System for making a geo-stabilized construction mat with exposed ribbing and associated methods
The system addresses soil instability in thermoplastic construction mats by creating geo-stabilized mats with exposed ribbing and interlocking edges, ensuring stability and cost-effective production.
Patent Information
- Authority / Receiving Office
- US · United States
- Patent Type
- Applications(United States)
- Current Assignee / Owner
- LOW IMPACT TECH USA INC
- Filing Date
- 2025-10-04
- Publication Date
- 2026-07-30
AI Technical Summary
Thermoplastic construction mats face issues with soil instability due to soft and pliable ground conditions, leading to ruts and uneven surfaces under heavy loads, as they lack effective ground stabilization.
A system utilizing a mold with articulating rib forms and vacuum pumps to create geo-stabilized construction mats with exposed ribbing, forming a grid pattern of ground stabilization pockets, and interlocking edges for enhanced stability and connection.
The system provides a stable, level surface by minimizing soil movement and maintaining structural integrity under heavy loads, reducing operating and capital costs through in-situ formation without injection molding or extrusion compression.
Smart Images
Figure US20260218461A1-D00000_ABST
Abstract
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part (CIP) of U.S. patent application serial no. 19 / 037,250, filed January 26, 2025, which is incorporated by reference herein in its entirety.TECHNICAL FIELD
[0002] The present disclosure relates to thermoplastic panels, and, more particularly, to a system for making geo-stabilized construction mats with exposed ribbing, and associated methods. BACKGROUND
[0003] Thermoplastic is a plastic polymer material that becomes pliable or moldable at elevated temperatures and solidifies upon cooling. Thermoplastic panels may be formed using compression molding or extrusion.
[0004] Compression molding is a manufacturing method for fabrication of composite materials. A preheated material is placed into an open heated mold cavity. The mold is closed and compressed under uniform pressure so that the polymer material contacts all areas of the mold. Then, the molding material is cured under determined temperature and pressure and removed from the system.
[0005] Extrusion is a process in which polymer material is melted and formed into a continuous profile. Objects with a specific cross-sectional shape may be made by forcing the polymer material through a die. The die may be a disk with an opening that is the desired shape and size. When pressure is applied to the polymer material as it passes through the die, it takes on the desired shape.
[0006] Thermoplastic panels may be utilized as construction mats to provide a temporary and rigid surface in remote or inaccessible areas, such as industrial or construction areas. A limitation with typical construction mats is that the soil beneath these mats may at times be soft and pliable. This typically leads to ruts and other soil movement issues beneath the construction mats due to heavy loads being applied. Once these sub surface soil conditions occur the constructions mats tend to break or the above ground surface becomes uneven. SUMMARY
[0007] A system for making a geo-stabilized construction mat includes a mold having a mold cavity, and articulating rib forms movable between an extended position within the mold cavity and a retracted position below the mold cavity. A first vacuum pump is configured to pull a vacuum on the mold cavity. A vacuum plate is movable between an up position and a down position, with the down position making contact with the mold cavity. A second vacuum pump is configured to pull a vacuum on the vacuum plate.
[0008] A controller is coupled to the articulating rib forms, the first vacuum pump and the second vacuum pump, and is configured to control the first and second vacuum pumps in response to the mold cavity receiving a pliable thermoplastic sheet while the articulating rib forms are in the extended position and the vacuum plate is in the down position.
[0009] The vacuum from the first vacuum pump is pulling down on the pliable thermoplastic sheet to cover the articulating rib forms and inner surfaces of the mold cavity. The vacuum from the second vacuum pump is pulling up on the pliable thermoplastic sheet so that ends of the articulating rib forms remain covered by the pliable thermoplastic sheet. The pliable thermoplastic sheet forms the geo-stabilized construction mat with exposed ribbing.
[0010] The exposed ribbing is on a bottom side of the geo-stabilized construction mat, with the exposed ribbing forming a grid pattern of ground stabilization pockets for stabilizing the geo-stabilized construction mat when placed on the ground.
[0011] The controller may be configured to move the articulating rib forms from the extended position to the retracted position as the geo-stabilized construction mat is being formed, causing internal voids to be formed in the exposed ribbing.
[0012] The articulating rib forms may be configured with vacuum holes, and as the articulating rib forms are moved to the retracted position, the first vacuum pump pulls a vacuum on the vacuum holes causing the internal voids in the exposed ribbing to be filled with the pliable thermoplastic sheet.
[0013] After the vacuum plate is moved to the up position, the controller may be configured to move the articulating rib forms back to the extended position to eject from the mold cavity the geo-stabilized construction mat with exposed ribbing.
[0014] The mold cavity may include an upper L-shaped edge section and a spaced apart lower edge L-shaped edge section so that an upper L-shaped interlocking edge section and a lower L-shaped interlocking edge section are formed in the geo-stabilized construction mat. The upper and lower L-shaped interlocking edge sections may be configured to interlock with one or more adjacent geo-stabilized construction mats.
[0015] The system includes an extruder to extrude the pliable thermoplastic sheet directly into the mold cavity. The geo-stabilized construction mat with the exposed ribbing is formed in-situ without using injection molding or extrusion compression.
