are butted together, then end fasteners 70a installed and suitable tension applied. Other desired sequences of assembly can of course be 15 used.
It is understood that other embodiments of neat assembly 80 omit filler blocks 60.
The resulting mat asseanbly 80 exhibits high rigidity and support stzength.
The tongue and groove profiles in the beam flanges transfer loads from on.e beam to the n.ea~t, and pleVez~t slipping of one beam relative to the next, lVlat assembly 80 may be pre-assembled before being 2o brought to the work site, and transported via truck and placed in position With fork lifts, cranes, etc. Alternatively, beams 10, filler blocks 60, and tension members 70 may be brought to the v,~ork site, and znat assembly 80 assembled on the spot.
EXPRESS MARL#~F190953B36US
~ 02440932 2003-09-16 The materials and structural shape of mat assembly 80 results in. a relatively light weight mat, in view of its load bearing capacity. >3y way of example, a mat assembly of dimensions of 4' x 24' weighs approximately 2000 pounds.
As seen irx the figures, especially 1 a, lb, and 3, the outer suxjFaces of flanges 20 are preferably formed with a tractioza surface, for example grooves 90. Grooves 90 may be readily formed dtuing the extrusion (or other forming) pracess_ In the assembled mats, grooves 90 run transverse t~ the normal direction of travel of (for example) wheeled vehicles traversing th..e mat, and grooves 90 thereby provide greatly increased traction. It is understood that other designs for traction surfaces, such as a diamond shape cross hatching or the like, can be formed, either Lo during the manufacturing of bear; 10 or subsequently by machining, ere-p.dditional surface treatments may be applied for skid resistance and traction, such as overlays which ~~r~ay be adhesi-vely bonded to the flange surfaces, or °'roll on" patterns.
While mat assembly 80 Iends itself to many different applications, one advantageous use ofthe present invention is in the support of heavy equipment, vehicles amd machinery over soft 1s terrain. lZoadways or pads can. be fon~ned from the mat assemhlies, wluch are capable of handling extremely high loads from wheeled or tracked vehicles such as draglines, etc., stationary equipment and the like, possible uses itxclude military applicationsy is well as industrial applications. Oilfield related use ~eay be in the applications traditionally filled by wooden "board roads." Yet another possible use is as decking to cover open spa,ns~ An zo advantage of the present invention is not only flee bigh load capability, but also the resistance to decay, making repeated azAd long term use even in °wret environments quite practical.
EXPRESS MAIL~EF190~53838U5 __ _ .. _ .. .. . . _ ~ 02440932 2003-09-16 - . ..... . ._ ... _ ._ Other embodirnents of the invention are possible. For example, Figs. 5a - Sc show an embodiment of mat assembly 80 cozz~prisiz~g end caps 100, which cover the outermost ends (beam cavities) of beams 10 in. an assembled mat. End caps 100 prevent dirt, rnud, etc. from filling th.e outermost cavity, and protect end fasteners 70a vrhicl~, would otherwise be exposed.
s End caps 100 comprise tongue and/or groove profiles to mate with the grooves andior tongues'of the beams to which they mount. End caps 100 tray be fastened to the mat assembly via adhesive or welding, oz' tension member 70 can penetrate end cap 100, then fastener 70a arid a gasket attached to ensure a seal.
Yet another embodiment is shown in rigs. 6a and 6b, arad 7a - 7e. This embodiment to comprises a "single I-beam" sEiape, instead of the "double I-beam" shape of the previously described embodiment. It is understood that the scope of the invention eanxprises any number of I-beam configurations, e.g. "triple I-beams," '°quadruple I-beams,"
ctc_ While the preceding description contains many details of the invention, it is understood that they are offered to illustrate some of the presently preferred embodiments and not by way of is limitation. Numerous changes are possible, while still falling within the scope of the invention.
For example, the bums and filler blocks rnay be formed by different methods aad of different materi,als_ Injection, extrusion, pour, plug, and compression moldir~ are all possible molding me~.ods. A wide variety of plastics, composite, fiber-reinforced composites, xesir~s, etc. may be used. Dix~ensions and shapes may be altered to suit particular applications.
