Dock Leveler Brush Seal for Cargo Frame Gap
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Solution Overview
Problem
Conventional dock leveler systems with dock seals or shelters fail to effectively seal the gap between the loading dock floor and the vehicle cargo frame, leading to significant leakage of outdoor environmental conditions into the cargo area, particularly due to the absence of a lower horizontal sealing member.
Innovation Solution
A sealing device with a base portion, a first brush portion, and a second brush portion is introduced, which includes a bottom surface for engagement with the loading dock floor, an inner vertical surface for engagement with the dock leveler lip, and a rear vertical surface for engagement with the vehicle cargo frame, effectively sealing the gap and preventing leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a traditional dock leveler system with dock seal or shelter is used, then the overhead door and vertical side members can seal the upper portion of the gap, but significant leakage occurs at the lower portion between the cargo area and loading dock floor due to the absence of a lower horizontal sealing member
Solution Approach 1:
The sealing device is divided into three distinct brush portions (first, second, and third) that address different segments of the leakage problem: the first brush portion seals against the cargo frame, the second brush portion seals against the leveler lip, and the third brush portion seals against the toe guard. This segmentation allows each brush portion to target specific leakage paths independently, comprehensively sealing the lower gap that traditional single-piece seals cannot address.
2Adaptability or versatility
If the dock leveler deck is made movable to permit height adjustment and movement between lowered, level, and raised positions, then a gap is formed along the adjacent edges of the deck and loading dock floor, but this gap creates a leakage path for environmental conditions
Solution Approach 1:
The sealing device incorporates flexible brush portions that can dynamically adapt to the moving dock leveler components. The bristles in each brush portion flex and conform as the leveler deck moves between lowered, level, and raised positions, maintaining continuous sealing contact with the cargo frame, leveler lip, and toe guard throughout the range of motion, thus preventing leakage while preserving full adaptability.
Solution Approach 2:
The sealing device uses brush portions with flexible bristles that act as compliant sealing elements. These flexible brush portions can deform and conform to the contours of the moving leveler components and stationary cargo frame, maintaining effective sealing contact despite the dynamic movement and position changes of the dock leveler assembly.
3Object-affected harmful factors
If dock seals and dock shelters include vertical side members and horizontal header, then upper portion sealing is achieved, but the deeper dock leveler pit requires additional lower horizontal sealing members that are not provided in conventional systems
Solution Approach 1:
The single sealing device performs multiple sealing functions that would otherwise require separate components: the first brush portion seals the gap between the cargo frame and dock, the second brush portion seals against the leveler lip, and the third brush portion seals against the toe guard. This multi-functional design consolidates what would traditionally require multiple separate sealing members into one integrated device, reducing overall complexity while improving sealing effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sealing device significantly reduces leakage zones by providing comprehensive sealing across the interface between the dock leveler assembly and the vehicle cargo frame, maintaining a seal even as the leveler is raised, thereby protecting the cargo area from outdoor conditions.
Implementation Method 1
a first brush portion adapted for sealing engagement with the rear cargo frame of the vehicle
Implementation Method 2
a second brush portion adapted for sealing engagement with an underside of the lip of the dock leveler assembly
Data Source
AI summary
A sealing device for use in sealing a gap formed by the interface between the floor, the dock leveler assembly, and a parked vehicle cargo frame includes a base portion having a bottom surface, an inner vertical surface, and a rear vertical surface. The bottom surface is adapted for sealing engagement with a loading dock floor. The sealing device further includes a first brush portion secured to the rear vertical surface of the base portion. The first brush portion includes a plurality of bristles and is adapted for sealing engagement with a vehicle cargo frame. The sealing device further includes a second brush portion secured to the inner vertical surface of the base portion. The second brush portion includes a plurality of bristles and is adapted for sealing engagement with an underside of the lip of a dock leveler assembly when the lip is in an extended position.