Overlapping modular mat systems

Abstract

Mats and methods associated therewith are described. The mats include a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other. The main body includes a pattern of internal walls that define internal voids within the main body. At least one primary structural support rib is arranged within the main body and extends between the two surface walls and from one of the plurality of side walls to another of the plurality of side walls. The at least one primary structural support rib traverses the internal voids defined by the pattern of internal walls.

What is claimed is: 
     
         1 . A method comprising:
 cutting a mat to form a first sub-mat and a second sub-mat, the mat comprising:
 a main body defined by a plurality of sidewalls and two exterior surface walls, wherein the main body includes a first primary structural support rib arranged within the main body and extending between the two exterior surface walls and extending from one of the plurality of side walls to another of the plurality of side walls, wherein the first primary structural support rib divides the main body into two sections, 
   wherein the cutting is performed along the first primary structural support rib to divide the two sections to form the first sub-mat and the second sub-mat.   
     
     
         2 . The method of  claim 1 , further comprising securing the first sub-mat to the second sub-mat to form a support surface. 
     
     
         3 . The method of  claim 1 , wherein:
 the mat comprises a second primary structural support rib that extends in a direction generally perpendicular to the first primary structural support rib, and   the first primary structural support rib and the second primary structural support rib define four sections configured to be divided into four sub-mats.   
     
     
         4 . The method of  claim 3 , wherein the cutting comprises cutting along the first primary structure support rib and along the second primary structural support rib to form the first sub-mat, the second sub-mat, a third sub-mat, and a fourth sub-mat. 
     
     
         5 . The method of  claim 4 , further comprising connecting at least one of the first sub-mat, the second sub-mat, the third sub-mat, and the fourth sub-mat to one or more full mats to form a support surface. 
     
     
         6 . The method of  claim 1 , further comprising joining at least one of the first sub-mat and the second sub-mat with a full mat to form a support surface. 
     
     
         7 . The method of  claim 1 , wherein the cutting is along the first primary structural support rib such that the first sub-mat and the second sub-mat each comprise a portion of the first primary structural support rib after being cut and separated from one another. 
     
     
         8 . The method of  claim 1 , wherein the main body comprises a pattern of internal walls that define internal voids within the main body, wherein each of the first sub-mat and the second sub-mat comprise a part of the of the pattern of internal walls when separated from each other. 
     
     
         9 . The method of  claim 8 , wherein the first primary structural support rib traverses the internal voids defined by the pattern of internal walls prior to the cutting. 
     
     
         10 . The method of  claim 8 , wherein the main body further comprises at least one secondary structural support rib that is arranged within one of the at least two sections defined by the first primary structural support rib, wherein the at least one secondary structural support rib traverses the internal voids defined by the pattern of internal walls. 
     
     
         11 . The method of  claim 10 , wherein the at least one secondary structural support rib divides the respective section into two or more subsections. 
     
     
         12 . The method of  claim 1 , wherein the main body further comprises at least one secondary structural support rib that extends from at least one of the side walls to the first primary structurally support rib. 
     
     
         13 . The method of  claim 1 , wherein the main body comprises a hook pocket defined along the first primary structural support rib, the hook pocket configured to enable a tool to engage with a sub-mat, wherein the cutting along the first primary structural support rib exposes the hook pocket. 
     
     
         14 . The method of  claim 13 , wherein the hook pocket is aligned with a pin aperture on a periphery of the main body. 
     
     
         15 . The method of  claim 1 , wherein the main body further comprises a lip structure extending outwardly from the plurality of sidewalls around a periphery of the main body. 
     
     
         16 . The method of  claim 15 , wherein the cutting separates the mat into a plurality of sub-mats and wherein each sub-mat includes a portion of the lip structure. 
     
     
         17 . The method of  claim 1 , wherein the first primary structural support rib defines a channel along which the cutting is performed. 
     
     
         18 . The method of  claim 1 , wherein the first primary structural support rib comprises two rib walls with a channel defined between the two rib walls, wherein the first primary structural support rib is configured to enable separation of the mat into the first sub-mat and the second sub-mat along the channel. 
     
     
         19 . The method of  claim 18 , wherein the first sub-mat is different from the second sub-mat and each sub-mat is configured to secure or connect to the other sub-mat. 
     
     
         20 . The method of  claim 1 , wherein each of the first sub-mat and the second sub-mat comprise a respective pin aperture, the method further comprising joining the first sub-mat to the second sub-mat by at least one pin installed through the respective pin apertures.