Tzipie, quadruple, etc. I-beam shapes couta be used, with various ~umbets of flaaages sharing a common central web. Yet another embodiment is I-bums having flaoge$ as disclosed, wherein a single I-beam has all tongue or all groove profiles on tlhe flange edges. Such an I-beam., far example having all EXPRESS MAIL #EF190953836115 _ ~ 02440932 2003-09-16 ;....
tongue profiles, would mate with another I-'beam having all gz~oove profiles on the flange edges.
For example, Figs. 8~ - 8c show addation~.l eznbodimetlts of the I-beam profiles, within the scope of the invention. More generally, any recurring flange edge geometry or hange edge treatment, for example that shown, in rig. 9, which permits meshing or unification of the beams into a mat asseaz~bly, could be used and is within the scope oFthe present invention.
TEre T~beams, and mats, could be of light weight metals such as aluminum.
Therefore, the scope of the invention should be limited not by the foregoing description, but by the scope of the appended Claims and their legal equivalents.
1.~ EXF~~~SS MAIL, #~F'90953838US
Pstent Applicafton of Meyissa B. l2ogers on Mat .Assembly fair ~feavy ~quipment'I'ransit and Sup~sort Eaclkground - Field o:f Art This invention rebates to structural members and assemblies thereof, used in.
various fabrication purposes. With more particularity, tl-~is invention relates to structural members preferably (but not exclusively) formed from plastic or camposite rz~.aterials, and a support mat 1o assembly fabricated therefrom.
Background - Related Art Structural members of many different varieties are old an the aa-t, In particular, so-called °'Z-beams," bearing tlaat name because the cr~ss-sectional shape of the structtu-al merr~ber resembles the letter "I," have been used for mazcy, ~ire.any years in building fabrication and the ><5 like. Such I-beams were primarily re~.ade 0f iron or steel. The typical I-beam, well ktaow~a in the art, has two spaced-apart parallel Flanges connected by a central web. A key advantage to use of an I-beam, as opposed to a solid beam having the same outer dimensions, is that the I-beam is much more structurally '°effacient_" By that is meant that a tremendously reduced volume and weight of material is needed to yield a structural member having nearly the same rigidity a~s a 2o solid beam. This is because the greatest rigidity is contributed by material a.t the most distant F~PRESS I1IIAIL#EF190853836US
_ _ ..._. _. ~ -02440932 P003-09-16 . .. . _ _ .....
paints from the bending axis of the beam. In a solid beast, the large volume of material relatively close to the beudzng axis contributes relatively little to rigidity_ In addition, due to their geometry, I-beams have high vettica.l or con~.pressive load capacity (that is, loads perpendicular to the face of the flange}. 'Thereby, I-bEam slruetural s .rtaembers are suitable and desirable for support sa~rfaces.
A drawback to I-bearrxs is relatively low torsional (t~risting) rigidity. This results, in part, ~xom the absence of t6.e material adjacent the centeal web.
These properties of I-beam structural rr~embers make them suitab)e for buildixxg transit and support areas for heavy equipment, especially on relatively soft terrs~in.
Such transit and 1~ support areas are frequently .needed in, for example, construetion, ~litary, axad oilfield applications. However, it is not feasible to use iron or steel I-beams for such applications, as they would be far too heavy and too expensive, arid further are subject to corrosion. While it may be passi.ble to form I-beams ou! of. lighter and less expensive materials such as wood, decay is a problem, since the application is often in a v~ret, soft terrain environment. Wooden members is therefore often turn out to be sinsle-use members due to rotting, breaking and splintering from high loads, etc.
It is desirable to form mat assemblies suitable for use in, soft terrain, wluch co~.nbine the favorable attributes olCrelatively law cost, lore weight, high load bearing capacity, and resistance to decay. The present invention combines certain favorable aspects of Z-beams (high rigidity, 2o high load bearing capability), while maintaining vertical load capacity and increasing torsional rigidity through the addition of filler blacks, and with highly decay_resrstant xo.ateriats (plastic or F~(PRESS MAlL #EF19085383f US
__.. ~ 02440932 2003-09-16 composite materials, or light weight metals such as aluminum), to form very strong gnat assemblies having a reasonable cost.
