Lightweight panel mat with interlocking elements

Abstract

A lightweight universal panel mat made of plastic or elastomeric material and having a first section that provides a relatively flat, textured or structured top surface to facilitate movement over the upper surface and a second section having geometry that includes a plurality of cells having top surfaces that support the first section. The panel mats also have first, second, third and fourth sides that are configured with tabular extensions or openings, slots or recesses configured and dimensioned to be able to receive the tabular extensions. At least some of the tabs and slots are configured to facilitate snap-locking. Thus, a plurality of similarly configured panel mats can be connected by interlocking of the tabs of one mat into the openings, slots or recesses of one or more adjacent similarly configured mats.

What is claimed is: 
     
         1 . A lightweight universal panel mat made of plastic or elastomeric material and designed to be interlocked with additional panel mats of similar configurations, comprising:
 a first section having an upper surface that forms a top surface of the panel mat and is relatively flat, textured or structured to facilitate movement over the upper surface;   a second section having geometry that includes a plurality of cells that are open or wherein some or all of the cells have top surfaces with the geometry supporting the first section and providing a plurality of open lower surfaces;   first, second, third and fourth sides wherein:   the first side is configured with a plurality of tabular extensions;   the second side is located adjacent the first side and is configured with a plurality of tabular extensions;   the third side is located opposite the first side and is configured with openings that are unobstructed and configured, dimensioned and arranged to receive therein the plurality of first side tabular extensions; and   the fourth side is located opposite the second side and is configured with slots or recesses that are configured, dimensioned and arranged to receive therein the plurality of second side tabular extensions,   wherein the tabular extensions on the first side, the second side or on both sides include either a protruding bump or depression, and the openings, slots or recesses of the third or fourth sides have an upper surface that includes a corresponding depression or protruding bump that enables the respective tabular extensions to be snap-lockingly engaged together;   wherein the tabular extensions and openings, slots or recesses are formed on the first section, the second sections, or partially on each section;   wherein the upper surface of the first section is generally rectangular of length L and width W where L and W each may be any value between 1 foot and 12 feet; and   wherein the first and second sections are welded or bonded together to form a unitary panel mat.   
     
     
         2 . The panel mat of  claim 1 , wherein the first and second sections are part of an integral component that is molded together, or the tabular extensions, openings and slots or recesses are milled or routered in a solid plastic or elastomeric component. 
     
     
         3 . The panel mat of  claim 1  further comprising metal wire, bar or plate reinforcement located within the second section or between the first and second sections. 
     
     
         4 . The panel mat of  claim 1  wherein the first side is configured with at least three tabular extensions; the second side is configured with at least three tabular extensions each having a depression on an upper surface; the third side is located opposite the first side and is configured with openings that are unobstructed and configured, dimensioned and arranged to receive therein the first plurality of tabular extensions; and the fourth side is located opposite the second side and is configured with spaced slots or recesses that are configured, dimensioned and arranged to receive the second tabular extensions therein, wherein the slots or recesses each have an upper surface that includes a protruding bump configured and dimensioned to at least partially engage a depression of the second tabular extension to provide snap-locking of the bumps into the depressions; wherein the tabular extensions and openings, slots or recesses are formed partially on each section. 
     
     
         5 . The panel mat of  claim 1 , wherein the first side is configured with at least three tabular extensions, each having a protruding bump on an upper portion thereof; the second side is configured with at least three tabular extensions each having a protruding bump on an upper portion thereof; the third side is located opposite the first side and is configured with openings that are unobstructed and configured, dimensioned and arranged to receive therein the plurality of first side tabular extensions, with the openings having an upper surface that includes a depression therein that is configured and dimensioned to receive a protruding bump of the first side tabular extensions; and the fourth side is located opposite the second side and is configured with spaced slots or recesses that are configured, dimensioned and arranged to receive the plurality of second side tabular extensions therein, wherein the slots or recesses each have an upper surface that includes a depression therein that is configured and dimensioned to receive a protruding bump of the second side tabular extensions. 
     
     
         6 . The panel mat of  claim 1 , wherein the first side is configured with at least two tabular extensions, each having at least two protruding bumps on an upper portion thereof; the second side is configured with at least two tabular extensions each having at least two protruding bumps on an upper portion thereof; the third side is located opposite the first side and is configured with openings that are unobstructed and configured, dimensioned and arranged to receive therein the first side tabular extensions, with the openings having an upper surface that includes at least two depressions therein that are configured and dimensioned to receive the protruding bumps of the first side tabular extensions; and the fourth side is located opposite the second side and is configured with spaced slots or recesses that are configured, dimensioned and arranged to receive therein the second side tabular extensions, wherein the slots or recesses each have an upper surface that includes at least two depressions therein that are configured and dimensioned to receive the protruding bumps of the second side tabular extensions. 
     
