MODULAR OVERLAPPING MATTRESS SYSTEMS

Abstract

The present invention describes mattresses and methods associated therewith. The mattresses include a main body defined by a plurality of side walls and two opposing outer surface walls. The main body includes a pattern of internal walls that define internal voids within the main body. At least one main structural support rib is arranged within the main body and extends between the two surface walls and from one plurality of side walls to another. At least one main structural support rib traverses the internal voids defined by the pattern of the internal walls.

Description

MODULAR OVERLAPPING MATTRESS SYSTEMS CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Application No. 16 / 890,510, filed on June 2, 2020, which is incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION When operating heavy equipment, it is useful to provide a firm, stable, and continuous support surface to support that equipment or, alternatively, a stable working surface and / or a support surface on which vehicles can be transported. Such support surfaces can provide support for equipment, vehicles, and personnel involved in the work processes and can be configured to withstand severe weather and other harsh environmental impacts. The components of the support surface can be installed quickly and easily and can be easily removed and reused. Historically, wooden beams or planks have been used to construct temporary roads and equipment support surfaces in remote or undeveloped areas where the ground lacks sufficient stability to adequately support trucks and other heavy equipment. These planks were typically placed end-to-end, or side-by-side, to form a continuous load-bearing surface. While individual wooden planks or boards have been used to construct support surfaces for some time, this method of constructing planks and other load-bearing surfaces has some significant disadvantages. A variety of mat systems have also been developed for constructing temporary walkways and bearing surfaces. These mat systems typically utilize multi-layered, prefabricated mats that can be installed in various configurations to create walkways or other bearing surfaces. Constructed from multiple individual boards or planks joined together in various configurations, these mats are generally interconnected or interlocked to form a continuous or near-continuous bearing surface. It can be advantageous to have improved mat systems for providing and creating temporary walkways and / or bearing surfaces. BRIEF DESCRIPTION OF THE INVENTION In accordance with certain modalities, mattresses are provided and described. The mattresses include a main body defined by a plurality of side walls and two opposing outer surface walls. The main body includes a pattern of internal walls that define voids within the main body. At least one main structural support rib is arranged within the main body and extends between the two surface walls and from one of the plurality of side walls to another of the plurality of side walls. At least one main structural support rib traverses the internal voids defined by the pattern of the internal walls. In addition to one or more of the features described above, or as an alternative, mattress modalities may include at least one main structural support rib dividing the main body into at least two sections. In addition to one or more of the features described above, or alternatively, the mat modalities may include at least one secondary structural support rib that is arranged within one of at least two sections defined by at least one primary structural rib support, wherein at least one secondary structural support rib passes through the internal gaps defined by the pattern of the internal walls. In addition to one or more of the features described above, or as an alternative, the mattress modalities may include at least one secondary structural support rib that divides the respective section into two or more subsections. In addition to one or more of the features described above, or alternatively, mattress modalities may include at least one secondary structural support rib extending from at least one of the side walls to at least one of the first structural support ribs. ni? ίη / ζζηζ / E / γίΛΐ In addition to one or more of the features described above, or alternatively, mat modalities may include at least one secondary structural support rib that has a length that is less than the length of at least one primary structural support rib. In addition to one or more of the features described above, or alternatively, mattress modalities may include at least one secondary structural support rib having a material thickness that is less than the material thickness of at least one primary structural support rib. In addition to one or more of the features described above, or alternatively, the mat configurations may include that at least one main structural support rib is configured to allow the mat to be separated into a plurality of sub-mattresses. In addition to one or more of the features described above, or as an alternative, the mat configurations may include that each submat is configured to secure or connect to another of the plurality of submats or another mat. In addition to one or more of the features described above, or as an alternative, mat modalities may include a defined hook pocket along at least one main structural support rib, the hook pocket configured to allow a tool to be attached to a sub-mat. In addition to one or more of the features described above, or alternatively, mattress modalities may include a rim structure that extends outward from the plurality of side walls around a periphery of the main body. In addition to one or more of the features described above, or as an alternative, the mat configurations may include that at least one main structural support rib is configured to allow the mat to be separated into a plurality of sub-mattresses and where each of the sub-mattresses includes a portion of the main structure. ni? ίη / ζζηζ / E / γίΛΐ In addition to one or more of the features described above, or alternatively, the mattress modalities may include that the internal gaps of the inner support structure define at least 45% of the inner volume of the main body. In accordance with certain modalities, the methods are described. The methods include cutting a mattress to form a first sub-mattress and a second sub-mattress. The mattress includes a main body defined by a plurality of side walls and two outer surface walls. The main body includes a first main structural support rib disposed within the main body and extending between the two surface walls and from one of the plurality of side walls to another of the plurality of side walls. The first main structural support rib divides the mattress into two sections, where the two sections form the first sub-mattress and the second sub-mattress. In addition to one or more of the features described above, or as an alternative, the methods may include securing the first submat to the second submat to form a support surface. In addition to one or more of the features described above, or alternatively, the modalities of the