Load-supporting surface with interfacing gap seal members and related apparatus and methods

1. Apparatus for forming a liquid-tight seal across gaps formed between adjacent components of a load-supporting surface useful at an outdoor worksite, the load-supporting surface being capable of supporting the weight of people, vehicles and equipment thereupon, the apparatus comprising:

at least first and second mats arranged and adapted to be positioned adjacent to one another and releasably interconnected in the load-supporting surface, each said mat being configured to support the weight of people, vehicles and equipment thereupon, each said mat having an upper surface, at least a first side and an outer edge extending at least partially along said first side, wherein when said first side of said first mat is positioned adjacent to said first side of said second mat and said first and second mats are interconnected in the load-supporting surface, said outer edge of said first side of said first mat faces said outer edge of said first side of said second mat and a gap is formed therebetween;

a first liquid impermeable, elongated seal member having a front portion and a rear portion, said rear portion of said first seal member being configured to be coupled to said outer edge of said first side of said first mat, said front portion of said first seal member being configured to extend laterally outwardly therefrom into a portion of said gap when said first side of said first mat is positioned adjacent to said first side of said second mat and said first and second mats are interconnected in the load-supporting surface; and

a second liquid impermeable, elongated seal member having a front portion and a rear portion, said rear portion of said second seal member being configured to be coupled to said outer edge of said first side of said second mat, said front portion of said second seal member being configured to extend laterally outwardly therefrom into a portion of said gap when said first side of said first mat is positioned adjacent to said first side of said second mat and said first and second mats are interconnected in the load-supporting surface,

wherein when said first side of said first mat is positioned adjacent to said first side of said second mat and said first and second mats are interconnected in the load-supporting surface, said respective front portions of said first and second seal members abut one another in said gap to form a liquid tight seal therebetween and prevent the entry of liquid into said gap from said upper surfaces of said first and second mats.

2. The apparatus of claim 1 wherein said first and second seal members are flexible and constructed at least partially of rubber, further wherein when said first side of said first mat is positioned adjacent to said first side of said second mat and said first and second mats are interconnected in the load-supporting surface, said gap has an initial width, further wherein said respective front portions of each of said first and second seal members each have a width, wherein the combined width of said front portions of said first and second seal members is greater than the initial width of said gap.

3. The apparatus of claim 1 wherein each said mat is configured to undergo movement relative to one or more other said mats without disengaging from the load-supporting surface during normal operating conditions, further wherein said seal members are configured so that said front portions thereof maintain a liquid tight seal therebetween regardless of movement of said first and second mats during normal operating conditions.

4. The apparatus of claim 1 wherein said rear portions of said first and second seal members are configured to sealingly engage said first and second mats, respectively, further wherein each said mat is configured to undergo at least one among geometric changes, expansion, compression and displacement during normal operating conditions of the load-supporting surface, and upon at last one among the geometric changes, expansion, compression and displacement of either or both of said first and second mats, said rear portion of each of said first and second seal members is configured to remain coupled to and sealingly engage said first and second mats, respectively, and said front portion of each of said first and second seal members is configured to undergo at least one among bending, moving and flexing within said gap without losing the liquid tight seal formed therebetween.

5. The apparatus of claim 1 wherein said first and second seal members are configured to extend into said gap at a height below said adjacent upper surfaces of said first and second mats, further wherein said first and second seal members are configured not to entirely fill said gap.

6. The apparatus of claim 5 wherein said seal members are constructed of neoprene-buna rubber blend.

7. The apparatus of claim 1 further including at least one elongated groove formed in each said outer edge of each said mat, wherein said rear portion of said first seal member is configured to be secured within at least one said groove formed in said first side of said first mat and said rear portion of said second seal member is configured to be secured within at least one said groove of said first side of said second mat.

8. The apparatus of claim 7 wherein each said mat includes first, second, third and fourth said sides and at least one continuous said outer edge extending around all of said sides and forming a perimeter of said mat, said at least one groove being formed in said continuous outer edge and extending around said perimeter, said at least one groove having a base, said perimeter having a length measured around said base of said at least one groove, further wherein each said seal member is formed in a closed-loop configuration having a length that is smaller than said length of said perimeter, wherein each said seal member is elastic and configured to be stretched around said perimeter of one of said mats and be elastically biased within said continuous outer groove formed therein.