Sr~rnmary of the Invention The present invontxon is a generally I-beam, shaped structural member having spaced apart flanges connected by a central web, and a mat assembly formed tom such T-beams. The edges of the I-beam flanges are formed into repeating geometric profiles, such as tan~ue az~d groove profiles, which mesh with ire tongues and grooves o~ adjacent I-beams when butted together. A preferred embodiment of the T-beam of the present invention is a "double°' I-beam, that is, resembling Owo I-beams stacked one atop the other; thereby yielding tree flanges lo connected by a central web. Preferably, the I-beam is fabricatEd vi.a, ex~udirlg plastic or composite materials. A rnat asseanbly, according to a preferred errabodiment of the present invention, is comprised of a plurality of I-beams, disposed adjacent one another and butted togetlier so that the flange edge tongues and grooves mesh together. Fillax blocks are disposed in at least some o~the cavities between the webs of adjacent I-beams, and provide increased strength and torsional rigidity. The filler blocks also prevent distorrion or bending of the central webs, thereby preserving the load bearing capacity of the r-beams, and serve to seal the cavities betuveen the webs, to prevent liquids and solids from entering the cavities. A
means for connecting the I-beams is provided, which in the preferred embodiment is a tension member, such as a rod, cable, chain, oz~ other means. 'The tension membe~°
extends through th.e wvebs and zo the filler blocks, and holds the I-beams and filler bloelcs together to form the zz~at assera~bly.
Adhesives and/or welding may optionally be used to join the I-beaans.
Brief Description of the Drawings EXPRE58 MAIL#Ef1909538361JS
_ ~ 02440932 2003-09-16 ._. _ Figs. la and Ib are perspective and cross section views o~one embodiment of the I-ream support member of the present invention.
Figs. ?a - 2d are perspective grad section Views of one embodiment of the dyer block_ Fig. 3 is a perspective view of a mat assembly, partially exploded, with certain element numbers omitted for clarity.
Fig. 4 is a cross section view of a mat assembly.
Figs. 5a - Sc show another embodiment of the izwention, comprising end caps.
Fig. 6 is a cross section view of another embadimezri o~the I-beam.
Figs. 7a - 7c are perspective and cross section views of a rrtat assembly formed with the I-lo beam shorvii in Fig. 6.
Figs. 8a - 8c show alternative embodiments of the y-beam.
Fig. 9 shows another embodiment of the I-beam.
Descri.ptiou of Some Presently Preferred Embodiments While the present invention lends itself to Various embodiments, as will be recognized by I5 those having ordinary skill in this art held, with reference to the drawxz~gs some presently preferred embodimexits will be described.
Figs. I a and 1 b are perspective and cross section views of one embodiment of the I-beam structural member of the present invention. In this embodiment, beam 1Q
comprises three spaced apart flanges 20 connected by webs 30. In effect, a "double I-beam.'°
is formed. Faeh edge of ~o ranges 20 comprise a recurring geometric profile adapted to rr~esh together with azn adjacent I-bean, and in the preferred embodiment is either a tongue 40 or groove 50 profile. Freferabl,y, each flange 24 has a tongue 4~0 on one edge and a groove 50 on its other edge.
Further, tech DCPR~S: MAIL FIB0953836US
_ _ _ ~ 02440932 2003-09-16 _ (large on a single beam lies its tongue and groove on the same side as the tongues and grooves of the other ranges on the same beam.. Said mother way, all tongues 4.0 arc on the same side of beams 1~, and, all grooves 50 are on the same side of besr~n 10. This facilitates the meshir»g together of beams 10, one to the next to form the mat assembly of this invention, as later described_ Preferably, beann 10 is formed from a composite or plastic anaterial.