methods may include the mattress comprising a second main structural support rib extending in a direction generally perpendicular to the first main structural support rib, and wherein the first main structural support rib and the second main structural support rib define four sections configured to be divided into four sub-mattresses. In addition to one or more of the features described above, or alternatively, the methods may include cutting the mattress along the first major structural support rib and the second major structural support rib to form a first sub-mattress, a second sub-mattress, a third sub-mattress, and a fourth sub-mattress. In addition to one or more of the features described above, or alternatively, the modalities of the methods may include connecting at least one of the first sub-mattresses, the second sub-mattress, the third sub-mattress and the fourth sub-mattress to one or more complete mats to form a support surface. In addition to one or more of the features described above, or alternatively, the methods may include joining at least one of the first submattress and the second submattress with a full mattress to form a support surface. In addition to one or more of the features described above, or as an alternative, the modalities of the methods may include that the cut is made along the first major structural support rib, so that the first submat and the second submat each have a portion of the first major structural support rib after being cut and separated from each other. The above features and elements may be combined in various non-exclusive combinations unless expressly stated otherwise. These features and elements, as well as their operation, will become more apparent in light of the following description and accompanying drawings. It should be understood, however, that the following description and drawings are intended to be illustrative and explanatory in nature and not limiting. BRIEF DESCRIPTION OF THE DRAWINGS The features of the invention are specifically noted and clearly claimed at the end of this specification. The foregoing features and other advantages of the present description are evident from the following detailed description taken in conjunction with the accompanying drawings, in which similar elements may be numbered in the same manner, and where: Figure 1A is a schematic illustration of a mat that may incorporate modalities of the present description; Figure 1B is a cross-sectional illustration of the mat of Fig. 1A viewed along line BB of Fig. 1A; ni? ίη / ζζηζ / E / γίΛΐ Figure 2 is a symmetrical illustration of a mattress that may incorporate features of the present disclosure, with a partial cutaway illustrating an internal structure of the mattress; Figure 3 is a schematic illustration of a set of two mats joined together that may incorporate modalities of the present disclosure; Figure 4A is an illustration of a partial top-down cross-section of a mat that may incorporate features of this disclosure; Figure 4B is a side elevation view of the mat in Fig. 4A illustrating line of sight AA for the illustration in Fig. 4A; Figure 5 is a schematic illustration of a mat in accordance with one modality of this disclosure; Figure 6 is a schematic illustration of a mat in accordance with one modality of this disclosure; Figure 7 is a schematic illustration of a mat in accordance with one modality of this disclosure; Figure 8 is a schematic illustration of a mat in accordance with one modality of this disclosure; Figure 9 is a schematic illustration of a mat in accordance with one modality of this disclosure; Figure 10 is a schematic illustration of a mat in accordance with one modality of this disclosure; Figure 11A is a schematic illustration of one aspect of a mat in accordance with one modality of the present description; ni? ίη / ζζηζ / E / γίΛΐ Figure 11B is a schematic illustration of the mat of Fig. 11A, with parts of the mat separated in accordance with a modality of this disclosure; Figure 12A is a schematic illustration of a mat in accordance with one modality of the present description; Figure 12B is a schematic illustration of a separation of sub-mattress assemblies from the mat of FIG. 12A in accordance with a modality of this disclosure; Figure 12C is a schematic illustration of a separation of sub-mattress assemblies from the mat of FIG. 12A in accordance with one embodiment of the present description; Figure 12D is a schematic illustration of a separation of the submats from the mat of FIG. 12A; Figure 13 is a schematic illustration of a set of mats having mats, sets of sub-mats and sub-mats in accordance with one embodiment of the present description; Figure 14A is a schematic illustration of a mat in accordance with one modality of this disclosure; Figure 14B is an enlarged illustration of a feature of the mat in Fig. 14A; and Figure 14C is an alternative enlarged illustration of the mat feature in Figure 14A. DETAILED DESCRIPTION OF THE INVENTION The features and advantages of the present description, and the additional features and benefits, will be readily apparent to those skilled in the art upon consideration of the following detailed description and the accompanying figures. It should be understood that the description of this invention and the associated drawings, which are illustrative embodiments, are not intended to limit the claims of this patent or any patent or patent application claiming priority thereof. Rather, the intention is to cover all modifications, equivalents, and / or alternatives appreciated by those skilled in the art. Many changes can be made to the particular embodiments and details described herein without departing from the scope of this disclosure. With reference to Figures 1A-1B, schematic illustrations of a mat 100 are shown, which may incorporate features of this disclosure. The mat 100 is configured to be a stand-alone structure or can be joined with one or more additional similar mats to define a support surface of a desired shape and / or size. The mat 100 is configured to provide a working or support surface on which vehicles can operate, equipment can be installed and operated, etc. Figure 1A illustrates a top-down plan view of the mat 100, and Figure 1B is a cross-sectional illustration of the mat 100 viewed along line BB in Figure 1A. The mat 100 includes a main body 102, a first edge structure 104, and a second edge structure 106.As illustrated, the main body 102 has a main body thickness To, and each edge structure 104, 106 has a respective edge structure thickness T1, T2. Because the mat 100 is configured to be able to join with other similar mats, the thicknesses Ti, T2 of the edge structure can each be, for example, equal to half the thickness To of the main body. In some configurations, the thicknesses Ti, T2 of the edge structure can each be, for example, substantially equal to the thickness To of the main body. Each of the edge structures 104, 106 extends outward from the main body 102. In one or more configurations, each of the edge structures 104, 106 may extend from approximately half the perimeter of the main body 102. Each of the edge structures 104, 106 includes, as shown, respective pinholes 