Field of invention

The present invention relates to a panel for a floor covering system and in particular, although not exclusively, to a panel having a ridge or thread pattern on the upper and lower faces to allow neighbouring panels to lock together when stacked vertically.

Background art

Modular ground protection flooring is used frequently to provide temporary protection for grass and turf areas such as sport stadiums. The modular systems create rigid floor surfaces that provide walkways, roads, parking areas and other types of flooring to support the passage of people and vehicles and allow storage and mounting of equipment.

Example modular flooring systems are described in WO 2011/130012; WO 2010/138604; US 5,364,204; US 2004/0005430 and GB 2261003. Existing plastic ground protection mats are typically hollow honeycomb constructions with examples described in US 5,653,551; US 6,511,257; US 6,649,110; US 6,695,527; and US2012/0266549. The honeycomb construction allows air and light to penetrate to the underlying grass and provides the required rigidity. However, existing panels are bulky and are accordingly difficult to store and transport. Sealed honeycomb bodies tend to become punctured and then to fill with water or mud. Additionally, existing systems do not interlock when stacked and accordingly become unstable in transit or if stored on an uneven ground. Accordingly, what is required a ground protection panel that addressee the above problem.

Summary of the Invention It is an objective of the present invention to provide a ground protection tile or panel that provides both a reliable and robust ground protection mat when in use and one that may be arranged with neighbouring panels to form an interlocked vertical stack so as to be convenient and robust for transport. It is a further specific objective to configure the panels for rapid, convenient and robust interconnection to form a substantially planar interlocked panel system when arranged over the ground.

The interlocking characteristic is achieved by the panel having a repeating pattern on the upper contact face and a repeating pattern on the downward facing ground engaging face. The present vertically stackable interlocking structure is achieved via individual projections extending either upwardly or downwardly from each respective contact or engaging face. The respective tread patterns on the contact and engaging faces are configured to enter engage one another to provide a self-locking interconnected structure. That is, the repeating pattern on each face is formed from projections that define gap regions that are dimensioned to accommodate the projections of the alternate engaging or contact face of a neighbouring panel. The ridge or tread profile on both faces is accordingly configured to provide traction for people or vehicles passing over the panels when assembled over the ground as a modular interlocking structure and also to allow the panels to be stacked vertically. The present ridge or tread pattern on both the engaging and contact faces are optimised for ease of manufacture, to be robust against lateral and sheer forces and to provide grip and traction independently of the direction of travel of a vehicle passing over the panel.

According to a first aspect of the present inventions there is provided a panel for a floor covering system, the panel comprising: a main body having a first substantially planar upward facing contact face and an opposed downward facing engaging face; the contact and engaging face each comprising a respective ridge or tread pattern such that neighbouring panels may be stacked on top of one another to form an interlocked stack via frictional engagement between the ridge or tread patterns at the opposed contact and engaging faces; wherein the ridge or tread pattern on one of the contact or engaging faces defines regions gap regions such that the ridge or tread pattern of a panel is configured to sit within the gap regions of a neighbouring panel when the panels are stacked vertically on top of one another.

The repeating ridge or tread pattern on the contact and engaging faces may be moulded or machined into the face by mechanical means such as routing or milling. The ridge and tread pattern provide a tessellating interlocking structure such that the respective ridge patterns define male and female ridges that are configured to cooperate and interlock..

Optionally, the panel further comprises a flange and overhang extending outwardly from at least two sides of the main body.

Optionally, the panel further comprises at least one first interconnect element and at least one second interconnect element to releasably lock the panel to a respective identical neighbouring panel.

Optionally, the panel further comprises apertures in the main body to allow transmission of air and light to penetrate through the main body to the underlying ground.

Optionally, the panel further comprises apertures in the flange and overhang to allow air and light to penetrate through the flange to the underlying ground.

Optionally, the ridge or tread pattern on the contact and engaging faces are configured to overlap in touching frictional contact with the ridges or tread pattern of a neighbouring panel so as to vertically stack and interlock neighbouring panels.