Preferred materials for fabrication of the bearer. are various plastics, composite materials, fiber-reinforced composites, etc., including (by way of examQle only) filled and unfilled polyethylene, poly propylene, and polyvinyl chloride (PVC)_ JFillers vrhich may be used in the present invention include fiberglass, to minerals, organic materials, silk, bagasse, and other na~,ura.l anal synthetic ~boz~s. resins knowvn in the art and suitable for the beam nay have tensile strengths of 12,0100 t~
20,0U0 psi. Beam 10 is preferably fo~nrned via extrusion, although it is understood that other forming moans known in th.e art could be used, including but not limited to pour molding, injection molding, compression zr~olding and the like. Other suitable materials for beann 10 are lightweight metals, such as p.5 alurnirtum and aluminurta alloys.
Beam, 10 may be made am many different dimensions to suit particular app~.cations.
Ho~vev~r, one exemplary ennbodiment suitable for many applications has x height H ~of approximately 8 inches, width W of approximately ~ iuzcltes, and a thicl~.ness of the flanges and web of approximately I inch_ When in these approximate crossmsection dimensions, most 2o materials yield a beam weigl~iug approximately 7 lb./linear foot_ Beam I O
m.ay be made iz~
waz-ious lengths, by way of example up to 3t3 to 4.0 feet long; however, longer or shorter lengths may be trade as desired, for easy handling in assembly arid of flee assembled mats, as described EXPRESS MAIL #EF190953836US
02440932 2003-09-16 - _.. .
later. IIowe~er, it is understood that the scope of the invention is not limited to any particular dimension or combination of dimealsions_ As gill be later described in more detail, the ~.nat assembly of the present inwe~ntion also comprises filler blocks 60, showc~ in Figs. 2a - 2d, which fill a portion of the cavities between s webs of adjacent beams 10, as shown in Figs. 3 and 4. Filler blocky 60 are elongated blocks having cross-sectional shapes and dimensions adapted to largely fill the cavities created bet~creen webs of adjacent beanns 10_ Approximate resulting dimensions are rounded rectangle approximately 3" high, 3" wide in cross section, and approximately 6" tong.
1'he embodinnent of filler blocks 60 shown fill only a portion of the beam cavity, adjacent to the tension member 1~ penetration (described later); however, it is tYnderstood that if desired Che entirety of the web cavity could be filled. Preferred materials for filler blocks 60 are -carious plastic and composite materials, arid may be formed from the same materials which bcatr~s 1. 0 are formed. 'Y'et another possible material for filler blocks 60 is urethane. In order to minimi~x the quantity of material used, and thus cost, filler blocks GO preferably h.awe a catacomb interior stzuctuze, as seen irx Figs.
~s 2a - 2d.
I=ig. 3 shows one embodiment of the maC assembly of the present invention. A
plurality of beams 10 are a~zanged adjacent oxie anothea~, and butted together, so that mating tongue 40 and groove 50 profiles of adjacent beams 10 mesh together. Filler blocks 60 are disposed in the cavities between the webs of adjacent lbearns 10_ Webs 30 and filler blocks 60 eomprisE holes 2o 30a and GOa, which are aligned with each other in the assembled rnat_ To assemble and hold together a desired number of beams 10 and flier blocks 60, a means for connecting the I-beams together is used. In one presently preferred embodiment, the means for connecting comprises EXPRESS MAIL itEF190953838US
. . . ~ 02440932 2003-09-16 . .. . _. _ . _. _.._ . . . .
tension member 70 run through beams 10 and fillex blocks 60 (Via holes ~Oa and GQa)_ End fasteners 70a are attached to apply tension to tension an.embers 70, and thereby force the plur~.lity of beams 10 tightly together to form mat assembly 80. In the presently preferred e~,bodxxrxent, tension member 70 comprises a steel "all thread." rod, ~ittt nuts sewing as end fasteners 70a.
s The nuts are simply made up on the all thread rods by wrenches, etc. as customary iwtlie art, to force beams 10 together. Alternative embodiments of tension member ?0 could be ropes of various materials, chain, plastic or composite rods, etc. It is fi~.rther understood that the means for connecting beams 10 to foam rnat assernbiy 80 may also comprise adhesives or welding (whether plastic welding or metal welding). The adhesives or welding to join I-beams 10 rr~ay be 1o in addition to tension me~mbez 70, or in lieu thereof.