108, 110 configured to receive a locking pin (not shown) for joining two mats arranged side by side with aligned pinholes. Such locking pins can be used to ensure a secure and continuous surface defined by the joined mats. ni? ίη / ζζηζ / E / γίΛΐ Therefore, when two mats similar to the one shown in FIGS. 1A-1B are joined by one or more locking pins installed through the aligned pin openings 108, 110, a first border structure 104 on one mat 100 can overlap a second border structure 106 of the adjacent mat, with the first and second border structures joined having the two mats having a thickness equal to the main body thickness. Although shown and described as distinct components or features, the main body 102, the first edge structure 104, and the second edge structure 106 may be formed from a single continuous material (e.g., a uniform body), from two panels or portions joined together, or from three or more panels or portions joined together. By way of non-limiting example, the edge structures 104 and 106 may be separately joined, bonded, or otherwise secured to the main body 102. As another example, the main body 102 may be formed from two panels, each having one of the edge structures 104 and 106, and the two panels may be joined, bonded, or otherwise secured. Accordingly, the illustrative configuration shown and described with respect to Figures 1A–1B is not intended to be limiting but is provided for illustrative and explanatory purposes only. Returning now to Fig. 2, a schematic illustration of a Mat 200 is shown, which may incorporate embodiments of the present disclosure. Mat 200 may have a construction similar to that shown and described with respect to Mat 100 in Figs. 1A-1B. For example, Mat 200 may be made of a rigid material capable of withstanding compressive forces, such as weights or other loads, placed upon it. For example, Mat 200 may be constructed of a thermoplastic polymer material, such as polyethylene or alcatene. In one or more embodiments, Mat 200 may be made of high-density polyethylene, medium-density polyethylene, low-density polyethylene, or mixtures thereof. The mattress 200 includes a main body 202, a first edge structure 204, and a second edge structure 206, with the first and second edge structures 204, 206 extending from the main body 202 as illustrated above. As described above, the first and second edge structures 204, 206 extend or cantilever from portions of the outer surfaces of the main body 202. ni? ίη / ζζηζ / E / γίΛΐ Each of the edge structures 204, 206 includes respective pin openings 210, 212 to allow the connection and joining of two adjacent mats. The edge structures 204, 206 may also include respective rib structures 214 (shown only for the second edge structure 206 in this illustration) which may be aligned (e.g., top to bottom) or misaligned with a similar rib structure of an adjacent mat when two mats are arranged side by side and connected by locking pins. The main body 202 includes an internal support structure 208. The internal support structure 208 is configured to provide strength to the mesh 200, such as crush resistance. The internal support structure 208 can be a combination of voids and ribs that are encapsulated by the outer surfaces of the main body 202. Therefore, the internal support structure 208 can allow for a weight reduction compared to a solid-body structured mattress. The internal support structure 208 of the main body 202 can, in some configurations, be an interconnected network structure, such as a honeycomb or other geometric pattern, which may be a repeating pattern of the same geometric shape. As noted, the internal support structure 208 defines voids within the main body 202. For example, in a non-limiting example, the gaps in the inner support structure 208 can define at least 30% of the inner volume of the main body 202 (i.e., the main body 202 has a 30% internal gap in this example). The size and shape of the repeating pattern of the interconnected network structure can be changed or modified to change the number of gaps in the main body 202. For example, the gaps can define at least 45%, at least 50%, at least 60%, at least 70%, and / or some other amount of the interior volume of the mat 200 that will be appreciated by those with ordinary knowledge of the art, depending on the application and use of the mat 200. In configurations where the interior support structure 208 is a repeating geometric pattern, each gap in the interior support structure 208 can be between approximately 2.5 inches (6.35 cm) and approximately 5 inches (12.7 cm) in its largest dimension. ni? in / zz / E / yLi Returning now to Fig. 3, a schematic illustration is shown of a mat assembly 300 that may incorporate features of the present disclosure. The mat assembly 300 includes, in this illustration, two joined mats 302, 304. The mat assembly 300 is a modular mat system incorporating the mats as shown and described above. A first mat 302 of the mat assembly 300 has a respective main body 306 with edge structures 308, 310 extending therefrom. A second mat 304 of the mat assembly 300 has a respective main body 312 with edge structures 314, 316 extending therefrom. The two mats 302, 304 are joined in overlapping edge structures 308, 316. Locking pins 318 are inserted through the aligned pin openings 320 of the two overlapping edge structures 308, 316.As such, a joined and overlapping part 322 is defined by a portion of the first mattress 302 and a portion of the second mattress 304. The overlapping part 322 has the same overall thickness as the main body 306 of the first mattress 302 and the main body 312 of the second mattress 304. Each of the main bodies 306, 312 may have an internal support structure including hollows and ribs that define the hollows, to provide strength and rigidity while allowing for a relatively lightweight overall structure. Figure 3 illustrates the modular nature of the mats described herein. Several mats can be placed together to define a continuous, connected support surface. Such a support surface can be used to provide a firm and secure surface or floor on which to transport vehicles, operate equipment, etc. Although Figure 3 illustrates only two mats placed side by side, those skilled in the art will appreciate that any number of mats can be interlocked and arranged to form a desired support surface with a geometry based on the arrangement of the mats. Turning now to Figs. 4A and 4B, schematic illustrations of a mat 400 are shown. Fig. 4A is a partial cutaway illustrating the interior structure of the mat 400 as seen along line AA in Fig. 4B, which is a side elevation view of the mat 400. In this configuration and illustration, the mat 400 has a main body 402, a first edge structure 404, and a second edge structure 406. The main body 402 defines a partially hollow interior that includes an internal wall pattern 408 and internal voids 410. ni? ίη / ζζηζ / E / γίΛΐ The pattern of the internal walls 408, in this illustrative configuration, is a geometric pattern substantially in the form of a hexagon, octagon, decagon, circle, or other shape or pattern. The internal voids 410 may correspond in shape to the geometric pattern and may be