FIBER-REINFORCED LOAD-SUPPORTING MATS
Mats and methods of making the same are described. The mats include a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other, a lip structure extending outwardly from the plurality of sidewalk around a portion of a periphery of the main body, and at least one fiber-reinforcement layer arranged between the two exterior surface walls of the mat. The methods include depositing a first deposition layer of material within a mold, positioning at least one fiber-reinforcement layer on the first deposition layer, depositing a second deposition layer of material within the mold over the at least one fiber-reinforcement layer and the first deposition layer, and treating the first deposition layer, the at least one fiber-reinforcement layer, and the second deposition layer to form a mat.
1 . A mat comprising:
a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other;
a lip structure extending outwardly from the plurality of sidewalls around a portion of a periphery of the main body; and
at least one fiber-reinforcement layer arranged between the two exterior surface walls of the mat.
2 . The mat of claim 1 , wherein the at least one fiber-reinforcement layer extends into a portion of the main body and a portion of the lip structure.
3 . The mat of claim 2 , wherein the at least one fiber-reinforcement layer extends a first distance into the material of the main body and a second distance into the material of the lip structure.
4 . The mat of claim 3 , wherein the first distance and the second distance are equal.
5 . The mat of claim 1 , wherein the at least one fiber-reinforcement layer defines a continuous layer around the periphery of the main body.
6 . The mat of claim 1 , wherein the at least one fiber-reinforcement layer defines a discontinuous layer around the periphery of the main body.
7 . The mat of claim 1 , wherein the at least one fiber-reinforcement layer comprises a backing and a plurality of fibers attached thereto.
8 . The mat of claim 1 , wherein the at least one fiber-reinforcement layer contains recycled carpet material.
9 . The mat of claim 1 , wherein the at least one fiber-reinforcement layer comprises synthetic fibers.
10 . The mat of claim 9 , wherein the synthetic fibers are made of nylon, polypropylene, or polyester.
11 . The mat of claim 1 , wherein the lip structure comprises at least one rib structure and at least one gap adjacent the at least one rib structure.
12 . The mat of claim 1 , wherein the at least one fiber-reinforcement layer is arranged to completely cover at least one of the exterior surface walls.
13 . A method comprising:
depositing a first deposition layer of material within a mold;
positioning at least one fiber-reinforcement layer on the first deposition layer;
depositing a second deposition layer of material within the mold over the at least one fiber-reinforcement layer and the first deposition layer; and
treating the first deposition layer, the at least one fiber-reinforcement layer, and the second deposition layer to form a mat.
14 . The method of claim 13 , wherein the treating comprises at least one of an application of heat and an application of pressure.
15 . The method of claim 13 , wherein the first deposition layer and the second deposition layer are formed of different compositions of material.
16 . The method of claim 13 , wherein the at least one fiber-reinforcement layer contains recycled carpet material.
17 . The method of claim 13 , wherein at least one fiber-reinforcement layer comprises synthetic fibers.
18 . The method of claim 17 , wherein the synthetic fibers are made of nylon, polypropylene, or polyester.
19 . The method of claim 13 , wherein the at least one fiber-reinforcement layer defines a continuous layer around a periphery of the first deposition layer.
20 . The method of claim 13 , wherein the at least one fiber-reinforcement layer defines a discontinuous layer around a periphery of the first deposition layer.