Portable porous pavement system and method for assembling such a pavement system

(54) Title: POROUS POROUS FLOORING SYSTEM AND METHOD FOR ASSEMBLING SUCH FLOORING SYSTEM (51) Int.CI .: E01C 5/00; E01C 9/08; E04B 1/61 (30) Unionist Priority: 24/01/2007 US 60 / 886,454 (73) Holder (s): REYNOLDS CONSUMER PRODUCTS, INC.

(72) Inventor (s): RICARDO SCHMALBACH RESTREPO; MARIO MORENO MANZANO; DANIEL F. SENF; GARY M. BACH “POROUS POROUS FLOORING SYSTEM AND METHOD FOR ASSEMBLING SUCH FLOORING SYSTEM”

This application is being filed on January 22, 2008, as an International PCT patent application in the name of REYNOLDS CONSUMER PRODUCTS, INC., An American national corporation, applicant for the designation of all countries except the United States, and Ricardo Schmalbach Restrepo, a citizen of Colombia; Mario Moreno Manzano, citizen of Ecuador; Daniel Senf, a citizen of the United States; and Gary Bach, a citizen of the United States, applicants for the designation of the United States only, and claims priority under 35 USC §119 (e) for US provisional patent application Serial No. 60/886 454, filed on January 24, 2007, whose full disclosure is hereby incorporated by reference.

Technical Field

This disclosure refers to porous floor system components and methods of use. In particular, it refers to a system that includes a plurality of porous floor units connected together by a plurality of specific types of fixing device.

Background

The need for an effective soil resistance improvement system capable of handling heavy loads and stabilizing poor soils has existed for many years. In certain applications, such as during oil exploration, it is necessary to transport heavy equipment and materials in remote areas that do not necessarily have roads or good sustainable soil. Some solutions used in the past used wooden boards to support loads in areas where the land is of poor quality. It is necessary to stabilize and / or connect the wooden boards together, and it was found that this is a time-intensive and labor-intensive process. When operational activity is completed, it can be a time-intensive process to dismantle and remove materials that are not biodegradable, such as nails or other metal piles. Improvements in systems are desirable to quickly install and remove these types of floor systems.

The transferee, Reynolds Consumer Products, Inc. d / b / a Presto Products, of Appleton, Wisconsin, manufactured a product sold under the trade name GEOBLOCK®. The GEOBLOCK® porous pavement system provides support for vehicle and pedestrian loads across grassy areas, while protecting the grass from the damaging effects of traffic. The unit is made of polyethylene, usually recycled polyethylene. Each unit includes intersecting walls, which define a plurality of cells. These units are typically transported to the region where they will be installed. The units are assembled and connected to each other. Once installed, heavy equipment can be driven over them, and the soil or earth is not pulled out and is not subject to unnecessary erosion or exhaustion.

Summary of Revelation

In general, a portable porous floor system includes a plurality of porous floor units and a plurality of fixing devices, wherein each of the porous floor units is connected to an adjacent porous floor unit by at least one fixing device . Each porous floor unit includes intersecting walls that define a plurality of cells. Each fixing device includes a first clamp and a second clamp. The first clamp defines a slot arrangement. The second clamp is in intimate communication with the slot arrangement of the first clamp. The second clamp has a twisted arrangement for attaching the second clamp and the first clamp to each other. Two adjacent walls of two adjacent porous floor units are fitted between the first clamp and the second clamp in order to secure the two adjacent porous floor units together.

A method for assembling a portable porous floor system includes providing a first and a second porous floor unit, each porous floor unit defining a mounting side and a user side. Then, a C-shaped fastener is mounted on two adjacent walls of the first and second porous floor units. The C-shaped fastener includes a first and a second arm joined by a base element. The two adjacent walls of the first and second porous floor units are between the first and second arms of the C-shaped fastener. The base element of the C-shaped fastener is against the mounting side of the porous floor. Then there is the step of orienting the first and second porous floor units, with the C-shaped fixture on a surface, such as the earth, with the free end of the first and second arms pointing away from the surface . The mounting side of the first and second porous floor units is flush with the surface, while the user side of the porous floor units is oriented away from the surface. The method then includes the step of obtaining a locking clamp that has a U-shaped section that extends between the first and second slotted wings. Then, there is the step of mounting the locking clamp on the C-shaped fastening element by orienting the U-shaped section on the two adjacent walls, with the first arm crossing the first slotted wing and the second arm crossing the second wing with a slit. Then there is the step of twisting the first arm and the second arm in order to secure the locking clamp and the C-shaped fixing element around the first and second porous floor units.