polygonal or circular. The pattern of the internal walls 408 is arranged within the interior of the main body 402. The interior of the main body 402 is bounded by side walls 410 and outer surface walls 411, 413. The pattern of the internal walls 408 may be formed by ribs, walls, fins, or similar structures that define the internal voids 410 and extend between a first wall surface 411 and a second wall surface 413. The pattern defined by the pattern of the internal walls 408 is contained within the side walls 410 of the main body 402. Returning now to Fig. 5, a mat 500 is shown in accordance with one embodiment of this disclosure. The mat 500 may be similar to that shown and described above, with a main body 502 defined by side walls 504 and surface walls (not shown in this view). In this view (similar to Fig. 4A), a border structure 506 extends outward from the side walls 504 along a perimeter or periphery thereof. Within the main body 502, there is a pattern of internal walls 508 that defines internal voids 510. As shown, the mat 500 further includes main structural support ribs 512 that traverse the pattern of the internal walls 508 and extend through the internal voids 510 defined by the pattern of the internal walls 508. The main structural support ribs 512 define sections 514 of the main body 502, which are defined between portions of the main structural support ribs 512 and the side walls 504 of the main body 502. Each section 514 contains a portion of the pattern of internal walls 508 and associated internal voids 510. It is noted that a portion or number of the internal voids 510 defined by the pattern of internal walls 508 are bisected or divided by the main structural support ribs 512.As a result, the main structural support ribs 512 partly define internal side walls that define sections 514 bounded by the main structural support ribs 512 and the side walls 504 of the main body 502. In some forms, and as illustrated, the geometric shape of sections 514, defined by the main structural support ribs 512 and the side walls ni? ίη / ζζηζ / E / γίΛΐ 504, have a different geometric shape than the internal voids 510 defined by the pattern of the internal walls 508. Also, in some non-limiting embodiments, the main structural support ribs 512 are configured to traverse the main body 502 from one side wall 504 to another side wall 504 (as shown in FIG. 5, extending between opposite side walls 504). For example, the main structural support ribs 512 may extend continuously from one side wall 504 to the other side wall 504. The main structural support ribs 512 are configured to increase the strength or durability of the mattress 500 compared to a mattress without such main structural support ribs 512.For example, the 512 main structural support ribs can increase bending strength and increase crushing load compared to mattresses that have an identical structure but without the 512 main structural support ribs. The main structural support ribs 512 may have a different thickness or dimensions than the thickness or dimensions of the internal wall pattern material 508. For example, the main structural support ribs 512 may have a greater material thickness than the internal wall pattern material 508. Returning now to Figure 6, a mat 600 is shown in accordance with one embodiment of this disclosure. The mat 600 may be similar to that shown and described above, with a main body 602 defined by side walls 604 and surface walls (not shown in this view). In this view (similar to Figure 4A), a rim structure 606 extends outward from the side walls 604 along a perimeter thereof. Within the main body 602 is a pattern of internal walls 608 that defines internal voids 610. The mat 600 includes main structural support ribs 612, similar to those shown in Figure 5, which define Articles 614. As illustrated, the mattress 600 includes secondary structural support ribs 616. The secondary structural support ribs 616 define subsections 618 that divide the sections 614 of the main structural support ribs 612 into smaller sections of the main body 602. The secondary structural support ribs 616, as shown in the modality of FIG. 6, pass through the sections 614 and the internal gaps 610 of the internal wall pattern 608.In this illustrative embodiment, the main body 602 is rectangular in shape, the main structural support ribs 612 are arranged to divide the rectangular main body 602 into rectangular sections 614, and the secondary structural support ribs 616 are arranged to divide the rectangular sections 614 into triangular subsections 618, with the pattern of internal walls 608 and internal gaps 610 generally having a circular or honeycomb shape. In some embodiments, the primary structural support ribs 612 and the secondary structural support ribs 618 may be substantially similar in shape or material dimension (e.g., material thickness). In other embodiments, the primary structural support ribs 612 and the secondary structural support ribs 618 may have different material dimensions. For example, in some embodiments, the primary structural support ribs 612 may have a greater material thickness than the secondary structural support ribs 618. Alternatively, in some embodiments, the primary structural support ribs 612 may have a smaller material thickness than the secondary structural support ribs 618. Returning now to Figure 7, a mattress 700 is shown in accordance with one embodiment of the present description. The mattress 700 may be similar to that shown and described above, with a main body 702 defined by side walls 704 and surface walls (not shown in this view). In this view (similar to Figure 4A), a border structure 706 extends outward from the side walls 704 along a perimeter thereof. Within the main body 702, there is a pattern of internal walls 708 that defines internal hollow voids 710. The mattress 700 includes main structural support ribs 712 that define sections 714, and secondary structural support ribs 716 that define subsections 718, which divide the sections 714 of the main structural support ribs 712 into smaller sections of the main body 702.In this configuration, each of the subsections 718 does not have a uniform or similar shape (for example, as shown in FIG. 6). It will be appreciated that various alternative geometries of the sections and subsections formed within the main bodies of the mattresses can be achieved without departing from the scope of the present description. Another example is shown in FIG. Figure 8 illustrates a mat 800 having primary structural support ribs 802 and secondary structural support ribs 804 with the secondary structural support ribs 804 arranged in an X shape within each section of the mat 800 defined by the primary structural support ribs 802. Figure 9 illustrates a mat 900 having primary structural support ribs 902 and secondary structural support ribs 904 with the secondary structural support ribs 904 arranged in a double X shape within each section of the mat 900 defined by the primary structural support ribs 902.As illustrated, each 800, 900 mat in FIGS. 8-9 includes an internal wall pattern that defines internal voids, similar to that shown and described above. In light of the above and the