[0016] Another aspect is directed to a method for making a geo-stabilized construction mat with a system as described above. The method includes placing a pliable thermoplastic sheet in the mold cavity while the articulating rib forms are in the extended position and the vacuum plate is in the up position. The vacuum plate is moved from the up position to a down position to make contact with the mold cavity. The first vacuum pump is operated so the vacuum therefrom pulls down on the pliable thermoplastic sheet to cover the articulating rib forms and inner surfaces of the mold cavity. The second vacuum pump is operated so that the vacuum therefrom pulls up on the pliable thermoplastic sheet so that ends of the articulating rib forms remain covered by the pliable thermoplastic sheet. The vacuum plate is moved from the down position to the up position, and the geo-stabilized construction mat with exposed ribbing is ejected from the mold cavity.
[0017] Yet another aspect is directed to a geo-stabilized construction mat including an upper surface, and a lower surface with exposed ribbing. The exposed ribbing forms a grid pattern of ground stabilization pockets for stabilizing the geo-stabilized construction mat when placed on the ground.
[0018] The geo-stabilized construction mat includes an upper L-shaped interlocking edge section and a lower L-shaped interlocking edge section, with the upper and lower L-shaped interlocking edge sections configured to interlock with one or more adjacent geo-stabilized construction mats.
[0019] Each of the upper and lower L-shaped interlocking edge sections may include spaced apart connector holes configured to receive connector pins to interlock with the one or more adjacent geo-stabilized construction mats.
[0020] The upper surface may be textured with threads to form a traction pattern.
[0021] A width of the upper surface is within a range of 6.5 to 8.5 feet, and a length of the upper surface is within a range of 11.5 to 14.5 feet. Each ground stabilization pocket may be rectangular shaped, and have a width within a range of 5 to 7 inches and have a depth within a range of 2 to 5 inches.BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic diagram of a system for making a panel with internal ribbing in which various aspects of the disclosure may be implemented, wherein thermoplastic sheets are positioned over a bottom mold and over a top mold in an upright position.
[0023] FIG. 2 is a schematic diagram of the system illustrated in FIG. 1, wherein the top mold has been inverted to make contact with the bottom mold.
[0024] FIG. 3 is a schematic diagram of the system as illustrated in FIG. 2, wherein the top mold has been moved back to an upright position and the panel with internal ribbing has been extracted from the bottom mold.
[0025] FIG. 4 is a cross-sectional view of the extracted panel with internal ribbing as illustrated in FIG. 3.
[0026] FIG. 5 is a perspective view of the bottom and top molds for the system illustrated in FIG. 1.
[0027] FIG. 6 is a perspective view of thermoplastics sheets applied to the bottom and top molds illustrated in FIG. 5.
[0028] FIG. 7 is a cross-sectional perspective view of the thermoplastic sheets after being vacuumed to the bottom and top molds illustrated in FIG. 6.
[0029] FIG. 8 is a perspective view of the top mold being positioned on the bottom mold illustrated in FIG. 7.
[0030] FIG. 9 is a cross-sectional perspective view of the bottom and top molds after the top mold has been positioned on the bottom mold illustrated in FIG. 8, with the articulating rib forms in the extended position.
[0031] FIGS. 10-11 are cross-sectional perspective views of the bottom and top molds illustrated in FIG. 9, with voids being formed in the internal ribbing as the articulating rib forms are lowered to the retracted position.
[0032] FIG. 12 is a cross-sectional perspective view of the bottom and top molds illustrated in FIG. 11, with the voids being filled in by pulling a vacuum on the bottom mold.
[0033] FIG. 13 is a cross-sectional perspective view of the top mold being removed from the bottom mold illustrated in FIG. 12.
[0034] FIGS. 14-15 are cross-sectional perspective views of the bottom mold illustrated in FIG. 12, with the articulating rib forms being moved back to the extended position for ejecting the panel with the internal ribbing.
[0035] FIGS. 16 is a cross-sectional perspective view of the bottom mold illustrated in FIG. 15, with extraction from the bottom mold of the panel with the internal ribbing.
[0036] FIG. 17 is a flowchart for making a panel with internal ribbing using the system illustrated in FIG. 1.
[0037] FIG. 18 is a schematic diagram of a system for making a geo-stabilized construction mat with exposed ribbing in which various aspects of the disclosure may be implemented, wherein a thermoplastic sheet to be received by a mold cavity is extruded by an extruder.
[0038] FIG. 19 is a schematic diagram of the system illustrated in FIG. 18, wherein the thermoplastic sheet is in the mold cavity while a vacuum plate is in an up position over the mold cavity.
[0039] FIG. 20 is a schematic diagram of the system as illustrated in FIG. 19, wherein the vacuum plate is in the down position to make contact with the mold cavity.
[0040] FIG. 21 is a schematic diagram of the system as illustrated in FIG. 20, wherein the vacuum plate is in the up position and a geo-stabilized construction mat has been extruded from the mold cavity.
[0041] FIG. 22 is a lower perspective view of the geo-stabilized construction mat formed by the system illustrated in FIG. 18.
[0042] FIG. 23 is an upper perspective view of the geo-stabilized construction mat illustrated in FIG. 22.
[0043] FIG. 24 is an upper perspective view of the mold cavity illustrated in FIG. 18, wherein the articulating rib forms are in an extended position.