The method includes the step of using a tool to twist the first arm and the second arm. The tool may include a torque wrench that has a throat with a head and a bar that extends from the throat. The head defines a shaped cavity to receive the individual free end of the first and second arms.

The method also includes, before the twisting step, inserting a suspension lever between the surface (such as the earth) and the base element of the C-shaped fastener. The suspension lever extends from the element from the base of the C-shaped fastening element, through a cell of one of the porous floor units, to the user side of the first and second porous floor units. After insertion, the person can step on a section of the suspension lever on the user side of the first and second porous floor units.

Brief Description of Drawings

Figure 1 is a schematic illustration of a portable porous floor system installed and in use;

Figure 2 is a top plan view of a plurality of individual porous floor units, which are interconnected and comprise the grid system shown in Figure 1;

Figure 3 is a schematic, exploded perspective view of a fixture that connects two porous floor units to each other;

Figure 4 is a perspective view of part of two porous floor units connected together with a pair of fixing devices;

Figure 5 is a side elevation view of a first clamp of the fixing device;

Figure 6 is a side elevation view of a second clamp of the fixing device;

Figure 7 is a top plan view of the first clamp used in the fixing device;

Figure 8 is a top plan view of the second clamp used in the fixing device;

Figure 9 is a perspective view of a suspension lever used to install the porous floor system of Figure 1;

Figure 10 is a side elevation view of the suspension lever of Figure 9;

Figure 11 is a schematic perspective view of a step of the method for connecting two porous floor units to each other using the connector arrangement, the suspension lever and a torque wrench;

Figure 12 is an enlarged perspective view of the system shown in Figure 11, after one of the arms of the second clamp is twisted by the torque wrench; and

Figure 13 is a schematic perspective view of the torque wrench used in the assembly method.

Detailed Description

Figure 1 shows a portable porous floor system 20. System 20 includes a grid 22 made of a plurality of individual porous floor units 24 (Figure 2) attached or connected together by a plurality of fixing devices 30 (Figure 3 ). In Figure 1, a truck 32 is shown being driven over the grid 22. The grid 22 is oriented on a surface 34, which will typically be the floor or ground. In many typical applications, it will be desirable to transport heavy equipment to an area that has no roads or stable soil. In such applications, a plurality of porous floor units 24 are mounted on the grid 22 and secured to each other by the fixing device 30. In such systems, the grid 22 is assembled quickly and easily and can be quickly and easily disassembled.

Figure 2 shows typical porous floor units 24 usable in system 20. Porous floor units 24 are portable in the sense that they are of a size that can be easily stacked on pallets and moved. In the example shown, each porous floor unit is approximately 1.0 mx 0.5 m, although other sizes can be used. Each of the porous floor units 24 has a depth of at least 25 mm, typically 50 mm, and a nominal coverage area of ​​at least 0.25 m² and typically 0.5 m². As can be seen in Figure 2, each of the porous floor units 24 is made up of a matrix or grid of intersecting walls 36. The intersecting walls 36 define a plurality of cells 38.

Each of the porous floor units 24 has a mounting side 40 and an opposite user side 42. The mounting side 40 is the side that is in contact with the earth surface 34. User side 42 is the side that it is open to the surrounding environment and is the side that is exposed to heavy equipment, such as truck 32 (Figure 1). In Figure 2, user side 42 is the side that is in view. In addition, Figure 4 shows parts of two porous floor units 24 with the user side 42 in view.