associated illustrations, some variations described herein refer to a stepped or multi-level support and structural configuration within the main body of the mat. At the widest or highest level, each mat has a main body with internal structures. At the smallest level within the main body, there is a generally repeating pattern defined by internal walls that create internal voids. These internal voids are spaces that do not contain additional structure and are usually filled with air or gas. One step or level higher are the subsections (if any) defined by secondary structural support ribs. These subsections contain internal structure in the form of an internal wall pattern. One step or level above this are the sections defined by primary structural support ribs.The sections contain an internal structure in the form of a pattern of internal walls and the structural elements and features of the subsections (e.g., secondary structural support ribs), if present. It will also be seen that in each of the above-described forms in FIGS. 6-9, at least some of the secondary structural support ribs extend from a side wall of the main body to a main structural support rib. As previously stated, in some embodiments, the primary and secondary structural support ribs may be substantially similar in shape or material dimension (e.g., material thickness). In other embodiments, the primary and secondary structural support ribs may have different material dimensions. For example, in some embodiments, the primary structural support ribs may have a greater material thickness than the secondary structural support ribs. Additionally, in some embodiments, the primary structural support ribs may have a lesser material thickness than the secondary structural support ribs. In some configurations, the length of the secondary structural support ribs is shorter than the longer primary structural support ribs.In some forms, the length of the secondary structural support ribs is shorter than the shorter primary structural support ribs. In some configurations, some secondary structural support ribs may be configured to span between two other secondary structural support ribs. Similarly, in some configurations, some secondary structural support ribs may extend from one external side wall of the main body to another external side wall of the main body, or they may extend between two primary structural support ribs. Advantageously, by incorporating primary and, optionally, secondary structural support ribs, mattresses can be given additional stiffness and / or strength compared to mattresses without such features. The structural support ribs can provide greater crush resistance. Furthermore, due to the increased strength, stiffness, flexural strength, and crush resistance, the internal voids defined by the internal wall pattern can be larger than in a mattress formed solely by the internal wall pattern, while maintaining comparable structural properties. In addition to providing greater strength and structural properties to the mats, the structural support ribs can offer additional features. For example, because the structural support ribs are configured to subdivide the main body into sections, it is possible to subdivide the entire mat into sub-mats or smaller mats. This can be achieved by physically cutting or dividing a mat along one or more of the structural support ribs. The cutting can be done using a saw, knife, blade, or other cutting tools and / or implements, as those skilled in the art will appreciate. Additionally, in some configurations, a cutting line to divide the mats can be visibly marked on the outer surfaces of the mats using dyes, lines, tracers, or other visible markings.Alternatively, or in combination with visible markings, the mats may, and particularly the structural support ribs, include embedded features (e.g., magnetic material) that can provide indication and cutting guidance for the mats described in the present invention. For example, returning now to FIG. 10, a split mat 1000 is shown in accordance with one embodiment of this disclosure. The mat 1000 has a structure and arrangement similar to that shown and described in FIG. 5, with the mat 1000 having main structural support ribs 1012 that traverse an internal wall pattern 1008 and pass through internal voids 1010 defined by the internal wall pattern 1008. The main structural support ribs 1012 are configured to allow the separation of parts of the mat 1000 to create sub-mats 1024, 1026, 1028, 1030. Each sub-mat 1024, 1026, 1028, 1030 includes one of the sections of the main body of the mat 1000. In this configuration and illustration, each sub-mat 1024, 1026, 1028, 1030 has the same size and dimension with respect to separation from the main body of the mat 1000.Advantageously, the main structural support ribs 1012 allow the sub-mattresses 1024, 1026, 1028, 1030 to separate and encapsulate completely in such a way that the side walls and edges do not allow external matter to enter the interior of each of the sub-mattresses 1024, 1026, 1028, 1030. Each of the sub-mats 1024, 1026, 1028, 1030 is individually configured to allow pairing and connection with another mat or sub-mat. That is, each sub-mat 1024, 1026, 1028, 1030 includes a secondary part of the main body, but also includes border structures that extend from one or more of its side walls. In this illustration, a first sub-mat 1024 includes an associated border structure 1032 along a section of it. The first sub-mat 1024 also includes a section border structure (not shown) that would extend downward from the first sub-mat 1024. A second sub-mat 1026 includes a border structure... ίη / ζζηζ / E / γίΛΐ associated 1034, a third sub-mat 1028 includes an associated edge structure 1036 shown and also an edge structure not shown.A fourth submat 1030 includes a border structure that is not fully shown. The associated border structures are shown more clearly in the modalities described later. To allow for the separation of sub-mattresses 1024, 1026, 1028, and 1030, the primary structural support ribs 1012 may have a double-ribbed structure. This double-ribbed structure of the primary structural support ribs 1012 enables the separation of the different sub-mattresses 1024, 1026, 1028, and 1030 and includes a portion of the primary structural support ribs 1012 that functions as an outer wall of the sub-mattress. In other words, once separated, the primary structural support ribs 1012 provide additional functionality by ensuring that the internal structure of the sub-mattresses 1024, 1026, 1028, and 1030 remains encapsulated, sealed, and / or structurally sound to function as part of a support surface.The main structural support ribs 1012 provide a continuous external surface around the body of the sub-mattresses 1024, 1026, 1028, and 1030, preventing material from invading or entering the interior of the respective sub-mattress 1024, 1026, 1028, and 1030. In some configurations, the main structural support ribs 1012 may not have a double-ribbed construction but may instead be a solid material structure. In such configurations, the primary structural support ribs 1012 may have sufficient material thickness to allow cutting through the material and forming the outer walls of the formed sub-mattresses, similar to that shown and described in the present invention. For example, going back to FIGS. 11A-11B, the schematic illustrations of an enlarged view of an 1100 mat have a configuration similar to that shown in FIG. 10. Figure 11A illustrates mat 1100 in an uncut state, and Figure 11B illustrates mat 1100 in a cut state. In Figure 11A, mat 1100 has a main structural support rib 1112 separating a first section 1114a from a second section 1114b, as described above. In the uncut state, mat 1100 has a first surface wall 1111 and a second surface wall 1113 that are parallel or substantially parallel to the mat walls. 