IP Library Granted Patent US 12,129,608
Granted Patent B2
US 12,129,608 · App. 16/890,510 · Granted Oct 29, 2024

Overlapping modular mat systems

Inventors: Saad Aziz (Carencro, LA); Gaurav Agrawal (Katy, TX)
Assignee: NEWPARK MATS & INTEGRATED SERVICES LLC
E01C9/086E01C9/08E01C11/16E01C5/20
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Quick Facts
Patent No.
US 12,129,608
App. No.
16/890,510
Granted
Oct 29, 2024
Kind
B2
Abstract

Mats and methods associated therewith are described. The mats include a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other. The main body includes a pattern of internal walls that define internal voids within the main body. At least one primary 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. The at least one primary structural support rib traverses the internal voids defined by the pattern of internal walls.

Claims (42)

1. A mat comprising:

a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other, wherein the main body includes a pattern of internal walls that define internal voids within the main body;

at least one primary structural support rib arranged within the main body and extending between the two exterior surface walls to a second of the two exterior surface walls and from a midpoint between ends of one of the plurality of side walls to a midpoint between ends of another of the plurality of side walls, wherein the at least one primary structural support rib traverses a first plurality of the internal voids defined by the pattern of internal walls, wherein the at least one primary structural support rib divides the main body into at least two sections; and

at least two secondary structural support ribs arranged within each of the at least two sections defined by the at least one primary structural support rib, wherein each secondary structure support rib extends between the two exterior surface walls, wherein each secondary structural support rib traverses a second plurality of the internal voids defined by the pattern of internal walls,

wherein each secondary structural support rib is arranged at an angle that is non-perpendicular relative the at least one primary structural support rib, and

wherein the at least one primary structural support rib is configured to enable separation of the mat into a plurality of sub-mats along a channel defined by the at least one primary structural support rib.

2. The mat of claim 1 , wherein the walls of the pattern of internal walls extend between the two exterior surface walls.

3. The mat of claim 1 , wherein the at least two secondary structural support ribs are arranged in an X-shape within a respective section defined by the at least one primary structural support rib.

4. The mat of claim 1 , wherein the at least two secondary structural support ribs divide the respective section into three or more subsections.

5. The mat of claim 1 , wherein at least one secondary structural support rib of the secondary structural support ribs extends from at least one of the side walls to the at least structural support rib.

6. The mat of claim 1 , wherein each secondary structural support rib has a length that is less than a length of the at least one primary structural support rib.

7. The mat of claim 1 , wherein each secondary structural support rib has a material thickness that is less than a material thickness of the at least one primary structural support rib.

8. The mat of claim 1 , wherein each sub-mat that is configured to be separated from the mat is configured to secure or connect to another one of the plurality of the sub-mats that is configured to be separated from the mat or another mat.

9. The mat of claim 1 , further comprising a hook pocket defined along the channel of the at least one primary structural support rib, the hook pocket configured to enable a tool to engage with a sub-mat.

10. The mat of claim 1 , further comprising a lip structure extending outwardly from the plurality of sidewalls around a periphery of the main body.

11. The mat of claim 10 , wherein the at least one primary structural support rib is configured to enable separation of the mat into a plurality of sub-mats along a channel defined by the at least one primary structural support rib and wherein each sub-mat includes a portion of the lip structure.

12. The mat of claim 1 , wherein the internal voids of the interior support structure define at least 45% of an interior volume of the main body.

13. The mat of claim 1 , wherein:

the plurality of sidewalls comprise a first sidewall, a second sidewall, a third sidewall, and a fourth sidewall,

the first sidewall and the third sidewall are opposite each other,

the second sidewall and the fourth sidewall are opposite each other,

the first and third sidewalls are arranged normal to the second and fourth sidewalls, and

wherein the at least one primary structural support rib comprises:

a first primary structural support rib that extends between the first sidewall and the third sidewall; and

a second primary structural support rib that extends between the second sidewall and the fourth sidewall.

14. A mat comprising:

a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other, wherein the main body includes a pattern of internal walls that define internal voids within the main body; and

at least one primary structural support rib arranged within the main body and extending from a first of the two exterior surface walls to a second of the two exterior walls and from one of the plurality of side walls to another of the plurality of side walls, wherein the at least one primary structural support rib traverses the internal voids defined by the pattern of internal walls, wherein the at least one primary structural support rib comprises two rib walls with a channel defined between the two rib walls, wherein at least one primary structural support rib is configured to enable separation of the mat into a plurality of sub-mats along the channel defined by the at least one primary structural support rib, and

wherein each sub-mat that is configured to be separated from the mat is different from each other sub-mat separated from the mat and is configured to secure or connect to another one of the plurality of the sub-mats or another mat.