Optionally, the panel further comprises a first overhang projecting laterally outward from a lengthwise end of the panel and an overhang projecting laterally outward from a widthwise end of the panel. Optionally, the panel further comprises a flange projecting laterally outwardly from a lengthwise end of the panel and a flange projecting laterally outward from the widthwise edge of the panel, the flange being dimensioned so as to sit underneath the corresponding overhang of an adjacent panel when neighbouring panels are positioned side-by-side over the ground to form an overlapping modular floor covering system.

Optionally, the flange and overhang comprise a plurality of boreholes to receive attachment bolts to interconnect a flange of a first panel to an overhang of a second panel forming part of the floor covering system.

Optionally, the panel comprises an annular shoulder projecting upward and extending around one end of the borehole at the flange so as to define a recess at one end of the borehole.

Optionally, the apparatus further comprises a plurality of inserts for positioning in contact with a region of the contact face and a plurality of second inserts for positioning in contact with the engaging face, the first and second inserts mountable in opposed and aligned configuration; the apparatus further comprising a plurality of fastening bolts extending axially through the first and second inserts to releasably lock neighbouring panels when arranged in position side-by-side.

Optionally, the first insert comprises an upstanding shoulder to surround and protect a head of a fasting bolt inserted through the first and second inserts.

Optionally, the contact face comprises a first ridge or tread pattern and the engaging face comprises a second ridge or tread pattern. Optionally, the first ridge or tread pattern is the same as second ridge or tread pattern. Optionally, the first ridge or tread pattern is different to the second ridge or tread pattern. Optionally, the ridge or tread pattern on the contact face defines a plurality of first geometrically shaped projections and the ridge or tread pattern on the engaging face defines second geometrical shaped projections.

Optionally, the ridge or tread pattern on one of the contact or engaging faces comprises regions that define octagonal shaped projections and the ridge or tread pattern on the alternate engaging or contact face comprises regions that define square or diamond shaped projections. Optionally, the square or diamond shaped projections define the gap regions within which the octagonal shaped projections are configured to sit. Optionally, each one of the octagons of the ridge or tread pattern of a first panel is surrounded by four squares of the ridge or the tread pattern of a second panel when stacked vertically together.

Each of the squares and octagons are formed as individual ridge extensions such that the respective perimeters of each of the octagons and squares are clearly defined and stand 'proud' of the underlying main body of the panel from which they project either in the upward direction (at the upper contact face) or in a downward direction (if provided at the lower ground engaging face). The octagonal, squares or diamond shaped projections are advantageous for manufacture as the number of straight line cuts that are required for a routing or milling process are minimised.

The octagonal shape profile is further advantageous for the upward facing contact surface so as to provide good traction for the wheels of traffic when the mats are in use and positioned over the ground. In particular, an octagon shape profile is advantageous as the grip is independent of direction of travel of the vehicles.

According to a further aspect of the present inventions there is provided a floor covering apparatus comprising a plurality of panels as claimed herein. According to a further aspect of the present inventions there is provided a modular ground protection system comprising a panel having a first repeating tread pattern on an upward facing contact surface and a second repeating tread pattern on a lower facing engaging face. The respective tread patterns are configured to interengage one another when adjacent panels are stacked vertically so as to provide a self-locking interconnected structure. The panels also comprise laterally extending overhangs and flanges so that neighbouring panels when positioned side-by-side at least partially overlap to form a tessellated ground protection system.

Optionally, each panel comprises an upstanding shoulder to surround and protect a head of each fasting bolt inserted through the first and second inserts.

Brief Decryptions of the drawings A specific implementation of the present invention will now be described, by way of example only and with reference to the accompanying drawings in which: Figure 1 is an upper perspective view of a ground protection panel according to a specific implementation of the present invention;

Figure 2 is a cross sectional side view through A-A of figure 1 ; Figure 3 is a cross sectional side view of the interlocking mechanism for connecting neighbouring panels in side-by-side relationship;

Figure 4 is a plan view of the interlocking ridge or tread pattern though a plane of two panels stacked vertically on top of one another;

Figure 5 is a cross sectional side view of the interlocking mechanism for connecting neighbouring panels in side-by-side relationship according to a further embodiment of the present invention; Figure 6 is an upper perspective view of a ground protection panel of figure 1 according to a further specific implementation.