[0044] FIG. 25 is an upper perspective view of a thermoplastics sheet received by the mold cavity illustrated in FIG. 24.
[0045] FIG. 26 is a cross-sectional side view of the mold cavity and the thermoplastic sheet illustrated in FIG. 25, wherein the vacuum plate is in the up position.
[0046] FIG. 27 is a cross-sectional side view of the mold cavity and the thermoplastic sheet illustrated in FIG. 26, wherein the vacuum plate is in the down position and the articulating rib forms are being moved to a retracted position
[0047] FIG. 28 is a cross-sectional side view of the mold cavity and the thermoplastic sheet illustrated in FIG. 27, wherein the articulating rib forms are in the retracted position leaving internal voids in the exposed ribbing.
[0048] FIG. 29 is a cross-sectional side view of the mold cavity and the thermoplastic sheet illustrated in FIG. 28, wherein the internal voids have been filled in by the thermoplastic sheet.
[0049] FIG. 30 is a cross-sectional perspective side view of the mold cavity illustrated in FIG. 29, wherein the geo-stabilized construction mat is being ejected therefrom.
[0050] FIG. 31 is a bottom view of the geo-stabilized mat illustrated in FIG. 22.
[0051] FIG. 32 is a top view of the geo-stabilized mat illustrated in FIG. 22.
[0052] FIG. 33 is a cross-sectional side view of the geo-stabilized mat illustrated in FIG. 22.
[0053] FIG. 34 is a flowchart for making the geo-stabilized mat using the system illustrated in FIG. 18.DETAILED DESCRIPTION
[0054] The present description is made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the particular embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout.
[0055] Referring initially to FIGS. 1-4, an overview of a system 20 for making a panel 70 with internal ribbing 72 will be discussed. The panel 70 with internal ribbing 72, as shown in FIG. 4, is advantageously formed in-situ without using injection molding or extrusion compression. The system 20 significantly lowers the operating and capital costs of making such a panel 70. The panel 70 may be joined with other panels to form a wall or other structure required to support heavy loads.
[0056] The system 20 includes a bottom mold 30 that includes a mold cavity 32 formed therein, articulating rib forms 36, and vacuum holes 34. A rib forms controller 60 is coupled to the articulating rib forms 36 for controlling movement thereof between an extended position and a retracted position. In the extended position, the articulating rib forms 36 are positioned within the bottom mold cavity 32. In the retracted position, the articulating rib forms 36 are positioned below the bottom mold cavity 32.
[0057] A first thermoplastic sheet 50 is placed over the bottom mold cavity 32 while the articulating rib forms 36 are in the extended position. The first thermoplastic sheet 50 is at an elevated temperature so that the sheet is soft and pliable. The elevated temperature may be within the range of 300–400°F, for example.
[0058] While the first thermoplastic sheet 50 is resting on the mold cavity 32, a first vacuum pump 64 is used to pull a vacuum on the mold cavity 32 via the vacuum holes 34. The vacuum may be within a range of 5-10 psi, for example. The vacuum holes 34 are spread out across a lower surface of the bottom mold 30 and interface with the bottom mold cavity 32. As the vacuum is applied to the bottom mold 30, the first thermoplastic sheet 50 is pulled down to cover the articulating rib forms 36 and the interior surfaces of the bottom mold cavity 32. The interior surfaces of the bottom mold cavity 32 includes side walls and bottom surfaces thereof.
[0059] The system 20 further includes a top mold 40 that includes a raised edge section 42 that is to interface with a corresponding recessed edge section in the bottom mold 30 to define opposing interlocking edge sections 76, 78 of the panel 70. The raised edge section 42 and the corresponding recessed edge section may be a L-shaped, for example. Vacuum holes 44 are spread out across an upper surface of the top mold 40.
[0060] A top mold control arm 62 is coupled to the top mold 40 for controlling movement thereof between an upright position as shown in FIG. 1, and an inverted position as shown in FIG. 2. A second thermoplastic sheet 52 is placed over the top mold 40 and the L-shaped raised edge section 42 while in the upright position. The second thermoplastic sheet 52 is also at the elevated temperature so that the sheet is soft and pliable.
[0061] While the second thermoplastic sheet 52 is resting on the top mold 40 and the L-shaped raised edge section 42, a second vacuum pump 66 is used to pull a vacuum on the top mold 40 via the vacuum holes 44. The vacuum may be within a range of 10-15 psi, for example.
[0062] As the vacuum is applied to the top mold 40, the second thermoplastic sheet 52 is pulled down to cover the L-shaped raised edge section 42 and to cover the upper surface of the top mold 40. The vacuum for the top mold 40 may be higher than the vacuum for the first mold 30 to ensure that the second thermoplastic sheet 52 is held in place as the top mold 40 is moved from the upright position to the inverted position.
[0063] The top mold control arm 62 then moves the top mold 40 from the upright position to an inverted position, as indicated by arrow 80 in FIG. 1. As the top mold 40 is inverted, the second vacuum pump 66 continues to pull a vacuum so that the second thermoplastic sheet 42 is held in place by the top mold 40.
[0064] The top mold 40 is inverted so that the second thermoplastic sheet 52 carried by the top mold 40 comes in contact with the thermoplastic sheet 50 in the bottom mold 30, as shown in FIG. 2. The top mold 40 is aligned with the bottom mold 50. As the first and second thermoplastic sheets 50, 52 come in contact with one another at the elevated temperature, they become fused together to form the panel 70 with internal ribbing 72.