9. The apparatus of claim 7 wherein each of said rear portions of said respective first and second seal members is configured to be at least one among glued, press fit, friction fit and mechanically coupled to said respective associated groove.

10. The apparatus of claim 1 wherein said front portion of each of said first and second seal members includes a front end and includes at least one face disposed at said front end, further wherein said respective faces of said first and second seal members are configured to abut one another to form the liquid tight seal therebetween regardless of movement of said first and second mats during normal operating conditions.

11. The apparatus of claim 1 wherein said front portion of each of said first and second seal members includes an elongated cavity extending therethrough and an outer wall extending around said cavity, wherein said outer wall includes curved upper and lower sections and a front section, said front section of said outer wall of said first seal member being configured to sealingly engage said front section of said outer wall of second seal member, said curved upper and lower sections of each said seal member being configured to allow said seal members to bend and maintain sealing engagement with one another during normal operating conditions of the load-supporting surface.

12. The apparatus of claim 11 further including at least one rib extending between said upper and lower sections and through said cavity of said front end of each said seal member to increase stiffness of said respective seal member.

13. The apparatus of claim 11 wherein said front section of said outer wall of each said front portion has a thickness of between 0.095″ and 0.100″.

14. The apparatus of claim 1 wherein each seal member is constructed of a plurality of linear portions and a plurality of corner portions formed in a frame-like configuration, each said corner portion having a curved-shaped bulb at its corner.

15. The apparatus of claim 14 wherein said linear portions and said corner portions of each said seal member are vulcanized together.

16. The apparatus of claim 14 further including a corner filler extending from at least one corner portion of each said seal member, said corner filler being configured to fill in space around said bulb of said respective corner portion.

17. The apparatus of claim 14 wherein said corner filler extends out from the said corner portion of said respective seal member to form a right angle.

18. The apparatus of claim 14 wherein said corner filler and said respective seal member are integrally formed in an injection molding process.

19. The apparatus of claim 14 wherein said corner filler has a generally triangular outer shape with first and second adjacent short sides forming a right angle and a curved hypotenuse side configured to abut, engage or be disposed adjacent to said bulb of said corner portion of said respective corner seal member, said first and second short sides being configured to sealingly engage at least one among one of said first and second short sides of another said corner filler or at least one other said seal members.

20. The apparatus of claim 19 wherein at least one space is formed between said curved hypotenuse side of said corner filler and said corresponding bulb to allow for relative movement therebetween.

21. Method of assembling a load-supporting surface having a liquid-tight seal across gaps formed between adjacent, releasably interconnectable, thermoplastic mats thereof, the load-supporting surface being useful at an outdoor worksite and configured to support the weight of people, vehicles and equipment thereupon, the method comprising:

positioning each mat adjacent to at least one other mat, and, in particular, positioning the first side of a first mat adjacent to the first side of a second mat, the first side of each mat having an outer edge, each mat being thermoplastic, having an upper surface and being configured to support the weight of people, vehicles and equipment thereupon;

releasably interconnecting adjacent mats to form the load-supporting surface, and, in particular, releasably interconnecting the first and second mats to form a gap between the adjacent outer edges of the respective first sides thereof;

the rear portion of a first liquid-impermeable, elongated seal member engaging the outer edge of the first side of the first mat;

the front portion of the first seal member extending laterally outwardly relative to the outer edge of the first side of the first mat and into the gap;

the rear portion of a second liquid-impermeable, elongated seal member engaging the outer edge of the first side of the second mat;

the front portion of the second seal member extending laterally outwardly relative to the outer edge of the first side of the second mat and into the gap; and

the respective front portions of the first and second seal members abutting one another in the gap to form a liquid tight seal therebetween and prevent the entry of liquid into the gap from the upper surfaces of the first and second mats.

22. The method of claim 21 , further including

the first and second mats each undergoing movement relative to one or more other mats in the load-supporting surface during normal operating conditions without losing its interconnection with at least one other mat, and

the respective front portions of the first and second seal members maintaining sealing engagement with one another in the gap regardless of movement of the first and second mats relative to at least one other mat during normal operating conditions.