1100 and define, a main body of the mattress 1100. In Fig. 11B, the mattress 1100 is separated and divided into sub-mattresses 1124, 1126. Additionally, the main structural support rib 1112 shown in FIG. 11A has been separated and portions of the main structural support rib 1112 now define external walls or surfaces of the sub-mattresses 1124, 1126. That is, the main structural support rib 1112 becomes an outer wall 1138 of the first submattress 1124 and an outer wall 1140 of the second submattress 1126. The outer walls 1138,1140 allow the resulting submattresses 1124,1126 to be properly sealed and protected from the outside environments after separation. That is, the exterior walls 1138, 1126 maintain the protection of the interior secondary structural support ribs (if they exist) and a defined internal pattern of walls and internal voids. The separation of the first sub-mattress 1124 from the second sub-mattress 1126 can be carried out with any cutting tool, as known in the prior art. Furthermore, although it is illustrated with the main structural support rib 1112 having a hollow interior that separates into two distinct outer walls 1138, 1140, this configuration is not so limited. For example, the main structural support rib can be a solid structure that is cut to divide the mattress into sub-mattresses. However, it will be appreciated that by having the main structural support rib 1112 as a hollow structure, some weight savings can be achieved. Returning now to Fig. 12A, a mat 1200 is shown which can be subdivided into sub-mats 1224, 1226, 1228, 1230 according to one embodiment of the present invention. The mat 1200 comprises a main body 1200 which includes internal features and structures, as described above, including at least one pattern of internal walls defining internal voids and two main structural support ribs 1212a, 1212b which separate the main body 1200 into four distinct sections, as shown and described above (e.g., as shown in Fig. 5). In some forms, each distinct section may include secondary structural support ribs, as shown and described above. Extending from the main body 1202 there is a first edge structure 1206 and a second edge structure 1208, similar to that shown and described with respect to FIGS. 1-2.Mat 1200 can be cut or otherwise separated into sub-mats 1224, 1226, 1228, and 1230 by cutting along the main structural support ribs 1212a and 1212b. This results in completely separate sub-mats 1224, 1226, 1228, and 1230, which can be assembled with other sub-mats or complete (non-separated) mats to form a desired work or support surface. As illustrated herein, the first sub-mat 1224 includes a portion of the main body 1202 and includes a continuous border structure 1232 around a portion of the body of the first sub-mat 1224, which is formed from a separate portion of the first border structure. 1206. The second submat 1226 includes a part of the main body 1202 and includes a discontinuous edge structure 1234, which is formed from a section of the first edge structure 1206 and a section of the second edge structure 1208.The third submat 1228 includes a portion of the main body 1202 and includes a continuous border structure 1236, which is formed entirely from a section of the second border structure 1208. The fourth submat 1230 includes a portion of the main body 1202 and includes a discontinuous border structure 1238, which is formed from a section of the first border structure 1206 and a section of the second border structure 1208. The different configurations of the edge structures extending from the bodies of sub-mattresses 1224, 1226, 1228, and 1230 allow for different arrangements and orientations of the sub-mattresses. The first sub-mattress, 1224, and the third sub-mattress, 1228, are mirror images of each other, and the second sub-mattress, 1226, and the fourth sub-mattress, 1230, are mirror images of each other. It will be appreciated that it is not necessary to separate mat 1200 into four distinct parts; instead, it could be cut in half along one of the two main structural support ribs 1212a and 1212b, as shown in Figures 12B–12D. As shown, a first main structural support rib 1212a extends in a direction generally perpendicular to the direction of a second main structural support rib 1212b. ni? ίη / ζζηζ / E / γίΛΐ Figure 12B illustrates mat 1200 separated into two halves along the first main structural support rib 1212a, with a first half formed by a first and a fourth sub-mattress 1224, 1230 and a second half formed by a second and third non-separated sub-mattress 1226, 1228. As such, a first sub-mattress set 1242 is formed by the first and fourth sub-mattresses 1224, 1230 and a second sub-mattress set 1244 is formed by the second and third sub-mattresses 1226, 1228. Figure 12C illustrates mattress 1200 separated into two halves along the second main structural support rib 1212b, with a first half formed by a first and second non-separated sub-mattresses 1224, 1226 and a second half formed by a third and fourth non-separated sub-mattresses 1228, 1230. Therefore, a first sub-mattress assembly 1246 is formed by the first and second sub-mattresses 1224, 1226 and a second sub-mattress assembly 1248 is formed by the third and fourth sub-mattresses 1228, 1230. Figure 12D illustrates the mattress 1200 separated along the first main structural support rib 1212a and the second main structural support rib 1212b, resulting in four separate sub-mattresses 1224, 1226, 1228, 1230. It will be appreciated that a partial cut along each of the main structural support ribs 1212a, 1212b can result in a substantially L-shaped submattress assembly formed from three submattresses and a single separate submattress. The construction, illustration, and detailed description with respect to FIGS. 12A-12D are based on the specific orientation and arrangement of the primary structural support ribs and the resulting sub-layers defined by them. However, alternative arrangements or geometries may be possible without departing from the scope of this disclosure. For example, a single mattress could be subdivided into six separate sub-mattresses that are substantially square with respect to the division of the main mattress body. In each case, the resulting sub-layers or sub-layer assemblies are inclusively sealed and structurally sound enough to serve as part of a support surface or structure (e.g., and / or sub-mattresses). Returning to Fig. 13, a schematic illustration of a mat assembly 1350 formed from several