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BACKGROUND AND SUMMARY OF THE INVENTION
The invention is directed to the design and construction of entrance mats,
for lobby and marquee areas, for example, and particularly to matting of
articulated construction, formed of relatively rigid, slat-like units,
connected by hinges and arranged to be rolled up for removal and storage.
Roll-up matting is, in general, known to the art in such forms as
reflected in the Bartlett U.S. Pat. No. 4,029,834, the Balzer U.S. Pat.
No. 4,568,587, the Ellingson U.S. Pat. No. Re. 32,061, and the like. Such
matting has been sold by Pawling Corporation under the trademarks "Rol
Del-I" and "Rol Dek-II" and is illustrated in Pawling Corporation's
"Selection Guide 1987, Floor Mats & Matting". In each of these known
constructions, a floor mat structure is comprised of elongated, relatively
narrow slat-like elements, formed of relatively rigid material, such as
extruded metal or extruded structural plastic. Extruded aluminum is a
material of choice for this purpose. The individual slats may be a few
inches in width and several feet in length, and are connected in an
articulated manner, so that each is hingedly associated with its neighbor.
In the construction of the Bartlett U.S. Pat. No. 4,029,834, ball and
socket type hinge element are integrally formed in the extruded slat-like
members. The ball and socket hinge elements are continuously extruded on
opposite edges of the members and enables one slat-like member to be
hingedly joined to its neighbor.
In the structure of the Balzer and Ellingson U.S. Pat. Nos. 4,568,587 and
Re. 32,061, adjacent slat-like members are joined by separate, elongated
hinging elements. In the case of the structure of the Balzer patent, the
hinge elements are formed of a flexible material, so that adjacent rigid
slat-like members are hingedly joined with each other through the medium
of a bendable, resilient connnector. In the case of the Ellingson U.S.
Pat. No. Re. 32,061, the principal slat-like members are joined by a rigid
ball and socket type hinge member which joins neighoring slats. The slats
thus may be formed with female hinge grooves, which are joined in the
assembly with an elongated, narrow hinge element, formed of a pair of
continuous ball-type hinge elements along its opposite edges.
In all of the foregoing constructions, matting of relatively rigid
construction, and typically formed of extruded aluminum slat-like
sections, can be easily rolled up for removal and storage.
The present invention is directed to roll-up matting of the general type
represented by the above described structures, which is characterized by
the corporation of a plurality of structural improvement features which
simplify and expedite the construction and assembly of the mat and thereby
significantly reduce its final cost.
In roll-up mats of known construction, the individual slat-like members are
commonly constructed of a principal structural element of extruded
aluminum. The aluminum slats are formed with an upwardly opening channel
on their upper faces, provided at opposite sides with short, inwardly
directed flanges. Elongated tread strips, wihch may be formed of
carpet-like material, plastic, or the like, are slideably received endwise
into the open slat channels or inserted by engaging one side of the slat
channel and then folding and snap-fitting the tread thus engaging the
other side and provide a resilient mat surface in the assembled structure.
The lower surface of the extruded aluminum slat section typically is
provided with a spaced apart pair of channels extending the full length of
the slat (i.e. from side to side of the assembled mat). These channels are
likewise formed with opposed, inwardly extending flanges, for receiving
resilient pad strips, which extend from one end to the other of the
slat-like members.
In most of the structures of heretofore known design, elements of generally
similar purpose to those described above have been utilized. In order to
retain the strip-like elements in their assembled positions within the
extruded slat-like sections, mat structures of known types historically
have utilized somewhat cumbersome and/or labor intensive arrangements. In
some cases, the tread strips may be riveted in place at one or both ends
of the metal slat, for example. If the element is designed to be
sufficiently frictionally tight on assembly, problems may be encountered
during the assembly operation in feeding a highly elongated, thin, narrow
strip into the full length of its supporting metal strip. Accordingly, it
is preferable to allow reasonable clearance to secure the tread strip
after its assembly. In the case of the pad strips, extending along the
bottom of the extruded slat-like sections, one common practice has
involved the use of elongatable, resilient elements, such as shown in the
Bartlett U.S. Pat. No. 4,029,834, for example. These elements can be
stretched lengthwise, by workers stationed at opposite ends of the mat
during assembly. The elongated elastic elements are thus reduced in
diameter sufficiently to be forced into restricted slat openings of
grooves provided for their reception. After insertion of the grooves, the
longitudinal tension can be removed, allowing the elements to contract in
length and expand in diameter sufficiently to be retained in position.
This operation, of course, requires the cooperation of two workers and is
highly labor intensive.