The sequence of beg X 0 anal filler block 60 assembly can be varied_ One presently preferred method is to essentially "stack" the 1-beams 10 aad filler blocks 60 (if used) onto te~iom zrte;nbers 70, until the desired number of beams 10 are butted together, then end fasteners 70a installed and suitable tension applied. Other desired sequences of assembly can of course be 15 used.
It is understood that other embodiments of neat assembly 80 omit filler blocks 60.
The resulting mat asseanbly 80 exhibits high rigidity and support stzength.
The tongue and groove profiles in the beam flanges transfer loads from on.e beam to the n.ea~t, and pleVez~t slipping of one beam relative to the next, lVlat assembly 80 may be pre-assembled before being 2o brought to the work site, and transported via truck and placed in position With fork lifts, cranes, etc. Alternatively, beams 10, filler blocks 60, and tension members 70 may be brought to the v,~ork site, and znat assembly 80 assembled on the spot.
EXPRESS MARL#~F190953B36US
~ 02440932 2003-09-16 The materials and structural shape of mat assembly 80 results in. a relatively light weight mat, in view of its load bearing capacity. >3y way of example, a mat assembly of dimensions of 4' x 24' weighs approximately 2000 pounds.
As seen irx the figures, especially 1 a, lb, and 3, the outer suxjFaces of flanges 20 are preferably formed with a tractioza surface, for example grooves 90. Grooves 90 may be readily formed dtuing the extrusion (or other forming) pracess_ In the assembled mats, grooves 90 run transverse t~ the normal direction of travel of (for example) wheeled vehicles traversing th..e mat, and grooves 90 thereby provide greatly increased traction. It is understood that other designs for traction surfaces, such as a diamond shape cross hatching or the like, can be formed, either Lo during the manufacturing of bear; 10 or subsequently by machining, ere-p.dditional surface treatments may be applied for skid resistance and traction, such as overlays which ~~r~ay be adhesi-vely bonded to the flange surfaces, or °'roll on" patterns.
While mat assembly 80 Iends itself to many different applications, one advantageous use ofthe present invention is in the support of heavy equipment, vehicles amd machinery over soft 1s terrain. lZoadways or pads can. be fon~ned from the mat assemhlies, wluch are capable of handling extremely high loads from wheeled or tracked vehicles such as draglines, etc., stationary equipment and the like, possible uses itxclude military applicationsy is well as industrial applications. Oilfield related use ~eay be in the applications traditionally filled by wooden "board roads." Yet another possible use is as decking to cover open spa,ns~ An zo advantage of the present invention is not only flee bigh load capability, but also the resistance to decay, making repeated azAd long term use even in °wret environments quite practical.
EXPRESS MAIL~EF190~53838U5 __ _ .. _ .. .. . . _ ~ 02440932 2003-09-16 - . ..... . ._ ... _ ._ Other embodirnents of the invention are possible. For example, Figs. 5a - Sc show an embodiment of mat assembly 80 cozz~prisiz~g end caps 100, which cover the outermost ends (beam cavities) of beams 10 in. an assembled mat. End caps 100 prevent dirt, rnud, etc. from filling th.e outermost cavity, and protect end fasteners 70a vrhicl~, would otherwise be exposed.
s End caps 100 comprise tongue and/or groove profiles to mate with the grooves andior tongues'of the beams to which they mount. End caps 100 tray be fastened to the mat assembly via adhesive or welding, oz' tension member 70 can penetrate end cap 100, then fastener 70a arid a gasket attached to ensure a seal.
Yet another embodiment is shown in rigs. 6a and 6b, arad 7a - 7e. This embodiment to comprises a "single I-beam" sEiape, instead of the "double I-beam" shape of the previously described embodiment. It is understood that the scope of the invention eanxprises any number of I-beam configurations, e.g. "triple I-beams," '°quadruple I-beams,"
ctc_ While the preceding description contains many details of the invention, it is understood that they are offered to illustrate some of the presently preferred embodiments and not by way of is limitation. Numerous changes are possible, while still falling within the scope of the invention.