Each of the cells 38 defined by the walls 36 has an opening 44 (Figures 2 and 4), which is shown as circular. The openings 44 are defined by a planar wall 46. The opposite side of the planar wall 46 is the mounting side 40. Extending perpendicularly from the planar wall 46 are the walls 36. The walls 36 form rectangles, in the modality squares are shown in which the free ends 52 (Figure 3) define and form the user side 42.

Each of the porous floor units 24, in typical embodiments, will have at least 30 cells 38, typically 70-80 cells. Each porous floor unit 24 is made of a non-metallic material, as, for example, it has been found that up to 100% recycled polyethylene is useful. Such material will result in a porous floor unit 24 that weighs no more than 10 kg, typically 4-5 kg. Each porous floor unit will have a minimum crush strength of 2000 kPa and a minimum bending module of 200 000 kPa. Typical implementations will include the material for the porous floor unit 24 as having a crush strength of at least 2900 kPa and a bending module of 220 000-260 000 kPa. Each cell 38 is about 60100 mm x 60-100 mm in size, typically about 78-82 x 78-82 mm. The open area on the user side 42 is at least 60%, typically 85-95% and, in an application, about 87%. The base open area is at least 25%, typically 30-50% and, in one application, about 40%.

In Figure 2, four porous floor units 24 are shown. These porous floor units 24 are attached to each other at joints 50 using the fixing device 30. Figure 4 shows two of the porous floor units 24 attached to each other another on two adjacent walls 36 with two fixing devices. In Figure 3, the fixture 30 is shown in an exploded view during a step of connecting two adjacent porous floor units 24 to each other.

In general, each fixture 30 will include a first clamp and a second clamp, which fit together in order to secure the two porous floor units 24 together in joints 50. As embodied herein, a first clamp is shown at 60, and a second cuff is shown at 80.

Referring now to Figures 3, 5 and 7, the specific embodiment of the first clamp 60 shown in the drawings includes a U-shaped section that extends between a first and a second wing 64, 66. As can be seen in the drawings, the first and second wings 64, 66 are generally flat extensions projecting from the open end of the U-shaped section 62. The first clamp 60 also includes a slot arrangement 70. In the embodiment shown, the slot arrangement 70 comprises a first slot 72 defined by the first wing 64 and a second slot 74 defined by the second wing 76.

Referring to Figure 7, each of the first and second slots 72, 74 has an aspect ratio of length to width of a specific strip. The selected aspect ratio is a reason that will allow the first clamp 60 to contact the second clamp 80 so that they are easy and quick to assemble and then are quickly and easily attached to each other. In general, it was found that the aspect ratio of length to width for each of the first and second slots 72, must be greater than 1. In many useful applications, the aspect ratio of length to width will be in the range of 2- 5 and, in the specific embodiment shown, the aspect ratio used will be 3-4, such as, for example, about 3.25.

In the embodiment shown in Figure 7, each of the first and second slots 72, 74 is rectangular, with a length greater than the width. In other embodiments, the first and second slits 72, 74 can be non-rectangular, including a regular or irregular, oval, ellipse or irregular polygon conformation. For any of these conformations, it is useful to have an aspect ratio that is greater than 1, where the aspect ratio would be the shorter length compared to the greater width compared to the useful part of the slot. In Figure 7, each of the slots 72, 74 has a length shown as 13 mm and a width shown as 4 mm.

Referring now to Figure 5, further details of the first clamp 60 are shown. The U-shaped section 62 includes a first and a second leg 67, 68 joined by a connecting section 69. The internal dimension between the first and second legs 67, 68 in the embodiment shown is 15 mm, while the length of the connecting section 69 is shown as 20 mm. The connecting section 69 is generally parallel to the first and second wings 64, 66. As can be seen, the first and second wings 64, 66 are each about 20 mm long. The height of the first and second legs 67, 68 is about 45 mm. In Figure 7, it can be seen that the total length of the free end 63 of the first wing 64 and the free end 65 of the wing 66 is about 59 mm. The total width of the first clamp 60, in the embodiment shown, is about 25 mm.

