Dock Leveler Lip Hinge Seal for Air Gap Control
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Solution Overview
Problem
The existing dock leveler designs suffer from significant air gaps between the deck and the lip when the lip is in a pendant position, leading to air leakage, condensation, and potential corrosion due to unsealed gaps between the hinge lugs, which compromises the indoor environment and equipment integrity.
Innovation Solution
A variety of seal configurations, including resiliently flexible members, tubular seals, and gas-filled tubes, are implemented to cover and obstruct the air gaps between the deck and lip, using attachments like screws, adhesives, clips, and magnets, and employing flexible materials like foam, plastic, or rubber to ensure sealing across the hinge pin and between the deck and lip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lip is stored in a pendant position, then the dock leveler can be easily stored and accessed, but significant air gaps are created between the deck and lip, leading to air leakage and moisture problems
Solution Approach 1:
The patent extracts the sealing function from the main lip-hinge-deck assembly by introducing a separate seal member that can be independently installed and removed. This seal member is attached to either the lip or deck and includes a flexible sealing element that specifically targets the gap between components, allowing the sealing function to be applied selectively when needed without interfering with the pendant storage capability
Solution Approach 2:
The patent employs a flexible sealing element made of resilient material such as rubber, foam, or plastic that can deform to conform to the varying gap between the lip and deck. This flexible membrane-like structure effectively blocks air and moisture passage while maintaining the mechanical movement of the lip between extended and pendant positions
2Device complexity
If the gap between deck and lip is left unsealed, then the structure remains simple and maintenance-free, but outdoor air is introduced into the pit area causing condensation and corrosion
Solution Approach 1:
The patent introduces a seal member as an intermediary component between the lip and deck that specifically addresses the harmful air gap without requiring fundamental changes to the existing hinge or structural design. This intermediary sealing element can be attached to existing surfaces and provides protection against moisture and air ingress while maintaining the original mechanical functionality
Solution Approach 2:
The seal member is designed as a relatively simple, inexpensive component made from common materials like rubber, foam, or plastic that can be easily replaced if worn or damaged. This approach prioritizes reliability and ease of maintenance over permanent, complex sealing solutions, allowing quick replacement without specialized tools or procedures
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 seals effectively prevent or control airflow through the gaps, reducing moisture issues and corrosion risks, maintaining a consistent indoor environment and extending the dock leveler's operational lifespan.
Implementation Method 1
A seal for a dock leveler's lip hinge includes a seal member that obstructs airflow through the gaps
Implementation Method 2
resiliently flexible members, tubular seals, and gas-filled tubes, are implemented to cover and obstruct the air gaps
Data Source
AI summary
A dock leveler comprising a vehicle-engaging lip pivotally coupled to the vertically adjustable front edge of a deck includes a seal or series of seal segments that close one or more air gaps that exist in the area where the lip is hinged to the deck. Such gaps are particularly large when the lip hinge comprises a hinge pin that couples a series of lugs extending from underneath the deck to a series of lugs extending from the lip, wherein the lugs are spaced apart along the length of the hinge pin. The seal or seal segments could be above the deck, below the deck, or interposed between the adjoining edges of the deck and the lip. In some cases, the seal is provided by an air curtain or by a tube that is inflatable or hermetically sealed.