Mat, portable porous construction mat system, tools, and methods

• US 9,206,559 B2
• Filed: 03/12/2013
• Issued: 12/08/2015
• Est. Priority Date: 03/12/2013
• Status: Active Grant

• Current Assignee: Reynolds Presto Products Inc. (Graeme Richard Hart, MBA)
• Original Assignee: Reynolds Presto Products Inc. (Graeme Richard Hart, MBA)
• Inventors: Bach, Gary Michael, Handlos, William Gregory, Wedin, Bryan Scott
• Primary Examiner(s): RISIC, ABIGAIL ANNE
• Application Number:
  US13/796,144
• Publication Number:
  US 20140270945A1
• Time in Patent Office: 1,001 Days
• Field of Search: 404/32, 404/34, 404/35, 404/36, 404/41, 411/403, 411/957
• US Class Current: 1/1
• CPC Class Codes: E01C 2201/12 vertically interlocking
• CPC Class Codes: E01C 5/005 Individual couplings or spacer elements for joining the prefabricated units E01C5/10 takes precedence
• CPC Class Codes: E01C 5/20 made of units of plastics, e.g. concrete with plastics, linoleumE01C5/18 takes precedence; of textiles made of synthetic fibres E01C5/008
• CPC Class Codes: E01C 9/086 made of concrete, wood, bitumen, rubber or synthetic material or a combination thereof

Abstract

A mat for use in a portable porous construction mat system includes tabs for providing connections to adjacent mats. A portable porous construction mat system includes a plurality of porous units connected together with fastener arrangements. A method of providing a construction mat system includes connecting together porous units with fastener arrangements. A kit includes at least first and second porous units and fastener arrangements.

Claims

1. A mat for use in a portable porous construction mat system;

the mat comprising;

(a) a porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter;

(b) the porous unit having a bottom mounting side and an opposite user side;

(i) the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

(ii) each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(c) a plurality of first and second tabs projecting from a remainder of the porous unit along the perimeter;

(i) each of the first tabs being recessed from the user side and even with the mounting side;

(ii) each of the second tabs being recessed from the mounting side and even with the user side;

(iii) each of the first and second tabs including an aperture therein constructed and arranged to allow releasable fastening thereto; and

wherein the porous unit includes a double wall structure framing the unit and extending between the outer perimeter and the matrix, the double wall structure including an aperture arrangement.

2. A mat according to claim 1 wherein:

(a) each of the apertures of the second tabs is an elongated non-circular opening.

3. A mat according to claim 1 wherein:

(a) each of the apertures of the first tabs includes a pair of opposing generally semi-circular surfaces defining a hole constructed to receive a nut.

4. A mat according to claim 1 wherein:

(a) the porous unit comprises a molded non-metal material.

5. A mat according to claim 1 wherein:

(a) the porous unit has a first pair of opposite sides and a second pair of opposite sides;

(b) at least two first tabs and at least two second tabs are along the perimeter of each of the sides of the first pair;

(c) at least one first tab and at least one second tab is along the perimeter of each of the sides of the second pair; and

(d) the first and second tabs alternate sequentially along each of the sides of the first pair and along each of the sides of the second pair.

6. A mat according to claim 5 wherein:

(a) the porous unit has a two-fold axis of symmetry about the axis.

7. A mat according to claim 1 wherein:

(a) the double wall structure is between the matrix and the plurality of first tabs and second tabs.

8. A mat according to claim 1 wherein:

(a) the aperture arrangement of the double wall structure is located between two walls of the double wall structure.

9. A mat according to claim 1 wherein:

(a) the double wall structure includes two parallel, spaced walls.

10. A mat according to claim 9 wherein:

(a) the aperture arrangement of the double wall structure is located between the two parallel walls.

11. A portable porous construction mat system comprising:

(a) a first porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter and having a bottom mounting side and an opposite user side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(i) a plurality of first and second tabs projecting from a remainder of the first porous unit along the perimeter;

each of the first tabs being recessed from the user side and even with the mounting side;

each of the second tabs being recessed from the mounting side and even with the user side; and

each of the first and second tabs including an aperture therein constructed and arranged to allow releasable fastening thereto;

(ii) the first porous unit including a double wall structure framing the first porous unit and extending between the outer perimeter and the matrix, the double wall structure including an aperture arrangement;

(b) a second porous unit laterally adjacent to and against the first porous unit;

the second porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter and having a bottom mounting side and an opposite user side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(i) a plurality of first and second tabs projecting from a remainder of the second porous unit along the perimeter;

each of the second porous unit first tabs being recessed from the user side and even with the mounting side;

each of the second porous unit second tabs being recessed from the mounting side and even with the user side; and

each of the second porous unit first and second tabs including an aperture therein constructed and arranged to allow releasable fastening thereto;

(ii) one of the second porous unit first tabs being oriented under one of the first porous unit second tab to define a first connection;

(iii) one of the second porous unit second tabs being oriented over one of the first porous unit first tabs to define a second connection;

(iv) the second porous unit including a double wall structure framing the second porous unit and extending between the outer perimeter and the matrix of the second porous unit, the double wall structure of the second porous unit including an aperture arrangement;

(c) the first connection including a fastener arrangement held within the apertures of the respective first and second tabs of the first connection; and

(d) the second connection including a fastener arrangement held within the apertures of the respective first and second tabs of the second connection.

