Methods of manufacturing load-supporting mats for use with actively connected gap seals

Abstract

Method of manufacturing mats for use with a plurality of top side seal members in a load-supporting surface includes at least one milling machine, router or thermoplastic mold forming at least one channel in the upper surface of each mat proximate to the outer edge of at least a first side thereof and configured to engage at least one dart of at least one of the seal members and a recess in each mat's upper surface around each respective channel and configured to seat at least part of one leg of at least one of the seal members.

1 . Method of manufacturing a plurality of load-supporting mats for use in a load-supporting surface at an outdoor worksite, the mats each having at least one upper surface, being useful with one or more top side seal members and configured to support the weight of people, vehicles and equipment thereupon, each top side seal member having a central body and first and second elongated legs extending outwardly from opposing sides thereof, each leg including at least one dart extending downwardly therefrom, each top side seal member being engageable with at least two adjacent mats in the load-supporting surface and configured to provide a liquid-tight seal across a gap formed between the adjacent mats, the method comprising:
 at least one router forming at least one elongated channel in the upper surface of at least first and second mats proximate to the outer edge of at least a first side of each mat, each channel being formed to a desired depth in the respective mat and configured to engage at least one of the darts of one of the legs of at least one of the top side seal members; and   at least one router forming an elongated recess in the upper surface of each of at least the first and second mats around each respective channel formed therein to a depth in the respective mat that is shallower than the depth of the respective associated channel, each recess extending from the corresponding outer edge of each mat to a location on the mat inwards of the corresponding channel and being configured to seat at least part of one of the legs of at least one of the top side seal members,   whereby when the first and second mats are positioned adjacent to one another in the load-supporting surface, the first mat is configured to engage the first leg of a first top side seal member and the second mat is configured to engage the second leg of the first top side seal member so that the first top side seal member extends between the first and second mats across the gap formed therebetween.   
     
     
         2 . The method of  claim 1  wherein each dart has a width, further including the at least one router forming each elongated channel with a width that is less than width of each dart of the top side seal members so that each dart can be friction fit into engagement with a channel of at least one of one of the mats. 
     
     
         3 . The method of  claim 1  wherein each dart includes at least one mating potion, further including the at least one router forming within each elongated channel at least one mating portion that mates with the at least one mating portion of each dart disposed therein to provide secure engagement therebetween. 
     
     
         4 . The method of  claim 1  further including securing at least one elongated retainer in each channel formed in one or more of the mats, each retainer being configured to grip at least one dart of at least one top side seal member leg seated in the associated recess of the corresponding mat. 
     
     
         5 . The method of  claim 4  wherein each elongated retainer includes opposing elongated interior side walls surrounding a cavity disposed therebetween and at least one lip extending into the cavity from one or both of the interior side walls, at least one lip of each retainer being configured to grip at least one dart of the leg of at least one top side seal member seated in the associated recess of the corresponding mat. 
     
     
         6 . The method of  claim 1  further including the at least one router forming each elongated recess to a depth in the respective mat that allows the at least one leg seated therein to sit flush with the upper surface of the corresponding mat. 
     
     
         7 . The method of  claim 1  further including the at least one router forming each elongated recess to a depth in the respective mat that allows the at least one leg seated therein to sit below the upper surface of the corresponding mat. 
     
     
         8 . Method of manufacturing a plurality of load-supporting mats for use in a load-supporting surface at an outdoor worksite, the mats each having at least one upper surface, being useful with one or more top side seal members and configured to support the weight of people, vehicles and equipment thereupon, each top side seal member having a central body and first and second elongated legs extending outwardly from opposing sides thereof, each leg including at least one dart extending downwardly therefrom, each top side seal member being engageable with at least two adjacent mats in the load-supporting surface and configured to provide a liquid-tight seal across a gap formed between the adjacent mats, the method comprising:
 at least one thermoplastic mold forming at least one elongated channel in the upper surface of at least first and second mats proximate to the outer edge of at least a first side of each mat, each channel being formed to a desired depth in the respective mat and configured to engage at least one of the darts of one of the legs of at least one of the top side seal members; and   at least one thermoplastic mold forming an elongated recess in the upper surface of each of at least the first and second mats around each respective channel formed therein to a depth in the respective mat that is shallower than the depth of the respective associated channel, each recess extending from the corresponding outer edge of each mat to a location on the mat inwards of the corresponding channel and being configured to seat at least part of one of the legs of at least one of the top side seal members,   whereby when the first and second mats are positioned adjacent to one another in the load-supporting surface, the first mat is configured to engage the first leg of a first top side seal member and the second mat is configured to engage the second leg of the first top side seal member so that the first top side seal member extends between the first and second mats across the gap formed therebetween.   
     