[0065] After the first and second thermoplastic sheets 50, 52 have been fused together, the rib forms controller 60 moves the articulating rib forms 36 from the extended position back to the retracted position. In the retracted position, the articulating rib forms 36 are positioned below the bottom mold cavity 32.
[0066] Retraction of the articulating rib forms 36 from the internal ribbing 72 in the bottom mold cavity 32 causes voids to be formed in the internal ribbing. To fill in the voids, the first vacuum pump 64 continues to pull a vacuum on the bottom mold cavity 32. This causes the first thermoplastic sheet 50 at the elevated temperature to fill in the voids via vacuum holes in the articulating rib forms 36. After the voids have been filled, the second vacuum pump 66 for the top mold 50 stops pulling a vacuum, and the top mold control arm 62 moves the top mold 40 back to the upright position, as indicated by arrow 82 and as shown in FIG. 3.
[0067] The panel 70 with the internal ribbing 72 is ready for extraction from the bottom mold cavity 32. This is accomplished by operating the rib forms controller 60 to move the articulating rib forms 36 back to the extended position. As the articulating rib forms 36 move back to the extended position, the panel 70 is pushed out of the bottom mold cavity 32 by the articulating rib forms 36, as indicated by arrow 84.
[0068] A cross-sectional view of the panel 70 is provided in FIG. 4. The panel 70 includes an upper surface 71 and a bottom surface 73, with the ribs 72 therebetween. Adjacent the ribs 72 are pockets 74 void of any thermoplastic material. The panel 70 includes an upper interlocking edge section 76 extending from one side of the panel 70, and a lower interlocking edge section 78 extending from an opposite side of the panel 70. The upper and lower interlocking edge sections 78 are used to join adjacent panels 70 together to form a wall or structure. Fasteners may be used to hold the panels together.
[0069] Referring now to FIGS. 5-16, the steps of forming the panel 70 with internal ribbing 72 will be discussed in greater detail. The articulating rib forms 36 are in the extended position within the bottom mold cavity 32 in the bottom mold 30, as shown in FIG. 5.
[0070] The bottom mold cavity 32 includes an upper extension area 96 for the upper interlocking edge section 76 of the panel that is to extend from one side of the panel 70, and a lower extension area 98 for the lower interlocking edge section 78 extending from an opposite side of the panel 70. The articulating rib forms 36 do not extend into the upper and lower extension areas 96, 98.
[0071] The top mold 40 includes an L-shaped raised section 42 that is to interface with a corresponding L-shaped recessed edge section 97 in the bottom mold 30 to define the interlocking edge sections 76, 78 of the panel 70. Vacuum holes 44 extend through the top mold 40 in order for the second vacuum pump 66 to pull a vacuum on the second thermoplastic sheet 52.
[0072] A first thermoplastic sheet 50 is positioned over the bottom mold 30, and a second thermoplastic sheet 52 is positioned over the top mold 40, as shown in FIG. 6. The first and second thermoplastic sheets 50, 52 are at elevated temperatures so that the sheets are soft and pliable. A cross-sectional view of the bottom mold 30 and the top mold 40 are shown in FIG. 7 after the first and second thermoplastic sheets 50, 52 have been vacuumed down to their respective molds.
[0073] As the vacuum is applied to the bottom mold 30, the first thermoplastic sheet 50 is pulled down to cover the articulating rib forms 36 to form the internal ribbing 72, and to cover the interior surfaces of the bottom mold cavity 32. The interior surfaces of the bottom mold cavity 32 includes side walls and bottom surfaces thereof.
[0074] As the vacuum is applied to the top mold 40, the second thermoplastic sheet 52 is pulled down to cover the L-shaped raised section 42 and the upper surface of the top mold 40.
[0075] The top mold 40 is moved from an upright position to an inverted position, as indicated by the dashed arrows in FIG. 8, while the second thermoplastic sheet 52 is being held in place by the second vacuum pump 66. The top mold 40 is inverted so that the second thermoplastic sheet 52 carried by the top mold 40 comes in contact with the first thermoplastic sheet 50 in the bottom mold 30, as shown in FIG. 9.
[0076] The top mold 40 is aligned with the bottom mold 50. As the first and second thermoplastic sheets 50, 52 come in contact with one another at the elevated temperature, they become fused or welded together to form the panel 70 with internal ribbing 72. In particular, an upper surface of the internal ribbing 72 formed with the first thermoplastic sheet 50 is welded to a bottom surface of the second thermoplastic sheet 52 while the articulating rib forms 36 are in the extended position.
[0077] The articulating rib forms 36 are then moved from the extended position to the retracted position as the first and second pliable thermoplastic sheets 50, 52 are being fused together, as shown in FIGS. 10-11. Retraction of the articulating rib forms 36 causes voids 79 to be formed in the internal ribbing 72.
[0078] The articulating rib forms 36 are in a partially retracted position in FIG. 10, and are in a fully retracted position in FIG. 11. The voids 79 increase in size as the articulating rib forms 36 are retracted. The first vacuum pump 64 continues to pull the vacuum on the bottom mold cavity 32 as the articulating rib forms 36 are being retracted. This causes the voids 79 in the internal ribbing 72 to be filled with the first thermoplastic sheet 50, as shown in FIG. 12.