12. A construction mat system according to claim 11 wherein:

(a) the fastener arrangements of each of the first and second connections each includes;

a split nut and a threaded bolt secured within the nut;

(b) the fastener-receiving apertures of each of the respective first tabs being shaped to receive one of the split nuts; and

(c) the fastener-receiving apertures of each of the respective second tabs being elongated and shaped to receive one of the bolts.

13. A construction mat system according to claim 12 wherein:

(a) the first and second porous units each comprises a molded non-metal material; and

(b) each of the split nut and bolt comprises a molded non-metal material.

14. A construction mat system according to claim 12 wherein:

(a) each of the bolts includes a socket.

15. A construction mat system according to claim 14 wherein:

(a) each of the bolts includes an outer polygon surface and an inner polygon surface lining the socket adapted to receive a torqueing tool.

16. A construction mat system according to claim 15 wherein:

(a) each of the bolts includes a through hole, smaller in outermost dimension than the socket, the through hole having an inner polygon surface lining at least a portion of the through hole adapted to receive a torqueing tool.

17. A construction mat system according to claim 12 wherein:

(a) each of the bolts includes a flange and a threaded shaft;

a plurality of projections extending from the flange in an axial direction toward the threaded shaft; and

(b) each of the second tabs has a flange-receiving axial surface adjacent to the apertures of the second tabs, the flange-receiving axial surface defining a tactile-inducing surface engaging the projections on the flange.

18. The construction mat system of claim 11 further comprising at least one ground anchor for placing through a first cell of one of the first and second porous units.

19. A construction mat system according to claim 11 further including:

(a) at least a third porous unit laterally adjacent to and against the first porous unit;

the third porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter and having a bottom mounting side and an opposite user side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(i) a plurality of first and second tabs projecting from a remainder of the third porous unit along the perimeter;

each of the third porous unit first tabs being recessed from the user side and even with the mounting side;

each of the third porous unit second tabs being recessed from the mounting side and even with the user side; and

each of the third porous unit first and second tabs including an aperture therein constructed and arranged to allow releasable fastening thereto;

(ii) one of the third porous unit first tabs being oriented under one of the first porous unit second tab to define a third connection attached by a fastener arrangement;

(iii) one of the third porous unit second tabs being oriented over one of the first porous unit first tabs to define a fourth connection attached by a fastener arrangement;

(iv) the third porous unit including a double wall structure framing the third porous unit and extending between the outer perimeter and the matrix of the third porous unit, the double wall structure of the third porous unit including an aperture arrangement; and

(b) the first, second, third, and fourth connections are all along a single side of the first porous unit.

20. A construction mat system according to claim 19 wherein:

(a) the second porous unit and the third porous unit are connected to each other at fifth and sixth connections along sides of the second and third porous units that are perpendicular to the single side of the first porous unit;

(i) the fifth connection includes one of the third porous unit first tabs being oriented under one of the second porous unit second tab and attached by a fastener arrangement; and

(iii) the sixth connecting includes one of the third porous unit second tabs being oriented over one of the second porous unit first tabs and attached by a fastener arrangement.

21. A construction mat system according to claim 20 wherein:

(a) the first and second tabs of each of the first porous unit, second porous unit, and third porous unit alternate sequentially.

28. The construction mat system of claim 18 wherein the at least one ground anchor includes a rod having an end for ground insertion and an opposite end having a washer thereon, the washer to be oriented against an inner axial surface of the walls defining the first cell.

22. A method of providing a construction mat system;

the method comprising;

(a) providing a first porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter and having a bottom mounting side and an opposite user side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(i) a plurality of first and second tabs projecting from a remainder of the first porous unit along the perimeter;

each of the first tabs being recessed from the user side and even with the mounting side;

each of the second tabs being recessed from the mounting side and even with the user side; and

each of the first and second tabs including a aperture therein constructed and arranged to allow releasable fastening thereto;

(ii) the first porous unit including a double wall structure framing the first porous unit and extending between the outer perimeter and the matrix, the double wall structure including an aperture arrangement;