It should be understood that, although these dimensions are typical, usable dimensions, the modalities of the first clamp 60 can be modified in several dimensions, depending on the specific planned objectives, the materials used and other factors.

Referring now to Figures 3, 6 and 8, other details of the second clamp 80 are shown. In the embodiment shown, the second clamp 80 comes into contact with the first clamp 60, so that it is in close contact with the slot arrangement 70 of the first clamp 60. The second clamp 80 also includes a twisted arrangement 82 (Figure 4) for securing the second clamp 80 and the first clamp 60 to each other. In Figures 3 and 4, it can be shown how two adjacent walls 36 of two adjacent porous floor units 24 are fitted between the first clamp 60 and the second clamp 80 in order to secure the two porous floor units 24 adjacent one in another.

In the embodiment shown, the second clamp 80 of each fixture includes a C-shaped element 84 defined by a first and a second generally parallel arms 86, 88, with a base element 90 joining the first and second arms 86, 88. In the embodiment shown in Figure 6, usable dimensions are shown. Again, these dimensions are just examples and several dimensions can be used. In the embodiment shown, the base element 90 has an internal length between the first and second arms 86, 88 of 37 mm, and an external length including the first and second arms 86, 88 of about 43 mm. The first and second arms 86, 88 each have a height of about 25 mm and a width of about 11 mm.

The conformation of the first and second arms 86, 88 is selected to be of a size and a conformation such that they can be received by the slits 72, 74. Therefore, the general cross-sectional conformation of each of the arms 86, 88 will have an aspect ratio that is compatible with the aspect ratio of slots 72, 74. This is explained below.

The twisted arrangement 82 includes a first twisted section 92 defined by the first arm 86 and a second twisted section 94 defined by the second arm 88 (Figures 4 and 12, with Figure 12 showing only the first twisted section 92). Comparing Figures 3, 4 and 12, it should be understood that, in use, the first arm 86 extends through the first slot 72 of the first wing 64, with the first twisted section 92 and the base element 90 of the element in C-shape 84 being on opposite sides of the first wing 64. The second arm 88 extends through the second slot 74 of the second wing 66, with the second twisted section 94 and the base element 90 of the C-shaped element being in the opposite sides of the second wing 66. Thus, the first and second twisted sections 92, 94 lock the second clamp 80 on the first clamp 60, with the walls 36 of the porous floor units 24 stuck between them.

Therefore, it should be understood that the relationship between the cross-sectional geometry of the first and second arms 86, 88 with the geometry of the first and second slots 72, 74 results in the first and second arms 86, 88 being able to be twisted in a way that prevents that the first and second arms 86, 88 recede out of the first and second slots 72, 74 and thus lock the second clamp 80 in the first clamp 60. In the embodiment shown, the cross-sectional shape of the first arm 86 and the second arm 88 is rectangular, with a width of less than 4 mm, for example, in the shown mode, of 2 mm, and a length of less than 13 mm, for example , in the modality shown, 11 mm. This gives the first and second arms 86, 88 a cross-section that has an aspect ratio of length to width of more than 1, for example 3-8, and in the embodiment shown, 5.5.

Although various materials are useful, it has been found that it is useful for the first and second clamps 60, 80 to be made of a resistant, durable, hard material, such as steel. Other materials can be used.

To assemble the system, several fixtures 30 will typically be used, including at least one and typically more than one fixture 30 to secure two adjacent porous floor units 24. In Figure 3, it can be seen how the second clamp 80 is arranged against the floor or surface 34 (Figure 1) and facing and against the mounting side 40 of the porous floor units 24. Thus, the base element 90 of each of the second clamps 80 is between the mounting side 40 of the porous floor units 24 and the floor 34. Two adjacent walls 36 are aligned in mutual adjacency, as shown schematically by the joints 50 in Figure 2 and in Figure 3, showing the walls 36 back to back and in mutual adjacency. The second clamp 80 is oriented so that the base element 90 crosses the joint 50 which extends under the two adjacent walls 36, with the first and second arms 86, 88 pointing upwards away from the floor surface 34 towards the user side 42 and, in the mode shown, through openings 44. The first clamp 60 is oriented so that the U-shaped section 62 defines a closed slot 76 defined by the first leg 67, the second loss 68 and the connecting section 69. The closed slot 76 extends over and receives the joint 50, which comprises the back-to-back walls 36 of the two adjacent porous floor units 24. The free ends 52 of the walls 36 are the ends that define the user side 42. These free ends 52 will face the closed portion of the closed slot 76 defined by the connecting section 69, when the first clamp 60 is oriented over the joint 50.