Detailed Description of preferred embodiment of the invention Referring to figure 1 a ground protection panel 100 comprises a generally planar configuration having an upward facing contacts face 101 and a downward facing ground engaging face 200. Contact face 101 is defined by a perimeter comprising a pair of lengthwise extending edges 107 and a pair of widthwise extending edges 108. Panel 100 comprises an overhang 112 provided at one of the widthwise edges 108 and a corresponding overhang 111 provided at one of the lengthwise extending edges 107. An opposite widthwise extending edge 108 comprises a flange 103 that represents an extension of a lowermost underside region of panel 100. Similarly, the remaining lengthwise extending edge 107 also comprises a corresponding flange 102. Each overhang 112, 111 and flange 102, 103 is dimensioned such that neighbouring panels 100 may be arranged side-by-side in touching contact such that overhang 112 of a first panel 100 overlaps to sit on to top of a flange 103 of a neighbouring panel 100 whilst overhang 111 is similarly configured to sit on top of flange 109 of the two panels 100.

Accordingly, panel 100 may be considered to comprise a dual layer structure in which a first upper layer is positioned off-set in both the lengthwise and widthwise directions relative to a lower layer.

Neighbouring panels 100 may be interlocked as described with reference to figure 3 via alignment of boreholes 105 provided at flanges 103, 102 with corresponding eyelets 106 formed within each overhang 111, 112.

According to the specific implementation, a repeating ridge or tread pattern 104 is provided at contact face 101 whilst a corresponding different ridge or tread pattern 408 is provided at underside ground engaging face 200. According to the specific

implementation, contact face ridge pattern 104 comprises a plurality of repeating octagonal shaped projections with each octagon unit representing a ridge projecting perpendicular to the plane of the panel 100. Similarly, the square or diamond projections are defined by ridges 408 that also extend perpendicular to the plane of panel 100. The ridges that define the octagons and squares/diamonds are formed integrally with the panel main body. Referring to figure 3, neighbouring panels 100 may be releasably interlocked when positioned side-by-side with an overhang 112 of a first panel 100 engaged so as to overlap onto a corresponding flange 103 of a neighbouring panel 100. As illustrated in figure 3, preferably the contact face 101 at overhang 112 is bevelled 300 such that the upper contact face 301 at overhang 112 is recessed vertically below contact face 101 (extending over the main body of panel 100). Neighbouring panels 100 are secured via a two part insert received and secured within the respective eyelets 106 and holes 105. In particular, a first insert part 303 is positioned on top of each eyelet 106 such that a shaft 307 extends through each eyelet 106 to emerge at an underside surface of overhang 112. A corresponding threaded second insert part 306 is located from an underside of each borehole 105 such that a corresponding shaft 308 is aligned coaxially with upper part shaft 307 with the first and second inserts 303, 306 locked together via a coaxially threaded bolt 302. Insert part 306 is secured in fixed position via retaining screws 305 projecting downwardly through flange 103. First insert part 303 comprises an annular shoulder 304 to at least partially surround and protect a head of bolt 302. A gap region 309 is provided within the region of each eyelet 106 so as to provide a thermal expansion space for each panel 100 in use.

Alternatively and according to further embodiments, elements 302, 303, 304 and 307 could be combined into a single threaded shoulder bolt assembly.

Referring to figure 4, the octagonal tread pattern 104 may be created conveniently at contact face 101 via moulding or in particular machining panel body 100 in four milling directions. In particular, a first cut direction is used to create octagon sides 402, a second cut direction creates octagon sides 403; a third cut direction creates octagon sides 404 whilst a fourth cut direction creates the remaining octagon sides 405. Similarly, the square or diamond repeating tread pattern 408 at ground engaging face 200 may be created conveniently via machining in two cut directions. In particular, a pair of opposed square sides 406 are created via a machining cut in a first direction whilst the remaining pair of sides 407 are created by machining in a second cut direction.