(b) providing a second porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter and having a bottom mounting side and an opposite user side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(i) a plurality of first and second tabs projecting from a remainder of the second porous unit along the perimeter;

each of the second porous unit first tabs being recessed from the user side and even with the mounting side;

each of the second porous unit second tabs being recessed from the mounting side and even with the user side; and

each of the second porous unit first and second tabs including an aperture therein constructed and arranged to allow releasable fastening thereto;

(ii) the second porous unit including a double wall structure framing the second porous unit and extending between the outer perimeter and the matrix of the second porous unit, the double wall structure including an aperture arrangement;

(c) orienting the second porous unit laterally adjacent to and against the first porous unit and so that;

(i) one of the second porous unit first tabs is oriented under one of the first porous unit second tab to define a first connection; and

(ii) one of the second porous unit second tabs being oriented over one of the first porous unit first tabs to define a second connection;

(d) putting a fastener arrangement within the apertures of the respective first and second tabs of the first connection; and

(e) putting a fastener arrangement within the apertures of the respective first and second tabs of the second connection.

26. The method of claim 22 further comprising inserting a ground anchor through a first cell of one of the first and second porous units.

27. The method of claim 26 wherein the step of inserting a ground anchor includes inserting an end of a rod into the ground and pressing a washer secured to the ground anchor against an inner axial surface of walls defining the first cell.

23. A kit comprising:

(a) a first porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter and having a bottom mounting side and an opposite user side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(i) a plurality of first and second tabs projecting from a remainder of the first porous unit along the perimeter;

each of the first tabs being recessed from the user side and even with the mounting side;

each of the second tabs being recessed from the mounting side and even with the user side; and

each of the first and second tabs including an aperture therein constructed and arranged to allow releasable fastening thereto;

(ii) the first porous unit including a double wall structure framing the first porous unit and extending between the outer perimeter and the matrix, the double wall structure including an aperture arrangement;

(b) a second porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter and having a bottom mounting side and an opposite user side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(i) a plurality of first and second tabs projecting from a remainder of the second porous unit along the perimeter;

each of the second porous unit first tabs being recessed from the user side and even with the mounting side;

each of the second porous unit second tabs being recessed from the mounting side and even with the user side; and

each of the second porous unit first and second tabs including an aperture therein constructed and arranged to allow releasable fastening thereto;

(ii) the second porous unit being constructed and arranged to be positioned laterally adjacent to and against the first porous unit and so that;

(A) one of the second porous unit first tabs can be oriented under one of the first porous unit second tab to define a first connection; and

(B) one of the second porous unit second tabs can be oriented over one of the first porous unit first tabs to define a second connection;

(iii) the second porous unit including a double wall structure framing the second porous unit and extending between the outer perimeter and the matrix of the second porous unit, the double wall structure including an aperture arrangement; and

(c) a plurality of fastener arrangements sized and shaped to fit within the apertures of the respective first and second tabs of the first connection and within the apertures of the respective first and second tabs of the second connection.

24. The kit of claim 23 further comprising at least one ground anchor for placing through a first cell of one of the first and second porous units.

25. The kit of claim 24 wherein the at least one ground anchor includes a rod having an end for ground insertion and an opposite end having a washer thereon, the washer to be oriented against an inner axial surface of the walls defining the first cell.

29. A portable construction mat system comprising:

(a) a mat comprising a porous unit having an outer perimeter and a matrix of intersecting walls defining a plurality of cells within the perimeter;

the cells having a through hole therethrough;

(i) the porous unit having a bottom mounting side facing ground, and a user side opposite the mounting side;

the matrix of intersecting walls defining the plurality of cells opening opposite the bottom mounting side;

each of the cells in the plurality of cells including a drainage aperture arrangement constructed to permit drainage through the bottom mounting side;

(ii) a plurality of first and second tabs projecting from the porous unit along the perimeter, each of the first and second tabs including an aperture therein to allow releasable fastening thereto;

(iii) the porous unit including a double wall structure framing the porous unit and extending between the outer perimeter and the matrix, the double wall structure including an aperture arrangement; and

(b) a ground anchor constructed and arranged to be oriented through a first one of the cells to secure the mat to the ground.

30. The construction mat system according to claim 29 wherein:

(a) the ground anchor comprises a solid rod, said rod having an insertion end for insertion in the ground and an opposite end having a washer secured thereto;

(i) the washer being configured and adapted to lie atop the mounting side of the first one of the cells when the rod is inserted through the through hole into the ground.

31. The construction mat system of claim 29 wherein the ground anchor includes:

(a) a foot to be embedded into the ground;

(b) a cable attached to the foot and to extend from the foot and through the first one of the cells;

(c) a washer to be oriented against an inner axial surface of the walls defining the first one of the cells; and

(d) a cable stop to be secured to the cable and oriented against the washer.

32. The construction mat system of claim 29 wherein:

(a) each of the first tabs is recessed from the user side and even with the mounting side; and

(b) each of the second tabs is recessed from the mounting side and even with the user side.