Dock Leveler Resilient Seal Gap Sealing
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Solution Overview
Problem
Conventional loading dock levelers create gaps that allow outside air, debris, and energy losses, as the existing bulb seals are inadequate in sealing the elongate gaps between the dock leveler structures, particularly between the deck and the support structure, leading to undesirable working conditions and energy inefficiencies.
Innovation Solution
A resilient seal with a medial portion and edge portions is used, which is pivotally coupled to the support structure and deck, extending between first and second end portions, and is bent to fit into the gap, pressing against the support structure and deck to maintain a seal throughout the deck's motion, effectively sealing the gaps between the dock leveler structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional bulb seals are used to seal gaps between dock leveler structures, then the sealing function is partially achieved, but the seal is inadequate and gaps remain that allow air and debris infiltration
Solution Approach 1:
The patent employs a flexible resilient seal member that can deform and conform to the gap geometry between the dock leveler structures. This flexible membrane approach allows the seal to effectively close irregular gaps that rigid conventional bulb seals cannot address, preventing air and debris infiltration while maintaining sealing reliability throughout the deck's range of motion.
Solution Approach 2:
The resilient seal member is designed to dynamically adapt its shape and position in response to the moving deck's various positions. As the deck pivots between raised and lowered positions, the seal flexes and reconfigures to maintain continuous contact and sealing effectiveness, unlike static conventional seals that fail to accommodate motion.
2Adaptability or versatility
If the deck is made movable to adjust for misalignment between dock floor and trailer bed, then adaptability is improved, but gaps are created that allow energy losses and debris infiltration
Solution Approach 1:
The flexible resilient seal member effectively closes the gaps created by the movable deck's adjustment function. This allows the system to maintain both the adaptability needed for misalignment compensation and the sealing capability to prevent energy losses, as the seal conforms to the varying gap dimensions during deck motion.
Solution Approach 2:
The resilient seal acts as an intermediary element between the movable deck and the stationary support structure. It mediates the gap formation caused by deck motion, transforming the harmful open gap into a sealed interface that prevents energy loss while allowing the deck to maintain its adjustable function.
3Reliability
If the seal is made resilient and bent to fit into the gap, then sealing effectiveness is improved, but the seal must withstand repeated deformation and mechanical stress
Solution Approach 1:
The resilient seal member is engineered with specific material parameters that balance flexibility and strength. By selecting materials with appropriate elastic modulus, tensile strength, and fatigue resistance, the seal can undergo repeated deformation cycles during deck motion while maintaining sealing effectiveness and resisting mechanical failure.
Solution Approach 2:
The seal may utilize composite material construction combining different polymer layers or material properties to achieve both the necessary resilience for conforming to gaps and the structural strength to withstand repeated mechanical stress and deformation during operational cycles.
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 solution provides a comprehensive seal that reduces energy losses, prevents debris and air infiltration, and maintains a secure environment by ensuring the seal remains effective throughout the range of deck motion, enhancing operational efficiency and reducing damage from trailer movement.
Implementation Method 1
A resilient seal is positioned between the support structure and the aft edge portion of the deck. The seal includes a medial portion extending longitudinally between first and second end portions. The seal further includes a first edge portion extending outwardly from the medial portion in a first direction, and a second edge portion extending outwardly from the medial portion in a second direction. When in position, the medial portion urges the first edge portion against the support structure and the second edge portion against the aft edge portion of the deck, throughout the range of deck motion including when the deck is in the lower position and when the deck is in the upper position.
Data Source
AI summary
Dock leveler seals and associated methods and systems are described herein. A dock leveler having a rear hinge seal configured in accordance with one embodiment of the disclosure includes a rear support frame and a movable deck. The rear support frame includes a plurality of first support members extending therefrom, and the aft edge portion of the deck includes a plurality of second support members pivotally coupled to the first support members along an axis. The seal of this embodiment includes a first edge portion extending outwardly from a medial portion in a first direction, and a second edge portion extending outwardly from the medial portion in a second direction. The medial portion urges the first edge portion against the support frame and the second edge portion against the aft edge portion of the deck as the deck pivots about the axis in operation.