[0079] After the panel 70 with the internal ribbing 72 has been formed, the top mold 40 is moved from the inverted position back to the upright position, as shown in FIG. 13. The top mold 40 is in position to receive another second thermoplastic sheet 52 for the next panel 70 with internal ribbing 72 to be formed.
[0080] With the top mold 40 in the upright position, this allows the panel 70 with the internal ribbing 72 to be extracted from the bottom mold cavity 32, as shown in FIG. 14. This is based on the articulating rib forms 36 being moved back to the extended position.
[0081] As the articulating rib forms 36 are moved, the panel 70 with the internal ribbing 72 is pushed out of the bottom mold cavity 32. With the articulating rib forms 36 in the fully extended position, the panel 70 with the internal ribbing 72 is ready for extraction, as shown in FIG. 15. The panel 70 with the internal ribbing 72 has been extracted, as shown in FIG. 16. The bottom mold 30 is ready to receive another first thermoplastic sheet 50 for the next panel 70 with internal ribbing 72 to be formed.
[0082] Another aspect is directed to a method for making a panel 70 with internal ribbing 72 using the system 20 as discussed above. Referring now to the flowchart 100 in FIG. 17, from the start (Block 102), the method includes providing a bottom mold 30 with articulating rib forms 36 in an extended position within a cavity 32 of bottom mold at Block 104. A first pliable thermoplastic sheet 50 is positioned over the bottom mold cavity 32 at Block 106. A vacuum is pulled on the bottom mold cavity 32 at Block 108 causing the first pliable thermoplastic sheet 50 to cover inner surfaces of the bottom mold cavity 32 and the articulating rib forms 36.
[0083] A second pliable thermoplastic sheet 52 is positioned over a top mold 40 at Block 110 while the top mold is in an upright position. A vacuum is pulled on the top mold 40 at Block 112 causing the second pliable thermoplastic sheet 52 to be held in place. The top mold 40 is moved from the upright position to an inverted position at Block 114 so that the second pliable thermoplastic sheet 52 comes in contact with the first pliable thermoplastic sheet 50 to fuse together to form the panel 70 with internal ribbing 72.
[0084] The articulating rib forms 36 are moved at Block 116 to a retracted position below the bottom mold cavity 32 while creating voids 79 in the internal ribbing 72. A vacuum is pulled on the bottom mold cavity 32 at Block 118 to fill in the voids 79 in the internal ribbing 72. The panel 70 with the internal ribbing 72 is ejected from the bottom mold 30 at Block 120 by moving the articulating rib forms 36 back to the extended position within the bottom mold cavity 32. The method ends at Block 122.
[0085] Referring now to FIGS. 18-21, an overview of a system 125 for making a geo-sta bilized construction mat 170 will be discussed. An underside 171 of the geo-stabilized construction mat 170 is shown in FIG. 22, and a topside 173 of the geo-stabilized construction mat 170 is shown in FIG. 23.
[0086] As will be discussed in greater detail below, the geo-stabilized construction mat 170 is advantageously formed with exposed ribbing 180. The exposed ribbing 180 forms a grid pattern of ground stabilization pockets 181 for stabilizing the geo-stabilized construction mat 170 when placed on the ground. The geo-stabilized construction mat 170 is advantageously formed in-situ without using injection molding or extrusion compression.
[0087] The geo-stabilized construction mat 170 is formed using a single thermoplastic sheet 150. The system 150 significantly lowers the operating and capital costs of making such a mat 170. The geo-stabilized construction mat 170 may be joined with other geo-stabilized construction mats to provide a temporary and rigid surface in remote or inaccessible areas, such as industrial or construction areas, for example.
[0088] The system 125 includes a mold 130 that includes a mold cavity 132 formed therein, articulating rib forms 136, and vacuum holes 134. A controller 160 is coupled to the articulating rib forms 136 for controlling movement thereof between an extended position and a retracted position. In the extended position, the articulating rib forms 136 are positioned within the mold cavity 132. In the retracted position, the articulating rib forms 136 are positioned below the mold cavity 132. A first vacuum pump 162 is configured to pull a vacuum on the mold cavity 132 via the vacuum holes 134.
[0089] The system 125 includes a vacuum plate 140 with vacuum holes 144 formed therein. The vacuum plate 140 is movable between an up position and a down position. A second vacuum pump 164 is configured to pull a vacuum on the vacuum plate 140 via the vacuum holes 144.
[0090] A thermoplastic sheet 150 is extruded by an extruder 155. The extruder 155 extrudes the thermoplastic sheet 150 directly into the mold cavity 132, as shown in FIG. 19. The thermoplastic sheet 150 is received by the mold cavity 132 while the articulating rib forms 136 are in the extended position. The thermoplastic sheet 150 is at an elevated temperature so that the sheet is soft and pliable. The elevated temperature may be within the range of 300–400°F, for example.
[0091] As soon as the thermoplastic sheet 150 has been received by the mold cavity 132, the vacuum plate 140 is moved from the up position to the down position, as shown in FIG. 20. In the down position, the vacuum plate 140 is making contact with the mold cavity 132.