For example, the bums and filler blocks rnay be formed by different methods aad of different materi,als_ Injection, extrusion, pour, plug, and compression moldir~ are all possible molding me~.ods. A wide variety of plastics, composite, fiber-reinforced composites, xesir~s, etc. may be used. Dix~ensions and shapes may be altered to suit particular applications.
Tzipie, quadruple, etc. I-beam shapes couta be used, with various ~umbets of flaaages sharing a common central web. Yet another embodiment is I-bums having flaoge$ as disclosed, wherein a single I-beam has all tongue or all groove profiles on tlhe flange edges. Such an I-beam., far example having all EXPRESS MAIL #EF190953836115 _ ~ 02440932 2003-09-16 ;....
tongue profiles, would mate with another I-'beam having all gz~oove profiles on the flange edges.
For example, Figs. 8~ - 8c show addation~.l eznbodimetlts of the I-beam profiles, within the scope of the invention. More generally, any recurring flange edge geometry or hange edge treatment, for example that shown, in rig. 9, which permits meshing or unification of the beams into a mat asseaz~bly, could be used and is within the scope oFthe present invention.
TEre T~beams, and mats, could be of light weight metals such as aluminum.
Therefore, the scope of the invention should be limited not by the foregoing description, but by the scope of the appended Claims and their legal equivalents.
1.~ EXF~~~SS MAIL, #~F'90953838US
Claims (20)
1. A support member, comprising:
an I-beam having at least two spaced apart parallel flanges connected by a web, when viewed in a plane perpendicular to a longitudinal axis of said I-beam, each of said flanges having outwardly facing outer edges at a point distal from said web, each of said outwardly facing outer edges comprising interlocking profiles which mesh together with corresponding interlocking profiles in the outwardly facing outer edges of the flanges of an adjacent I-beam and prevent relative vertical movement between adjacent I-beams when a plurality of said I-beams is butted together.
an I-beam having at least two spaced apart parallel flanges connected by a web, when viewed in a plane perpendicular to a longitudinal axis of said I-beam, each of said flanges having outwardly facing outer edges at a point distal from said web, each of said outwardly facing outer edges comprising interlocking profiles which mesh together with corresponding interlocking profiles in the outwardly facing outer edges of the flanges of an adjacent I-beam and prevent relative vertical movement between adjacent I-beams when a plurality of said I-beams is butted together.
2. The support member of Claim 1, wherein said I-beam is formed of a plastic material.
3. The support member of Claim 2, wherein said I-beam is formed by extrusion.
4. The support member of Claim 3, wherein said I-beam further comprises a traction surface on an outmost surface of said flanges.
5. The support member of Claim 1, wherein said interlocking profiles comprise tongues and grooves.
6. The support member of Claim 5, wherein said I-beam is formed of a plastic material.
7. The support member of Claim 6, wherein said I-beam is formed by extrusion.
8. The support member of Claim 7, wherein said I-beam further comprises a traction surface on an outmost surface of said flanges.
9. The support member of Claim 1, wherein said I-beam comprises at least three spaced apart parallel flanges connected by a central web, each of said flanges having two outwardly facing outer longitudinal edges, and wherein said interlocking profiles comprise tongues and grooves.
10. The support member of Claim 9, wherein said I-beam is formed of a plastic material.
11. The support member of Claim 10, wherein said I-beam is formed by extrusion.
12. A support member, comprising:
a beam comprising an I-beam cross section shape, comprising at least three spaced apart flanges connected by a central web, each of said flanges having two opposing outwardly facing longitudinal outer edges at a point distal from said web, wherein on each of said flanges, one of said outwardly facing outer edges comprises a tongue profile, and the other of said outwardly facing outer edges comprises a groove profile.
a beam comprising an I-beam cross section shape, comprising at least three spaced apart flanges connected by a central web, each of said flanges having two opposing outwardly facing longitudinal outer edges at a point distal from said web, wherein on each of said flanges, one of said outwardly facing outer edges comprises a tongue profile, and the other of said outwardly facing outer edges comprises a groove profile.