different mats / submats is shown. In this illustrative configuration, two complete mats 1352, 1354 are used and assembled together using locking pins through the pin openings of overlapping edge structures. Two individual submats 1356, 1358 are arranged along one side of the assembled complete mats 1352, 1354 and connected by overlapping edge structures. Between the two individual submats 1356, 1358 is a submat assembly 1356 formed by two non-separated submats. In Fig. 13, the dashed lines indicate which parts of the edge structures overlap. Returning now to Figs. 14A-14C, a mat 1400 and aspects thereof are illustrated. The mat 1400 is similar to that shown and described above, and therefore several aspects will not be described again. The mat 1400 includes a main body having edge structures 1406 extending from it, as described above. The mat 1400 further includes main structural support ribs 1412a, 1412b that provide additional structural support and allow the mat 1400 to be separated into sub-mats and / or sub-mat assemblies, as illustrated and described above. Figure 14A presents a plan view illustration of the interior structure of the mattress 1400, which includes hook pockets 1460 arranged in locations along the main structural support ribs 1412a, 1412b. The hook pockets 1460 are arranged in locations along the respective main structural support ribs 1412a, 1412b in locations opposite or aligned with the pin openings 1408 in the edge structures 1406. If the 1400 mattress is in its complete or non-separated configuration, it can be manipulated or moved using a tool that engages with the pin openings 1408 on opposite sides. However, if the 1400 mattress is split, as described above, it can be difficult to lift, move, and maneuver the sub-mattresses or sub-mattress assemblies that are created. Dividing the mattress 1400. The hook pockets 1460 are exposed when the mattress 1400 is cut along the main structural support rib(s) 1412a, 1412b, allowing a tool to hook onto the undermat or undermat assembly and permit movement, positioning, and other manipulation of the undermat or undermat assembly.Hook pockets 1460 are recesses or indentations in the body that are configured, in size and shape, to be held by an individual or a tool for moving or handling the mat. If the mat 1400 is cut or otherwise separated as described above, hook pockets 1460 may be exposed in each of the sub-mats. Hook pockets 1460 may be sized and shaped to receive a gripping device for lifting or moving the sub-mats of the mat 1400. For example, each hook pocket 1460 may align with one or more pin openings 1408 of the edge structures 1406 and form pairs of hooks 1462 so that a tool can be attached to opposite sides / ends of the sub-mats or formed sub-mats, mat assemblies. Figures 14B-14C showed more enlarged and detailed illustrations of a hook pocket 1460 in accordance with one modality of this disclosure. As indicated, the hook pocket 1460 is arranged along and forms part of the primary structural support ribs 1412a. Hook pockets 1460 are pockets arranged along the primary structural support ribs 1412a and define an enlarged cavity or space along a channel 1464 of the primary structural support ribs 1412a. After cutting a submat or submat assembly from the complete mat 1400, the walls or structure of the primary structural support ribs 1412a and the hook pockets 1460 are exposed.It is observed that this structure (channel 1464 and hook bag 1460) is not exposed to the elements until the mattress 1400 is cut or otherwise divided / subdivided into sub-mattresses and / or sub-mattress assemblies. Advantageously, the modalities of this disclosure are directed to mats and mat systems improved to provide and create temporary ribs and / or support surfaces. The mats of this disclosure have further advantages through the inclusion of structural support ribs arranged within a main body of the mat, which overlays a defined pattern of internal walls and voids. As such, the mats can be improved by reducing weight (achieved through the inclusion of the internal voids) while maintaining high flexural and crush resistance. It is noted that although flexural resistance is provided, the mats can bend or flex under weight, so that they are neither brittle nor inflexible.However, the flexural strength provided by the structures described herein (the primary and secondary structural support ribs) prevents the mattress from buckling completely when weight or forces are applied. In other words, the embodiments described herein allow for the creation of mattresses and mattress systems that have reduced weight while maintaining the desired crush resistance and flexibility. Advantageously, the modalities described herein provide modular mat systems that allow a single mat to be divided or subdivided into sub-mats and sub-mat assemblies, enabling customization of the size, shape, and dimensions of a temporary roadway and / or support surfaces adapted to a specific application. In other words, the area covered by the mats and mat systems described herein is significantly more customizable than previous systems that were not subdivisible. Furthermore, such subdivisible mats may include features that allow for easy handling and movement of the mats after they have been subdivided into sub-mats or sub-mat assemblies.The under-mattresses and under-mattress assemblies are configured to seal themselves so that the inner structure of the mattress bodies is not exposed after separation, thus preventing debris or moisture from entering the mattresses and causing problems with them. As described in the present invention, the terms "approximately" and "substantially" include the degree of error associated with measuring the particular quantity according to the equipment available at the time of filing the application. For example, "approximately" may include a range of ±8%, 5%, or 2% of a given value or other percentage change, as will be appreciated by those skilled in the art for the particular measurement and / or dimensions referred to. The terminology used in this invention is intended to describe particular embodiments only and is not intended to be limiting. As applied, the singular forms a, an, and the also include the plural forms ni, unless the context clearly indicates otherwise. It is further understood that the terms comprise and / or comprising, when used in this application, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more additional features, integers, steps, operations, elements, and / or groups thereof. Although the present description has been given with reference to one or more illustrative embodiments, those skilled in the art will understand that various changes may be made and elements thereof may be substituted with equivalents without departing from the scope of this disclosure. Likewise, many modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from its essential scope. Therefore, it is intended that the present invention not be limited to the particular embodiment disclosed as the best contemplated mode for carrying out this invention, but rather that the present invention shall include all embodiments falling within the scope of the claims.