     
         9 . The method of  claim 8  wherein each dart has a width, further including the at least one thermoplastic mold forming each elongated channel with a width that is less than width of each dart of the top side seal members so that each dart can be friction fit into engagement with a channel of at least one of one of the mats. 
     
     
         10 . The method of  claim 8  wherein each dart includes at least one mating potion, further including the at least one thermoplastic mold forming within each elongated channel at least one mating portion that mates with the at least one mating portion of each dart disposed therein to provide secure engagement therebetween. 
     
     
         11 . The method of  claim 8  further including securing at least one elongated retainer in each channel formed in one or more of the mats, each retainer being configured to grip at least one dart of at least one top side seal member leg seated in the associated recess of the corresponding mat. 
     
     
         12 . The method of  claim 11  wherein each elongated retainer includes opposing elongated interior side walls surrounding a cavity disposed therebetween and at least one lip extending into the cavity from one or both of the interior side walls, at least one lip of each retainer being configured to grip at least one dart of the leg of at least one top side seal member seated in the associated recess of the corresponding mat. 
     
     
         13 . The method of  claim 8  further including the at least one thermoplastic mold forming each elongated recess to a depth in the respective mat that allows the at least one leg seated therein to sit flush with the upper surface of the corresponding mat. 
     
     
         14 . The method of  claim 8  further including the at least thermoplastic mold forming each elongated recess to a depth in the respective mat that allows the at least one leg seated therein to sit below the upper surface of the corresponding mat. 
     
     
         15 . Method of manufacturing a plurality of load-supporting mats for use in a load-supporting surface at an outdoor worksite, the mats each having at least one upper surface, being useful with one or more top side seal members and configured to support the weight of people, vehicles and equipment thereupon, each top side seal member having a central body and first and second elongated legs extending outwardly from opposing sides thereof, each leg including at least one dart extending downwardly therefrom, each top side seal member being engageable with at least two adjacent mats in the load-supporting surface and configured to provide a liquid-tight seal across a gap formed between the adjacent mats, the method comprising:
 at least one milling machine forming at least one elongated channel in the upper surface of at least first and second mats proximate to the outer edge of at least a first side of each mat, each channel being formed to a desired depth in the respective mat and configured to engage at least one of the darts of one of the legs of at least one of the top side seal members; and   at least one milling machine forming an elongated recess in the upper surface of each of at least the first and second mats around each respective channel formed therein to a depth in the respective mat that is shallower than the depth of the respective associated channel, each recess extending from the corresponding outer edge of each mat to a location on the mat inwards of the corresponding channel and being configured to seat at least part of one of the legs of at least one of the top side seal members,   whereby when the first and second mats are positioned adjacent to one another in the load-supporting surface, the first mat is configured to engage the first leg of a first top side seal member and the second mat is configured to engage the second leg of the first top side seal member so that the first top side seal member extends between the first and second mats across the gap formed therebetween.   
     
     
         16 . The method of  claim 15  wherein each dart has a width, further including the at least one milling machine forming each elongated channel with a width that is less than width of each dart of the top side seal members so that each dart can be friction fit into engagement with a channel of at least one of one of the mats. 
     
     
         17 . The method of  claim 15  wherein each dart includes at least one mating potion, further including the at least one milling machine forming within each elongated channel at least one mating portion that mates with the at least one mating portion of each dart disposed therein to provide secure engagement therebetween. 
     
     
         18 . The method of  claim 15  further including securing at least one elongated retainer in each channel formed in one or more of the mats, each retainer being configured to grip at least one dart of at least one top side seal member leg seated in the associated recess of the corresponding mat. 
     
     
         19 . The method of  claim 15  further including the at least one milling machine forming each elongated recess to a depth in the respective mat that allows the at least one leg seated therein to sit flush with the upper surface of the corresponding mat. 
     
     
         20 . The method of  claim 15  further including the at least one milling machine forming each elongated recess to a depth in the respective mat that allows the at least one leg seated therein to sit below the upper surface of the corresponding mat.