     
         7 . The panel mat of  claim 1 , wherein each spaced slot or recess of the fourth side of the panel has a lower surface that includes a bridge or rail structure forming a lower entry of the slot or recess for initial contact with the lower surface of a second side tabular extension that is to be received therein. 
     
     
         8 . The panel mat of  claim 7 , wherein the second side tabular extensions are configured with an angled bottom portion that allows the forward end of the second side tabular extensions to move away from the upper portion of the slot or recess to allow detachment of the second side tabular members from the slots or recesses. 
     
     
         9 . The panel mat of  claim 7 , wherein the protruded bumps and depressions are circular or oval in configuration and the depression has a slightly larger circumference than the protruding bumps, and wherein some or all of the openings, slots or recesses includes either a cut out end portion, an open bottom, or an opening adjacent and behind the bridge or rail structure to allow mud, dirt or water to exit the opening, slot or recess and to facilitate entry of the tabular members therein. 
     
     
         10 . The panel mat of  claim 1 , wherein the upper surface of the first section is a structured surface that includes a raised pattern of spaced elements in a pattern, or channels that allow water to drain from the mat, with the channels molded therein or formed between a plurality of raised islands spaced by and closely arranged, with the islands having a polygonal, circular, or elliptical shape; and the lower surface of the second section is structured and includes openings or channels to provide a secure footing when the panel mat is placed on wet or muddy ground. 
     
     
         11 . The panel mat of  claim 10 , wherein the structured lower surface of the second section includes a plurality of cells having a polygonal, circular or elliptical shape forming bottom openings in the lower surface, wherein some or all of the cells have a top surface that extends to and supports the upper surface of the first section to strengthen the panel mat, and wherein some or all of the cells have a flat bottom surface. 
     
     
         12 . The panel mat of  claim 1  further comprising a third section located below and welded, molded, bonded, joined or sealed together to the second section, the third section configured and dimensioned to close off the plurality of bottom openings of the cells or when applicable to receive flat bottom surfaces of some or all of the cells, and form a bottom surface for the panel mat that is relatively flat, textured or structured with the panel mat being able to withstand point loads of between 300 and 500 psi and spread loadings of 40,000 to 50,000 pounds per square foot. 
     
     
         13 . The panel mat of  claim 12 , wherein the upper surface of the first section is relatively flat and the third section is a relatively flat plate, so that the bottom surface of the third section is also relatively flat. 
     
     
         14 . The panel mat of  claim 1 , which is either rectangular wherein W=2 L or square wherein W=L, and wherein L is preferably 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, or 8 feet and W is preferably 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 14 or 16, and when square has two or three each of the first tabular members, second tabular members, openings and slots or recesses or when rectangular has four or six first tabular members, four or six openings, two or three second tabular members and two or three slots or recesses. 
     
     
         15 . The panel mat of  claim 1  wherein the first section at the third and fourth sides of the panel mat is configured to include a lip portion that covers edges of the respective first and second sides of adjacently connected similarly configured panel mats and provides channels that assist in allowing drainage of water from the top surface of the panel mat. 
     
     
         16 . The panel mat of  claim 1  wherein each side includes multiple tabular members and the multiple openings with between 2 and 8 tabular members and openings being provided on each side of the mat. 
     
     
         17 . The panel mat of  claim 1  further comprising one, two, three or four lifting elements that are affixed to the mat to allow lifting and installation or reclamation of the mat, with the lifting element including (a) a ring or U or D shaped member that is movable between first and second positions, wherein the first position is one where the member resides below the surface of the mat and the second position is an operative position where the ring or U or D shaped member is exposed for engagement with lifting equipment, and (b) a structure that secures the ring or U or D shaped member to the mat. 
     
     
         18 . A temporary support surface, deck, walkway or roadway comprising a plurality of connected panel mats according to  claim 1  with the first side tabular extensions of a first mat engaging the third side openings of one or more adjacent similarly configured panel mats and with the second side tubular extensions of the first mat engaging the slots or recesses of the fourth side of one or more adjacent similarly configured panel mats. 
     
     
         19 . The invention of  claim 18  wherein the mats can be joined together in a manner that provides a staggered configuration that avoids generating long straight seams between rows of joined mats. 
     
     
         20 . The temporary invention of  claim 19  wherein the tabular members and openings are arranged on the sides of the mat in a configuration that allows the mats to be joined in an offset manner so that the ends of the mat are not aligned when installed.