Claims

1. A mattress comprising: a main body defined by a plurality of side walls and two opposing outer surface walls, wherein the main body includes a pattern of internal walls defining internal voids within the main body; and at least one main structural support rib disposed within the main body and extending between the two surface walls and from one of the plurality of side walls to another of the plurality of side walls, wherein at least one main structural support rib traverses the interior voids defined by the pattern of the internal walls.

2. The mattress according to claim 1, wherein at least one main structural support rib divides the main body into at least two sections.

3. The mattress according to claim 2, further comprising at least one secondary structural support rib arranged within one of at least two sections defined by at least one main structural support rib, wherein at least one secondary structural support rib passes through the internal voids defined by the pattern of the internal walls.

4. The mattress according to claim 3, wherein at least one secondary structural support rib divides the respective section into two or more subsections.

5. The mattress according to claim 1, further comprising at least one secondary structural support rib extending from at least one of the side walls to at least one of the main structural support ribs.

6. The mattress according to claim 1, further comprising at least one secondary structural support rib having a length that is less than the length of at least one primary structural support rib.

7. The mattress according to claim 1, further comprising at least one secondary structural support rib having a material thickness that is less than the material thickness of at least one primary structural support rib.

8. The mattress according to claim 1, wherein at least one main structural support rib is configured to allow the mattress to be separated into a plurality of sub-mattresses.

9. The mattress according to claim 8, wherein each submattress is configured to secure or connect to another of the plurality of submattresses or another mattress.

10. The mat according to claim 8, further comprising a hook pocket defined along at least one main structural support rib, the hook pocket being configured to allow a tool to be attached to a sub-mat.

11. The mattress according to claim 1, further comprising a rim structure extending outwards from the plurality of side walls around a periphery of the main body.

12. The mattress according to claim 9, wherein at least one main structural support rib is configured to allow the mattress to be separated into a plurality of sub-mattresses and wherein each sub-mattress includes a portion of the edge structure.

13. The mattress according to claim 1, wherein the internal voids of the inner support structure define at least 45% of the inner volume of the main body.

14. A method comprising: cutting a mattress to form a first sub-mattress and a second sub-mattress, the mattress comprising: a main body defined by a plurality of side walls and two outer surface walls, wherein the main body includes a first primary structural support rib disposed within the main body and extending between the two surface walls and from one plurality of side walls to another of the plurality of side walls, wherein the first primary structural support rib divides the mattress into two sections, wherein the two sections form the first sub-mattress and the second sub-mattress.

15. The method according to claim 14, further comprising securing the first submattress to the second submattress to form a support surface.

16. The method according to claim 14, wherein: the mattress comprises a second main structural support rib extending in a direction generally perpendicular to the first main structural support rib, and the first main structural support rib and the second main structural support rib define four configured sections to be divided into four sub-mattresses.

17. The method according to claim 16, further comprising cutting the mattress along the first main structural support rib and the second main structural support rib to form a first sub-mattress, a second sub-mattress, a third sub-mattress, and a fourth sub-mattress.

18. The method according to claim 17, further comprising connecting at least one of the first submattress, the second submattress, the third submattress and the fourth submattress to one or more complete mattresses to form a support surface.

19. The method according to claim 14, further comprising joining at least one of the first submattresses and the second submattresses to a complete mattress to form a support surface.

20. The method according to claim 14, wherein the cut is made along the first main structural support rib, such that the first submat and the second submat each have a portion of the first main structural support rib after being cut and separated from each other.

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