In accordance with the present invention, a roll-up mat structure is
provided, which is so designed as to enable the upper tread elements and
the lower pad strips to be freely inserted endwise or topwise, from one
side of the mat. A resilient nosing strip, extending along each side edge
of the mat, and which is easily and quickly attached to the assembled
slat-like elements, serves to retain all of the tread strips and pad
strips in their assembled positions. The resilient nosing strips, pursuant
to the structure of the invention, are quickly and easily attached along
the side edges of the mat structure without riveting or other time
consuming manufacturing steps. The various elements of the mat are
effectively maintained in assembled relation, yet substantial
manufacturing cost is avoided.
For a better understanding of the above and other features and advantages
of the invention, reference should be made to the following detailed
description of a preferred embodiment and to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified, perspective view of a fully assembled mat
constructed in accordance with the teachings of the present invention,
with a small area broken away for illustration.
FIG. 2 is a highly enlarged, fragmentary perspective view of a corner area
of the mat of FIG. 1, showing certain of the parts in a partially exploded
view to illustrate the manner of assembly.
FIG. 3 is an enlarged, transverse, cross sectional view as generally on
line 3--3 of FIG. 2.
FIG. 4 is an enlarged, fragmentary, cross sectional view as taken generally
on line 4--4 of FIG. 6.
FIGS. 5 and 6 are enlarged, fragmentary perspective views illustrating a
sequence of steps involved in assembly of a resilient nosing strip to the
side edge of a mat structure.
FIG. 7 is a highly enlarged, fragmentary perspective view of a mat
structure as taken generally on line 7--7 of FIG. 2.
FIG. 8 is an enlarged, fragmentary cross sectional view showing details of
hinge structure and locking means.
FIG. 9 is a cross sectional view of a form of adapter strip utilized at one
end of the mat structure for joining two "male" hinge elements.
DESCRIPTION OF A PREFERRED EMBODIMENT
Referring now to the drawings, and initially to FIG. 1 thereof, the
reference numeral 10 designates in a general way an articulated mat
structure formed of a plurality of laterally extending, relatively rigid,
slat-like sections 11, secured to adjacent sections along their full
length by hinge joints 12 (see FIG. 8). A mat structure is provided which
is relatively rigid in the width direction, but which may be rolled up in
the lengthwise direction for removal and storage. In some installations,
the articulated slat sections 11 are installed in a recess (not shown)
provided in the flooring area. In other cases, the mat structure is simply
laid over the top of an existing floor surface. In the latter case, nosing
strips 13, 14 are provided around the four edges of the mat. The nosing
strips are of tapered cross sectional profile to provide a transition from
the floor level to the somewhat more elevated level of the mat surface.
With reference now to FIG. 3, the articulated, slat-like strips 11 are
comprised of alternating pairs of "male" and "female" metal strip sections
15, 16. Most desirably, the strip sections 15, 16 are formed of extruded
aluminum, but in some cases extruded plastic materials are also
satisfactory. Along each side edge of the "male" strip sections 15 is a
continuous hinge element comprising a relatively narrow neck 17, extending
horizontally from the side of the strip section, and an enlarged,
cylindrical hinge element 18. In the adjacent "female" slat sections 16,
there are provided continuous cylindrical recesses 19, partially open at
the side edges of the strips 16. The recesses 19 are open at a width less
than the maximum diameter of the cylindrical hinge sections 18 but greater
than the thickness of the neck 17. Accordingly, when an adjacent pair of
slat sections 15, 16 is assembled by endwise insertion of the hinge
sections 18 into the recesses 19, the adjacent sections are secured
together for limited articulated motion. The limit of the hinging action
is determined by the thickness of the neck portion and the width of the
opening 18 at the side of the recess 19, as will be understood.
In the illustrated construction, the cylindrical hinge sections 18 are
provided at one or more locations, preferably adjacent the ends of
convenience, with transverse slots 20 (see FIG. 7, 8). These transverse
slots are aligned, in the assembled mat structure, with vertical bores 21,
extending through the female strips 16 and intersecting the cylindrical
hinge recesses 19. When a connected pair of strips 15, 16 is properly
assembled and aligned, a pin 22, preferably a hollow, tapered roll pin, is
driven into the bore 21. This locks the articulated members against
relative lateral motion, while permitting the desired degree of hinge
motion.
Along the bottom of each of the metal strips 15, 16 there are provided
spaced, downwardly opening recesses 23, extending continuously over the
full length of the strips, from one side to the other of the mat
structure. In the illustrated arrangement, the recesses 23 are of
generally T-shaped cross section, although the particular cross section is
not critical. Received in the spaced recesses 23 are spaced pad strips 24,
which desirably are of a squat "I-shaped" cross section, having short
flange portions 25, 26 extending respectively above and below inwardly
projecting flange elements 27 formed integrally with the metal strips 15,
16. The resilient pad strips 24 are assembled with the metal strip
sections 15, 16 by inserting the pad strips lengthwise into their
respective recesses. The dimensions and tolerances of the parts is such
that a relatively easy sliding assembly can be accomplished.