Figure 4 illustrates the tessellation of the repeating ridge and tread patterns at the respective upper and lower faces 101, 200 when neighbouring panels 100 are stacked vertically on top of one another. That is, the octagons 104 are configured to sit in the space 409 between the ordered array of square ridges 408 so as to provide a locking

interconnected structure.

Figures 5 and 6 illustrate a further embodiment of the ground protection panel 100. The features and function of the embodiment of figures 5 and 6 correspond to those of the embodiment of figures 1 to 4 but differs by the interlocking mechanism for connecting panels 100 side-by-side and in an overlapping configuration via flanges 103 and overhangs 112. In particular, and referring to figure 5, each panel 100 according to the further embodiment, comprises eyelets 106 provided at the region of overhang 112 that are defined at their uppermost contact surface 101 by a respective integrally formed annular shoulder 500. Each shoulder 500 is raised so as to stand proud from contact face 101. The bore that defines the eyelet 106 is flared radially outward at the region of contact surface 101 to define a recess 503 being radially enlarged relative to bore 106. Recess 503 is defined, in part, by the annular shoulder 500. An axial depth of recess 503 is configured to correspond approximately to the height (or thickness) of a head 502 of attachment bolt 302 so as to be effective to protect bolt 302 and head 502 from impacts in the lateral sideways direction. As with the embodiment of figures 1 to 4, the attachment mechanism of figure 5 also comprises a first insert 504 inserted within eyelet 106 and a second insert 306 threaded and mounted within borehole 105 within flanges 102, 103. As with the embodiment of figures 1 to 4, the two inserts 504, 306 comprise respective axial shafts 505, 308 with central bores. Shaft 308 is also internally threaded to receive threaded bolt 302 that couples axially the two inserts 504, 306 and locks the neighbouring panels 100 together.

Insert 504 also comprises an annular flange 507 projecting radially outward from one end of shaft 505. Flange 507 is configured to sit in mating contact with a surface of a shoulder 506 defined at the axial junction between bore 106 and recess 503. The interaction between flange 507 and shoulder 506 prevents insert 504 from passing through borehole 106. A corresponding gap region 309 is provided to extend at least partially around insert 504 to act as a thermal expansion space for panel 100. According to the specific implementation, a height by which the annular protection shoulder 500 extends from the upper contact surface 101 is greater than the height of a raised tread indicated generally by reference 501 that is formed as repeating raised octagonal projections extending from surface 101. Shoulder 500 is accordingly configured to extend circumferentially around bolt head 502 and insert 504 such that a large portion of the bolt 302 (including head 502) and insert 504 is concealed and located within the region of overhang 112. According to further embodiments, flange 112 may comprise a thickness (in a direction perpendicular to the plane of surface 101) that is sufficient to accommodate bolt head 502 (and insert 504) within recess 503. Accordingly, such an embodiment would not comprises the annular shoulder 500 being raised relative to surface 101. To facilitate insertion and alignment of first insert 504 within borehole 106, the leading end 508 of first insert shaft 505 may be tapered. That is, a wall thickness of the shaft 505 at its leading end may be reduced relative to the thickness of the shaft main length.

The main body of panel 100 may be solid so as to comprise no internal cavities or voids. According to further embodiments, the panel main body may be formed as an internal honeycomb, cellular or foam construction or a solid construction having internal cavities so as to minimise the total weight of the panel 100.

According to further embodiments, the contact face ridge/tread pattern 104 and the ground engaging face ridge/tread pattern 408 may comprise the same repeating pattern formed by ridges or projections extending from the main body of panel 100. The ridges or projections may be formed as individual projections or ridges or the ridges may define geometrical shapes such as circles, ovals, ellipses, polygons, triangles, diamonds, rectangles, squares, pentagons, hexagons, heptagons, octagons. Optionally, the geometrical shaped profiles may be regular or irregular. Optionally, the ridge pattern at one of the contact face 101 or ground engaging face 200 may be formed from ridges or projections whilst the tread profile at the alternate ground engaging face 200 or contact face 101 comprises ridges that define a repeating geometrical shape between or within which provides gap regions to accommodate the ridges or projections of the alternate face 101, 200.