To facilitate the quick assembly and disassembly of the system 20, tools are useful. Figures 9 and 10 show a suspension lever 100. Specific preferred techniques for using the suspension lever 100 are described below in connection with methods for assembling the system 20. Figure 9 shows the suspension lever 100 in perspective view, while Figure 10 shows the suspension lever in a side elevation view. In general, the suspension lever 100 includes an extension 102, which has an opposing first and second surface 104, 106. The first and second surfaces 104, 106 have four side walls joining them, including two elongated side walls 112, 114 and two end side walls 116, 118. It should be understood that, in general, the suspension lever 100 is generally symmetrical.

Still referring to Figures 9 and 10, the suspension lever 100 has a total lateral profile that looks like a Z-shape stretched outwards. In particular, the suspension lever 100 includes a first section 122, a second section 124 generally parallel to the first section 122 and a connecting section 126, which extends between the first section 122 and the second section 124. In the embodiment shown, the connecting section 126 is inclined at an angle 130 with respect to the second section 124 in an obtuse manner, over 90 degrees. Likewise, the connecting section 126 is inclined with respect to the first section 122 at an angle 132, which is greater than 90 degrees. In preferred embodiments, the first angle 130 and the second angle 132 are approximately the same.

In preferred implementations, the first section 122 will have a length between the end sidewall 116 and the fold 132 (the fold 134 is where the connecting section 126 begins) that is long enough to support a part of a human foot. The reasons for this are explained below. A usable length would be at least 40 mm, typically 50-200 mm, such as, for example, about 90-110 mm.

The second section 124 will typically have a length between the end sidewall 118 and the fold 136 (the fold 136 is where the connecting section 126 begins) which is large enough to extend under and support the second clamp 80. The reasons of this are described below. Typically, this length will be approximately the same length as the first section 122 (although it does not have to be the same) and thus will be at least 40 mm, typically 50-200 mm, for example, about 90- 110 mm.

The width of the suspension lever 100 between the elongated side wall 112 and the elongated side wall 114 will be selected so that it is narrow enough to fit inside cells 38 and, in particular, inside openings 44. Thus, the width will be 2560 mm, such as 30-50 mm. The total length of wrench 100 will typically be at least 200 mm, typically 220-500, such as, for example, 280320 mm. Methods for using wrench 100 are described below. In preferred embodiments, wrench 100 is made of steel.

A second tool, exemplified as a torque wrench 160, is shown in Figures 11-13 and specifically in Figure 13. The torque wrench 150 includes a throat 152, which has a head 154. Head 154 defines a receiving cavity 156 which has the same cross-sectional conformation as the first and second arms 86, 88 and sized to be able to receive, individually, the first and second arms 86, 88. Extending from the throat 152 is a holding bar 158. As can be seen in Figure 13, the holding bar 158 forms the top of a T-shape with respect to the throat 152.

In the embodiment shown, the receiving cavity 156 has a rectangular cross-sectional shape. As mentioned above, the cavity is dimensioned to receive, individually, the ends of the first and second arms 86, 88. In preferred arrangements, the conformation of the receiving cavity will have an aspect ratio of length to width that is more than 1, for example, in the 2-5 range.

