Method for making an oil field mat

摘要

A method making an oil field mat from a plurality of synthetic board to create a tri-layer oil field mat usable to support trucks, equipment, and personnel around a derrick, or a Christmas tree having central couplers and end caps.

主权项

1. A method for making an oil field mat from a plurality of synthetic boards comprising the steps of:
a. blending together ranging from 20 minutes to 40 minutes:
i. 50 weight percent to 75 weight percent low density recycled polyethylene;ii. 10 weight percent to 35 weight percent high density recycled polyethylene;iii. 1.0 weight percent to 5.0 weight percent filler;iv. 0.1 weight percent to 0.5 weight percent ultraviolet stabilizers; andv. 8.0 weight percent to 15 weight percent antistatic carbon black; b. heating the blend to a temperature ranging from 350 degrees Fahrenheit to 400 degrees Fahrenheit forming a molten blend; c. injecting the molten blend into a board mold; d. slowly quenching the molten blend in the board mold; e. removing the board from the board mold; f. cooling the board for twenty-four hours at an ambient temperature; g. sizing the board; h. forming a groove in the board; i. drilling holes for fasteners and connectors into the board; j. forming a bottom layer of a first mat in a jig, wherein the bottom layer comprises a bottom layer orientation, and wherein the bottom layer further comprises: a plurality of identical bottom layer boards connected in parallel; k. forming a first interlock assembly secured to the bottom layer of the mat, wherein the first interlock assembly comprises:
i. two first aligned locking members attached to the bottom layer of the mat aligned with a first side of the mat; andii. a first offset locking member disposed between the aligned locking members and positioned apart from the first side of the mat proximate to an edge of the bottom layer; l. forming a middle layer from a plurality of parallel middle layer boards forming a middle layer orientation at a right angle to the bottom layer orientation; m. forming a second interlock assembly when the middle layer is formed on a side of the mat opposite the first interlock assembly, wherein the second interlock assembly comprises:
i. two second aligned locking members that attach to the middle layer of the mat on the side of the mat opposite the first two aligned locking members; andii. a second offset locking member disposed between the second aligned locking members and positioned proximate to an edge of the middle layer; n. connecting a plurality of connectors between the middle layer and the bottom layer for maintaining the original shape of the mat; o. forming a top layer comprising: a plurality of identical top beveled boards connected in parallel having a top layer orientation, and wherein the top layer is fastened through the middle layer to the bottom layer at a right angle to the middle layer orientation; p. connecting a plurality of fasteners through the top layer through the middle layer to the bottom layer to fasten the bottom layer to the middle layer and the top layer forming the first mat; q. repeating the above steps to form a second mat; r. using a center coupler for connecting the first mat with the second mat while simultaneously preventing lateral and longitudinal movement of the pairs of mats; and s. using half end caps to engage portions of the interlock assemblies of the mat.