Segmented panel mat

Abstract

A lightweight universal panel mat made of plastic or elastomeric material and having a first section that provides a relatively flat surface and provides a frame for receiving a plurality of removable panels that form a working surface within the panel mat. The panel mat includes a second section having geometry that supports the first section. The mats also include first, second, third and fourth sides forming a perimeter of the mat, wherein the first and second sides include upper structures having a sloped lower surface and the third and fourth sides include lower structures having sloped upper surfaces. The sloped surfaces are configured to allow for overlapping with sloped surfaces other like mats for interlocking therewith while forming a generally flat continuous top and bottom surface of the overlapped mats. The mats may be interlocked by a fastening member which fits in aligned openings of the adjacent mats for connection therewith.

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 peripheral top surface of the panel mat and is relatively flat and provides a receptacle that is adapted to receive one or more removeable panels;   a second section having geometry that supports the first section;   first, second, third and fourth sides forming a perimeter of the mat, wherein:   the first and second sides are adjacent and each includes an upper structure that has an upper surface that extends the top surface of the mat and a lower surface that slopes downwardly towards the bottom surface of the mat;   the third and fourth sides are adjacent and each includes a lower structure that has a lower surface that extends the bottom surface of the mat and an upper surface that slopes upwardly towards the top surface of the mat;   each upper and lower structure includes at least one opening passing therethrough;   wherein the downwardly sloped lower surface of the upper structure and the upwardly sloped upper surface of the lower structure are configured to allow for overlapping with respective lower and upper structures of other like mats when placed adjacent thereto for joining therewith by which the overlapped upper and lower structures form a generally flat continuous top and bottom surface of the overlapped mats; and   wherein the first and second sections are welded or bonded together to form a unitary panel mat.   
     
     
         2 . The mat of  claim 1  further comprising one or a plurality of removable panels received in the receptacle wherein the panels have upper surfaces that conform to the top surface of the mat and the first and second sections form a frame around a plurality of the removable panels. 
     
     
         3 . The mat of  claim 2 , wherein the first section comprises four sections that are attached together and form a frame that shapes sidewalls for the receptacle. 
     
     
         4 . The mat of  claim 3 , wherein the panels are locked to each other to thereby form a working surface and the panels are removable from the working structure to be replaced if damaged. 
     
     
         5 . The mat of  claim 3 , wherein the sidewalls of the receptacle include protrusions or recesses for joining with mating recesses or protrusions of the removable panels so that the panels can be locked to and secured to the sidewalls of the receptacle or to each other. 
     
     
         6 . The mat of  claim 2 , wherein the panels have a uniform configuration to facilitate removal and replacement of damaged panels. 
     
     
         7 . The mat of  claim 2 , wherein the panels are removable panels of at least two different types that interengage. 
     
     
         8 . The mat of  claim 2 , wherein removable panels have rectangular or square shape and a plurality of apertures that are configured to align with adjacent similarly configured panels. 
     
     
         9 . The mat of  claim 8 , wherein the one or more panels comprises an array of removable panels wherein each removable panel comprises a cam that connects to an adjacent removable panel. 
     
     
         10 . The mat of  claim 2 , wherein each removable panel comprises a cam and a hook that engages a cam of an adjacent panel when locked. 
     
     
         11 . The mat of  claim 2 , wherein each removable panel comprises a protrusion and recess that mates with a recess and protrusion of an adjacent panel when locked. 
     
     
         12 . A support surface, deck, walkway or roadway comprising the mat of  claim 1  that further includes an array of removable panels locked to each other and positioned in the receptacle of the mat. 
     
     
         13 . The invention of  claim 12 , wherein the second section includes cells under the first section in an area that forms a frame for the removable panels. 
     
     
         14 . A support surface, deck, walkway or roadway comprising a plurality of the mats of  claim 12  that are attached each other wherein the panels are removable when damaged and are replaced by a like configured the service panel to extend life of the support surface, deck, walkway or roadway. 
     
     
         15 . A method of extending the service life of a support surface, deck, walkway or roadway which comprises:
 constructing the support surface, deck, walkway or roadway with a plurality of mats according to  claim 2 ; and   replacing any of the removable panels that become damaged to allow continued use of the support surface, deck, walkway or roadway without having to replace an entire mat.   
     
     
         17 . A method of extending the service life of a support surface, deck, walkway or roadway which comprises:
 constructing the support surface, deck, walkway or roadway with a mat according to  claim 2 ; and   replacing any of the removable panels that become damaged to allow continued use of the support surface, deck, walkway or roadway without having to replace an entire mat.