Each of the metal strips is also provided with a continuous tread strip 28.
The tread strips 28 typically may be formed of a relatively strong,
resilient plastic material provided adjacent its bottom surface with
outwardly extending flange portions 29, 30. The flange portions are
received within inwardly facing channels formed by upwardly facing support
surfaces 31 of the metal strips and inwardly directed flanges 32, 33 which
overlie edge portions of the support surfaces 31. The tread strips 28
advantageously are of extruded plastic construction, designed to have a
sliding fit with the respective metal strip sections 15, 16, in order to
accommodate assembly by endwise insertion of the tread strips into the
metal strips. Carpet strips and the like may also be utilized, in
accordance with known technology.
At the opposite ends of the mat structure, there are provided end nosing
members 14. These, for the sake of manufacturing convenience, are provided
with "male" hinge elements 34, for running continuously the full width of
the mat. Depending on the particular length and construction of the mat,
the endmost articulated slat-like strips 15, 16 could be either both
"male", "female" or one of each. Accordingly, transition elements 35 (FIG.
3) and 36 (FIG. 9) are provided to accommodate any of these situations. As
shown in FIG. 3, a male/female transition element 35 is installed. It is
provied on one side with a male hinge element 37 and on the opposite side
with a recess 38 for reception of the nosing hinge element 34. The
transition element 36, shown in FIG. 9, is female/female, and is provided
with hinge recesses 19 on opposite sides. The transition element 36 is
utilized where the endmost strip is a "male" strip 15.
In accordance with the invention, a simplified and highly advantageous
arrangement is provided for securing the various pad strips 24 and tread
strips 28 in assembled relation with the respective metal strips 15, 16.
Instead of individually riveting or otherwise securing elements to the
metal strips, which can involve numerous time consuming and expensive
operations, or relying upon high friction or distortion fits, which makes
the assembly somewhat difficult and more labor intensive, the present
invention allows for relatively free sliding, endwise insertion or
replacement of the pad and tread strips, and secures these elements in
assembled position by means of the edge nosing strips 13. Thus, as
reflected particularly in FIGS. 4-6, the edge nosing strips 13 are
provided with generally vertical inner walls 40, which extend from the
floor surface approximately to the tops of the tread strips 28. When these
nosing strips are positioned adjacent the side edges of the assembled,
articulated mat structure, the slideable strips 24, 28 are blocked against
lateral displacement from their assembled positions.
Pursuant to the invention, the side nosing strips 13 are provided along
their inner edges with flexible, elastic loop tabs 41 for attachment of
the nosing strips to the articulated mat. The loop tabs are provided at
spaced intervals along the length of the nosing strips 13, ideally one
such loop tab 41 opposite each articulated slat-like strip of the mat. The
loop tabs 41 may be formed by extruding along the inner edge of the strip
a continuous, laterally projecting flange, and then die cutting or
otherwise removing spaced, intervening portions of the flange leaving
relatively narrow laterally projecting loop tabs 41, as shown in FIG. 5,
for example.
To particular advantage, the attachment of the loop tabs to the articulated
mat strips is accomplished by means of punched-out offset hook tabs 42
formed in the central flat lower surface portions 43 of the metal strips
15, 16. By means of a simple punching and forming operation, an L-shaped
hook tab 42 may be displaced upwardly from the bottom surface 43,
providing a short upwardly extending tab section 44 integrally attached to
the strip 15 or 16, and a horizontally extending portion 45 projecting
inwardly, parallel to the bottom surface 43 but spaced thereabove a
distance corresponding generally to the thickness of the loop tabs 41. The
loop tabs 41, attached to the nosing strips, are provided with internal
openings 46 of a size and shape to be received over the free ends of the
offset hook tabs 42. The geometry of the hook tabs 42 and the loop tabs 41
is such that, when the elements are engaged, the nosing strips 13 are held
closely against the side edges of the articulated mat strips, as reflected
particularly in FIGS. 4 and 6. Advantageously, cooperating pairs of hook
and loop tabs are provided at the ends of each of the articulated
sections.
As reflected in FIG. 3, the bottom surfaces 43 of the metal strip sections
15, 16 are offset below the arched lower surfaces 47 of the tread strips.
This provides sufficient open space to accommodate the presence of the
respective hook and loop tabs 42, 41.
Assembly of the resilient pad strips 24 and the tread strips 28 is
extremely simplified and expeditious in the structure of the invention.