[0092] The controller 160 is coupled to the articulating rib forms 136, the first vacuum pump 162 and the second vacuum pump 164. The controller 160 is configured to control the first and second vacuum pumps 162, 164 in response to the mold cavity 132 receiving the pliable thermoplastic sheet 150 while the articulating rib forms 136 are in the extended position and the vacuum plate 140 is in the down position.
[0093] The vacuum from the first vacuum pump 162 pulls down on the pliable thermoplastic sheet 150 to cover the articulating rib forms 136 and inner surfaces of the mold cavity 132. The vacuum from the second vacuum pump 164 pulls up on the pliable thermoplastic sheet 150 so that ends of the articulating rib forms 136 remain covered by the pliable thermoplastic sheet 150. The vacuum from the first and second vacuum pumps 162, 164 may be within a range of 5-10 psi, for example.
[0094] As will be described in greater detail below, the controller 160 is configured to move the articulating rib forms 136 from the extended position to the retracted position as the geo-stabilized construction mat 170 is being formed, causing internal voids to be formed in the exposed ribbing 180. The articulating rib forms 136 are configured with vacuum holes, and as the articulating rib forms 136 are moved to the retracted position, the first vacuum pump 162 pulls a vacuum on the vacuum holes causing the internal voids in the exposed ribbing 180 to be filled with the pliable thermoplastic sheet 150.
[0095] After the vacuum plate 140 is moved to the up position, as shown in FIG. 21, the controller 160 is configured to move the articulating rib forms 136 back to the extended position to eject from the mold cavity 132 the geo-stabilized construction mat 170 with exposed ribbing 180. The geo-stabilized construction mat 170 is ejected after a sufficient time for the geo-stabilized construction mat 170 to solidify while cooling. Depending on the size of the geo-stabilized construction mat 170, a duration on the cooling may be within a range of 5 to 9 minutes, for example.
[0096] Referring now to FIGS. 24-30, the steps of forming the geo-stabilized construction mat 170 with exposed ribbing 180 will be discussed in greater detail. The articulating rib forms 136 are in the extended position within the mold cavity 132, as shown in FIG. 24.
[0097] The mold cavity 132 includes an upper L-shaped edge section 135 and a spaced apart lower L-shaped edge section 137 so that an upper L-shaped interlocking edge section 172 and a lower L-shaped interlocking edge section 174 are formed in the geo-stabilized construction mat 170. The upper and lower L-shaped interlocking edge sections 172, 174 are configured to interlock with one or more adjacent geo-stabilized construction mats. Although not shown in the figures, a surface of the mold cavity 132 may include recesses or notches so that threads 178 may be formed by the thermoplastic sheet 150.
[0098] The articulating rib forms 136 do not extend into the lower L-shaped edge section 137. Travel of the articulating rib forms 136 within the mold cavity 132 is equal to a height of the lower L-shaped edge section 137 within the mold cavity 132. That is, the articulating rib forms 136 do not extend past the lower L-shaped edge section 137.
[0099] The thermoplastic sheet 150 is received by the mold cavity 132, as shown in FIG. 25. The thermoplastic sheet 150 is at an elevated temperature so that the thermoplastic is soft and pliable. The thermoplastic sheet 150 is to cover the articulating rib forms 136 and inner surfaces of the mold cavity 132. As soon as the thermoplastic sheet 150 has been received by the mold cavity 132, the vacuum plate 140 is moved from the up position to the down position, as shown in FIG. 26. In the down position, the vacuum plate 140 contacts the mold cavity 132, as shown in FIG. 27.
[0100] As noted above, the controller 160 is configured to control the first and second vacuum pumps 162, 164 in response to the mold cavity 132 receiving the pliable thermoplastic sheet. The vacuum from the first vacuum pump 162 pulls down on the pliable thermoplastic sheet 150 to cover the articulating rib forms 136 and inner surfaces of the mold cavity 132. The vacuum from the second vacuum pump 164 pulls up on the pliable thermoplastic sheet 150 so that ends of the articulating rib forms 136 remain covered by the pliable thermoplastic sheet 150.
[0101] As the articulating rib forms 136 are moved from the extended position to the retracted position internal, internal voids 185 are formed in the exposed ribbing 180, as shown in FIG. 27. The articulating rib forms 136 are in a partially retracted position in FIG. 27, and are in a fully retracted position in FIG. 28.
[0102] The internal voids 185 increase in size as the articulating rib forms 36 are retracted. The first vacuum pump 164 continues to pull the vacuum on the vacuum holes in the articulating rib forms 136 as the articulating rib forms 136 are being retracted. This causes the internal voids 185 in the exposed ribbing 180 to be filled with the thermoplastic sheet 150, as shown in FIG. 29.
[0103] After the geo-stabilized construction mat 170 with the exposed ribbing 180 has been formed, the vacuum plate 140 is moved to the up position. After a sufficient cooling off period, the geo-stabilized construction mat 170 is ejected from the mold cavity 132, as shown in FIG. 30. This is based on the articulating rib forms 136 being moved back to the extended position.
[0104] The geo-stabilized construction mat 170 is not limited to being formed by the above-described system 125. The geo-stabilized construction mat 170 may also be formed using other methods, such as compression molding or injection molding. Moreover, more than one thermoplastic sheet may be used to form the geo-stabilized construction mat 170.