15. The mat of claim 14 , wherein the at least one primary structural support rib divides the main body into at least two sections, the mat further comprising:

at least one secondary structural support rib arranged within each of the at least two sections defined by the at least one primary structural support rib, wherein the at least one secondary structural support rib traverses the internal voids defined by the pattern of internal walls, wherein the at least one secondary structural support rib divides a respective section into two or more subsections.

16. The mat of claim 14 , further comprising at least one secondary structural support rib that extends from at least one of the side walls to at least one of the at least one primary structural support rib.

17. The mat of claim 14 , further comprising at least one secondary structural support rib, the at least one secondary structural support rib having at least one of (i) a material thickness that is less than a material thickness of the at least one primary structural support rib and (ii) a length that is less than a length of the at least one primary structural support rib.

18. The mat of claim 14 , further comprising a hook pocket defined along the channel of the at least one primary structural support rib, the hook pocket configured to enable a tool to engage with a sub-mat.

19. The mat of claim 14 , further comprising a lip structure extending outwardly from the plurality of sidewalls around a periphery of the main body, wherein the at least one primary structural support rib is configured to enable separation of the mat into the plurality of sub-mats along the channel defined by the at least one primary structural support rib and wherein each sub-mat includes a portion of the lip structure.

20. A mat comprising:

a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other, wherein the main body includes a pattern of internal walls that define internal voids within the main body;

at least one primary structural support rib arranged within the main body and extending between the two exterior surface walls to a second of the two exterior walls and from a midpoint between ends of one of the plurality of side walls to a midpoint between ends of another of the plurality of side walls, wherein the at least one primary structural support rib traverses a first plurality of the internal voids defined by the pattern of internal walls, wherein the at least one primary structural support rib divides the main body into at least two sections;

at least two secondary structural support ribs arranged within each of the at least two sections defined by the at least one primary structural support rib, wherein each secondary structure support rib extends between the two exterior surface walls, wherein each secondary structural support rib traverses a second plurality of the internal voids defined by the pattern of internal walls; and

a lip structure extending outwardly from the plurality of sidewalls around a periphery of the main body,

wherein each secondary structural support rib is arranged at an angle that is non-perpendicular relative the at least one primary structural support rib, and

wherein the at least one primary structural support rib is configured to enable separation of the mat into a plurality of sub-mats along a channel defined by the at least one primary structural support rib and wherein each sub-mat includes a portion of the lip structure.

Assignments (6)
RELEASE OF SECURITY INTEREST Recorded Jun 20, 2025
From: BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT
To: NPK ACCESS SOLUTIONS LLC (AS SUCCESSOR IN INTEREST TO NEWPARK MATS & INTEGRATED SERVICES LLC)
Reel/Frame 071468/0929 →
SECURITY INTEREST Recorded Jun 20, 2025
From: NPK ACCESS SOLUTIONS LLC
To: BANK OF AMERICA, N.A.
Reel/Frame 071472/0422 →
CHANGE OF NAME Recorded Jan 30, 2025
From: NEWPARK MATS & INTEGRATED SERVICES LLC
To: NPK ACCESS SOLUTIONS LLC
Reel/Frame 070057/0653 →
CORRECTIVE ASSIGNMENT TO CORRECT THE SECOND INVENTOR'S NAME FROM GARAUV AGRAWAL TO GAURAV AGRAWAL PREVIOUSLY RECORDED ON REEL 052881 FRAME 0850. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded May 20, 2021
From: AZIZ, SAAD; AGRAWAL, GAURAV
To: NEWPARK MATS & INTEGRATED SERVICES LLC
Reel/Frame 056320/0572 →
SECURITY INTEREST Recorded Dec 7, 2020
From: NEWPARK MATS & INTEGRATED SERVICES LLC (A TEXAS LIMITED LIABILITY COMPANY)
To: BANK OF AMERICA, N.A. (A NATIONAL BANKING INSTITUTION)
Reel/Frame 054567/0840 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 9, 2020
From: AZIZ, SAAD; AGRAWAL, GARAUV
To: NEWPARK MATS & INTEGRATED SERVICES LLC
Reel/Frame 052881/0850 →
Cited By (1)
US 12,674,330