Initially, the pad strips 24 are inserted endwise in their respective
channels 23. This may be done before or after the plurality of slat-like
metal strip sections 15, 16 have been joined and pinned. Preferably, the
pad strips are inserted after assembly of the hinged metal sections to
each other.
After all of the hingedly connected sections of the assembly have been
joined, including the transition elements 35, 36 and end nosings 14, and
after the pad strips 24 have been inserted lengthwise in their retaining
channels, the edge nosing strips 13 are assembled and secured. This is
quickly and easily accomplished by tilting the edge nosing upward,
substantially to a vertical orientation, enabling the respective loop tabs
41 to project downward to be applied over the inwardly projecting ends of
the hook tabs 42.
The length of the integral loop tabs 41 is such as to enable the outermost
transverse element 50 thereof to be engaged underneath the upwardly
displaced hook tabs 42, when the nosing strip 13 is generally vertically
oriented with the loop tabs projecting downward. The nosing may thereafter
be displaced laterally outward and then rotated downward the horizontal
position, as reflected in FIG. 6. When the nosing is in a horizontal
position, the front elements 50 of the loop tabs is locked under the hook
tabs 42, retaining the nosing 13 in position adjacent and generally
abutting the end edges of the articulated strips.
Pursuant to the invention, the elasticity in the retaining elements 41,
together with the provision of some clearance space between the transverse
section 50 and the upwardly extending hook tab section 44, enables the
nosing strip 13 to be pivoted downwardly, relative to the articulated
strips, sufficiently to allow access for the slide-in assembly of the
tread strips 28. After installation of the tread strips 28, the downward
pivoting force on the nosing strip 13 is released, allowing the nosing
strip to return to a more normal position, in which the just-installed
tread strips 28 are effectively locked in place. When the mat is in use,
of course, the side nosing strips 13 are supported by the floor surface
and are thus prevented under any circumstances from being pivoted in a
downward direction. As reflected particularly in FIG. 4, the location of
the loop tabs 41 is substantially closer to the bottom surface 51 of the
nosing strip 13 than to the upper surface 52. Accordingly, while the
nosing may readily be pivotally diplace in a downward direction, for
assembly of the tread strips 28, pivoting in the upward direction is
effectively prevented after assembly of the tread strips 28.
Inasmuch as the side nosing strips 13 are formed of a resilient material,
they flex sufficiently to accommodate rolling up of the articulated
slat-like elements for removal and storage of the assembled mat. In the
rolled-up condition of the mat, the side nosing strips 13 are effectively
locked against any pivoting action, assuring that the pad strips 24 and
tread strips 28 remain effectively retained in their assembled positions.
The features of the invention enable articulated mat structures, in
themselves generally of known design and construction, to be assembled
more expeditiuosly and more economically by using edge strips on opposite
sides to retain a plurality of pad strips and tread strips in their
assembled positions with respect to individual articulated slat sections.
Once the individual elements have been assembled, all of the strip-like
pads and treads are automatically retained in assembled position without
individual securement, by the presence of the edge strips, which prevent
lateral displacement of the pad and tread strips.
To particular advantage, the side edge strips are securable to the
articulated slat sections, by a series of loop-like securing elements
extending integrally from the edge strips and joined with offset hook tabs
formed integrally in the articulated slat sections. The initial assembly
of the edge strips requires a generally upright rotational orientation
thereof, in order to effect initial engagement of the tabs. Subsequently,
after the tread strips have been installed in position, it is no long
possible to pivot the edge strips back into a generally vertical
orientation. As a result, while the edge strip serves to retain the tread
strips in assembled relation, the tread strips in turn serve to lock the
edge strips in assembled relation. All of this is accomplished without the
use of time consuming (and therefore costly) procedures of the prior art.
These have included the use of rivets, the staking of assembled parts, the
installation of pad strips by elastic distortion, etc. With the mat design
of the present invention, all of the strip-like elements may be designed
for relatively easy slide-in assembly, and the necessary retention is
provided by the presence of the edge strips 13.
It should be understood, of course, that the specific form of the invention
herein illustrated and described is intended to be representative only, as
certain changes may be made therein without departing from the clear
teachings of the disclosure. By way of example, the illustrating edge
strip is in the form of a tapered nosing, utilized to provide for
elevational transition when the mat is placed on a flat floor. For
articulated mat assemblies designed for installation in a recessed frame,
flush with the floor level, the tapered nosing strips are replaced by
narrower, untapered edge strips forming a thin, resilient border between
the articulated structural elements and the surrounding recessed frame.
The side edge strips, for such installations, will function in the same
way as the nosing strips 13 specifically illustrated, as regards the
assembly and retention procedures. Accordingly, reference should be made
to the following appended claims in determining the full scope of the
invention.
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