[0105] Referring now to FIGS. 31-33, the geo-stabilized construction mat 170 will be discussed in greater detail. This discussion is independent of how the geo-stabilized construction mat 170 is to be formed. The geo-stabilized construction mat 170 includes an upper surface 171 and an opposing lower surface 173 with exposed ribbing 180. The exposed ribbing 180 forms a grid pattern of ground stabilization pockets 181 for stabilizing the geo-stabilized construction mat 170 when placed on the ground.
[0106] Dimensions of the geo-stabilized construction mat 170 will vary based on the intended areas in need for a temporary and rigid surface. An example width of the geo-stabilized construction mat 170 may be within a range of 6.5 to 8.5 feet. An example length of the geo-stabilized construction mat 170 may be within a range of 11.5 to 14.5 feet. These dimensions are not to be limiting as smaller or larger sizes of the geo-stabilized construction mat 170 may be readily formed.
[0107] The geo-stabilized construction mat 170 includes an upper L-shaped interlocking edge section 172 and a lower L-shaped interlocking edge section 174. The upper and lower L-shaped interlocking edge sections 172, 174 are configured to interlock with one or more adjacent geo-stabilized construction mats. Each of the upper and lower L-shaped interlocking edge sections 172, 174 include spaced apart connector holes 176 configured to receive connector pins to interlock with the one or more adjacent geo-stabilized construction mats.
[0108] An example height of the exposed ribs 180 may be within a range of 2 to 5 inches. Each of the ground stabilization pockets 181 formed by the exposed ribs 180 intersecting one another may have equal length sides. The ground stabilization pockets 181 may be square shaped, with a separation between opposing sides being within a range of 5 to 7 inches. This corresponds to each ground stabilization pocket 181 having a surface area within a range of 25 to 49 square inches. Based on the example height of the exposed ribs 180, each ground stabilization pocket 181 may have a corresponding volume within a range of 50 to 245 cubic inches. In other embodiments, the exposed ribs 180 intersecting one another may not have equal length sides so that the ground stabilization pockets 181 are rectangular-shaped.
[0109] Often times, the soil under the geo-stabilized construction mat 170 is soft and pliable. The grid of ground stabilization pockets 181 advantageously holds the soil in place to minimize any spreading or pushing out of the soil under the geo-stabilized construction mat 170 when heavy loads are applied.
[0110] For high traffic areas, the geo-stabilized construction mat 170 significantly minimizes movement and separation of the soil where the tire tracks are being applied. This allows the loads applied to the geo-stabilized construction mat 170 to be spread over the entire surface area of the mat instead of being concentrated to the surface area of the mat receiving the pressure points of where the loads are being applied. Consequently, the geo-stabilized construction mat 170 maintains a level surface when being utilized in the field. The upper surface or topside 173 of the geo-stabilized construction mat 170 is textured with threads 178 to form a traction pattern.
[0111] Another aspect is directed to a method for making the geo-stabilized construction mat 170 using the system 125 as discussed above. Referring now to the flowchart 200 in FIG. 34, from the start (Block 202), the method includes placing a pliable thermoplastic sheet 150 in the mold cavity 132 at Block 204 while the articulating rib forms 136 are in the extended position and the vacuum plate 140 is in the up position. The vacuum plate 140 is moved from the up position to a down position to make contact with the mold cavity 132 at Block 206.
[0112] The first vacuum pump 162 is operated at Block 208 so the vacuum therefrom pulls down on the pliable thermoplastic sheet 150 to cover the articulating rib forms 136 and inner surfaces of the mold cavity 132. The second vacuum pump 164 is operated at Block 210 so that the vacuum therefrom pulls up on the pliable thermoplastic sheet 150 so that ends of the articulating rib forms 136 remain covered by the pliable thermoplastic sheet 150.
[0113] The articulating rib forms 136 are moved from the extended position to the retracted position at Block 212 as the geo-stabilized construction mat 170 is being formed. This causes internal voids 185 to be formed in the exposed ribbing 180. As the articulating rib forms 136 are moved to the retracted position, the first vacuum pump 162 is operated at Block 214 to pull a vacuum on vacuum holes in the articulating rib forms 136 causing the internal voids 185 to be filled with the pliable thermoplastic sheet 150.
[0114] The vacuum plate 140 is moved from the down position to the up position at Block 216. The geo-stabilized construction mat 170 is ejected from the mold cavity 132 at Block 218 by moving the articulating rib forms 136 back to the extended position. The method ends at Block 220.
[0115] Many modifications and other embodiments will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the foregoing is not to be limited to the example embodiments, and that modifications and other embodiments are intended to be included within the scope of the appended claims.
Claims
1. A system for making a geo-stabilized construction mat comprising:a mold having a mold cavity, and comprising articulating rib forms movable between an extended position within the mold cavity and a retracted position below the mold cavity;a first vacuum pump configured to pull a vacuum on the mold cavity;a vacuum plate movable between an up position and a down position, with the down position making contact with the mold cavity;a second vacuum pump configured to pull a vacuum on the vacuum plate; anda controller coupled to the articulating rib forms, the first vacuum pump and the second vacuum pump, and configured to perform the following: control the first and second vacuum pumps in response to the mold cavity receiving a pliable thermoplastic sheet while the articulating rib forms are in the extended position and the vacuum plate is in the down position, with the vacuum from the first vacuum pump pulling down on the pliable thermoplastic sheet to cover the articulating rib forms and inner surfaces of the mold cavity, with the vacuum from the second vacuum pump pulling up on the pliable thermoplastic sheet so that ends of the articulating rib forms remain covered by the pliable thermoplastic sheet, andwith the pliable thermoplastic sheet forming the geo-stabilized construction mat with exposed ribbing.