13. The support member of Claim 12, wherein all of said tongue profiles are on one side of said I-beam, and all of said groove profiles are on the other side of said beam.
14. The support member of Claim 12, wherein said support member is formed of a plastic material.
15. The support member of Claim 14, wherein said support member is formed by extrusion.
16. The support member of Claim 13, wherein said support member is formed of a plastic material.
17. The support member of Claim 16, wherein said support member is formed by extrusion.
18. A support member assembly, comprising:
at least two adjacently disposed, butted together I-beams, each of said I-beams when viewed in a plane perpendicular to a longitudinal axis thereof having at least two spaced apart parallel flanges connected by a web, each of said flanges having outwardly facing outer edges at a point distal from said web, each of said outwardly facing outer edges comprising interlocking profiles which mesh together with corresponding interlocking profiles in the outwardly facing outer edges of the flanges of said adjacent I-beam and prevent relative vertical movement between said adjacent I-beams.
at least two adjacently disposed, butted together I-beams, each of said I-beams when viewed in a plane perpendicular to a longitudinal axis thereof having at least two spaced apart parallel flanges connected by a web, each of said flanges having outwardly facing outer edges at a point distal from said web, each of said outwardly facing outer edges comprising interlocking profiles which mesh together with corresponding interlocking profiles in the outwardly facing outer edges of the flanges of said adjacent I-beam and prevent relative vertical movement between said adjacent I-beams.
19. A support mat assembly comprising:
a) a plurality of structural members, each comprising I-beams having at least three spaced apart parallel flanges connected by a web, when viewed in a plane perpendicular to a longitudinal axis of said I-beam, each of said flanges having outwardly facing outer edges at a point distal from said web, each of said outwardly facing outer edges comprising tongues and grooves which mesh together with corresponding tongues and grooves in the outwardly facing outer edges of the flanges of an adjacent I-beam and prevent relative vertical movement between adjacent I-beams, said plurality of I-beams disposed adjacent one another so that said tongues and grooves of said outwardly facing outer flange edges of adjacent I-beams mesh together, thereby forming cavities between said webs of said adjacent I-beams; and b) a means for connecting said I-beams together comprising a tension member disposed through holes in said webs, and fasteners on either end of said tension members.
a) a plurality of structural members, each comprising I-beams having at least three spaced apart parallel flanges connected by a web, when viewed in a plane perpendicular to a longitudinal axis of said I-beam, each of said flanges having outwardly facing outer edges at a point distal from said web, each of said outwardly facing outer edges comprising tongues and grooves which mesh together with corresponding tongues and grooves in the outwardly facing outer edges of the flanges of an adjacent I-beam and prevent relative vertical movement between adjacent I-beams, said plurality of I-beams disposed adjacent one another so that said tongues and grooves of said outwardly facing outer flange edges of adjacent I-beams mesh together, thereby forming cavities between said webs of said adjacent I-beams; and b) a means for connecting said I-beams together comprising a tension member disposed through holes in said webs, and fasteners on either end of said tension members.
20. The mat assembly of claim 19, further comprising filler blocks disposed in at least some of the cavities created between said webs of said adjacent I-beams, and wherein said tension member is further disposed through holes in said filler blocks.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/245,467 | 2002-09-16 | ||
| US10/245,467 US7370452B2 (en) | 2002-09-16 | 2002-09-16 | Mat assembly for heavy equipment transit and support |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2440932A1 CA2440932A1 (en) | 2004-03-16 |
| CA2440932C true CA2440932C (en) | 2009-11-03 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002440932A Expired - Lifetime CA2440932C (en) | 2002-09-16 | 2003-09-16 | Mat assembly for heavy equipment transit and support |
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| US (2) | US7370452B2 (en) |
| CA (1) | CA2440932C (en) |
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-
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-
2008
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Also Published As
| Publication number | Publication date |
|---|---|
| CA2440932A1 (en) | 2004-03-16 |
| US20080271398A1 (en) | 2008-11-06 |
| US7370452B2 (en) | 2008-05-13 |
| US20040049995A1 (en) | 2004-03-18 |
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| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20230918 |