In use, each of the free ends of the first and second arms 86, 88 is inserted into the receiving cavity 156 of the head 154. Then, the holding bar 158 can be held on opposite sides 161, 162 from the throat 152 and rotated or twisted. In the embodiment shown, sides 161, 162 are equal in length. This rotation will translate into a rotational force at the ends of any arm 86, 88, whatever is inside the receiving cavity 156. Thus, the torque wrench 150 creates the first twisted section 92 and the second twisted section 94 by applying a rotational or twisting force to the first and second arms 86, 88 of the second clamp 80. A usable material for the spanner torsion 150 and steel.

The suspension lever 100 is used before the twisting step by inserting the wrench 100 between the floor surface 34 and the base element 90 of the C-shaped fixture 84, so that the second section 124 is between the floor surface 134 and base element 90, with the connecting section 126 extending through one of the openings 44, and the first section 122 is exposed on the user side 42 of the porous floor unit 24. Figures 11 and 12 show the suspension lever 100 extending through a cell 38 of one of the porous floor units 24 to the user side 42. After the suspension lever 100 is inserted, the first section 122 is staggered by someone who is on the user side 42 of the porous floor units 24. This provides stability, allowing the torque wrench 150 to be mounted on one of the arms 86, 88 and to apply a torque force to create one of the twisted sections 92, 94. The suspension lever 100 can then be removed from the cell 38 and used again.

In Figures 11 and 12, two fixing devices 30 are visible, with one of them being shown immediately after the first twisted section 92 has been created by the combination of torque wrench 150 and suspension lever 150. The other fixture 30 visible in Figures 11 and 12 shows the first and second clamps 60, 80 brought into contact with each other, but not locked together with the twisted arrangement 82 in place.

A method for assembling the portable porous floor system 20 should now be evident. At least one first and a second porous floor unit 24 are shown. The C-shaped fastener 84 is mounted on two adjacent walls 36 between the first and second arms 86, 88 of the C-shaped element 84, and the base element 90 of the C-shaped element is against the side for mounting porous floor units 24. The porous floor units 24 with the C-shaped fixture 84 are mounted on the surface 34, such as the floor or floor, with the free ends of the first and second arms 86, 88 pointing away from the floor 34. The mounting sides 40 of the porous floor units 24 face the floor surface 34.

Then, the first clamp, which includes a locking clamp that has the U-shaped section 62, which extends between the first and second wings 64,

66, is mounted on the C-shaped fastener 84 by orienting the U-shaped section 62 on the two adjacent walls 36, with the first arm 88 crossing the first wing with slot 64 and the second arm 88 crossing the second wing with a slot 66.

Then, the suspension lever 100 is inserted between the floor surface 34 and the base element 90 of the C-shaped fixture 84, the suspension lever 100 extending from the base element 90 through cell 38 of the porous floor unit up to the user side 42. In particular, section 122 extends under the base element 90 of the second clamp 80, the connecting section 126 extends through opening 44 and the first section 122 extends over and above the user side 42.

The user then steps on the first section 122, which results in an upward force being displayed on the second clamp 80 of the base element 90. This helps to stabilize the first and second clamps 60, 80 through the next method step .

The next step includes using the torque wrench 150 to individually twist the first arm 86 and the second arm 88 in order to obtain the first twisted section 92 and the second twisted section 94. In particular, the receiving cavity 156 is fitted over the free end of a first individual arm 86 or second arm 88, and then a rotational force is produced by pressing against the opposite sides 161, 162 of the holding bar 158. This results in the torsion force being transferred to the throat 152, 154 and then to the torsion of the first or second arm 86, 88.

After creating each of the first and second twisted sections 92, 94, another fixing device can be secured by mutual locking of the first clamp 60 and the second clamp 80. The suspension lever 100 can be removed from cell 38 and used in the device next fixture 30, while the torque wrench 150 is removed for use in the next fixture 30.

To dismantle system 20, the above process is reversed. The twisted sections 92, 94 can be undone by using the torque wrench 150 in order to allow the disassembly of the first clamp 60 and the second clamp 80.

The report, examples and data above provide a complete description of the components and the use of the components of the invention. Since many embodiments of the invention can be manufactured without abandoning the spirit and scope of the invention, the invention resides in the appended claims.