2. The system according to claim 1 wherein the exposed ribbing is on a bottom side of the geo-stabilized construction mat, with the exposed ribbing forming a grid pattern of ground stabilization pockets for stabilizing the geo-stabilized construction mat when placed on the ground.
3. The system according to claim 1 wherein the controller is configured to move the articulating rib forms from the extended position to the retracted position as the geo-stabilized construction mat is being formed, causing internal voids to be formed in the exposed ribbing.
4. The system according to claim 3 wherein the articulating rib forms are configured with vacuum holes, and as the articulating rib forms are moved to the retracted position, the first vacuum pump pulls a vacuum on the vacuum holes causing the internal voids in the exposed ribbing to be filled with the pliable thermoplastic sheet.
5. The system according to claim 1 wherein after the vacuum plate is moved to the up position, the controller is configured to move the articulating rib forms back to the extended position to eject from the mold cavity the geo-stabilized construction mat with exposed ribbing.
6. The system according to claim 1 wherein the mold cavity comprises an upper L-shaped edge section and a spaced apart lower edge L- shaped edge section so that an upper L-shaped interlocking edge section and a lower L-shaped interlocking edge section are formed in the geo-stabilized construction mat, with the upper and lower L-shaped interlocking edge sections configured to interlock with one or more adjacent geo-stabilized construction mats.
7. The system according to claim 1 comprising an extruder to extrude the pliable thermoplastic sheet directly into the mold cavity.
8. The system according to claim 1 wherein the geo-stabilized construction mat with the exposed ribbing is formed in-situ without using injection molding or extrusion compression.
9. A method for making a geo-stabilized construction mat with a system comprising a mold having a mold cavity and articulating rib forms movable between an extended position within the mold cavity and a retracted position below the mold cavity, a first vacuum pump configured to pull a vacuum on the mold cavity, a vacuum plate movable between an up position and a down position, and a second vacuum pump configured to pull a vacuum on the vacuum plate, the method comprising:placing a pliable thermoplastic sheet in the mold cavity while the articulating rib forms are in the extended position and the vacuum plate is in the up position;moving the vacuum plate from the up position to a down position to make contact with the mold cavity;operating the first vacuum pump so the vacuum therefrom pulls down on the pliable thermoplastic sheet to cover the articulating rib forms and inner surfaces of the mold cavity,operating the second vacuum pump so that the vacuum therefrom pulls up on the pliable thermoplastic sheet so that ends of the articulating rib forms remain covered by the pliable thermoplastic sheet;moving the vacuum plate from the down position to the up position; and ejecting the geo-stabilized construction mat with exposed ribbing from the mold cavity.
10. The method according to claim 9 wherein the exposed ribbing is on a bottom side of the geo-stabilized construction mat, with the exposed ribbing forming a grid pattern of ground stabilization pockets for stabilizing the geo-stabilized construction mat when placed on the ground.
11. The method according to claim 9 comprising moving the articulating rib forms from the extended position to the retracted position as the geo-stabilized construction mat is being formed, causing internal voids to be formed in the exposed ribbing.
12. The method according to claim 11 wherein the articulating rib forms are configured with vacuum holes, and as the articulating rib forms are moved to the retracted position, comprising operating the first vacuum pump to pull a vacuum on the vacuum holes causing the internal voids in the exposed ribbing to be filled with the pliable thermoplastic sheet.
13. The method according to claim 9 comprising moving the articulating rib forms back to the extended position to eject the geo-stabilized construction mat with exposed ribbing.
14. A geo-stabilized construction mat comprising: an upper surface; anda lower surface with exposed ribbing, with the exposed ribbing forming a grid pattern of ground stabilization pockets for stabilizing the geo-stabilized construction mat when placed on the ground.
15. The geo-stabilized construction mat according to claim 14 comprising an upper L-shaped interlocking edge section and a lower L-shaped interlocking edge section, with the upper and lower L-shaped interlocking edge sections configured to interlock with one or more adjacent geo-stabilized construction mats.
16. The geo-stabilized construction mat according to claim 15 wherein each of the upper and lower L-shaped interlocking edge sections include spaced apart connector holes configured to receive connector pins to interlock with the one or more adjacent geo-stabilized construction mats.
17. The geo-stabilized construction mat according to claim 14 wherein the upper surface is textured with threads to form a traction pattern.
18. The geo-stabilized construction mat according to claim 14 wherein each ground stabilization pocket is rectangular shaped, and has a width within a range of 5 to 7 inches and a depth within a range of 2 to 5 inches.
19. The geo-stabilized construction mat according to claim 14 wherein a width of the upper surface is within a range of 6.5 to 8.5 feet, and has a length within a range of 11.5 to 14.5 feet.
20. The geo-stabilized construction mat according to claim 14 wherein the upper and lower surfaces comprise a thermoplastic material.