Dock seal and method of producing the same

Details Dock seal and method of producing the same Dock seal and method of producing the same

1999-11-08

2001-01-09

Safavi, Michael (Department: 3635)

Static structures (e.g., buildings)

Combined

With a loading dock seal

C052S309600, C052S309900, C428S308400, C428S318600

Reexamination Certificate

active

06170205

ABSTRACT:

FIELD OF THE INVENTION
The present invention generally relates to the field of loading docks, and more specifically to dock seals that are positioned around a loading dock opening to provide a seal between the loading dock and the open end of a vehicle (e.g., a truck or trailer).
BACKGROUND OF THE INVENTION
Most warehouses, manufacturing facilities and large retail stores include loading docks that provide a location for loading and unloading vehicles. Loading docks typically include a raised platform and a dock opening positioned above the raised platform. The dock opening is formed by a dock wall having two vertical side portions extending upwardly from the platform, and a horizontal upper portion connecting the top of the side portions. Vehicles can back toward the dock opening until the back of the vehicle is abutting the platform. The platform sometimes includes a dockleveler that provides a ramp between the platform and the bed of the vehicle to facilitate loading and unloading thereof (e.g., by a fork-lift).
Many loading docks include dock seals that provide a seal between the dock wall and the back of the vehicle. For example, such dock seals can include side pads and a head pad positioned along the side portions and upper portion, respectively. The pads are commonly made from a wear resistant fabric (e.g., urethane-coated fabric) surrounding a resilient material (e.g., foam) that is compressed when the back of the vehicle is positioned against the loading dock. The compressed pads provide a barrier against the elements (e.g., wind, rain and snow), thereby providing a comfortable working environment for the personnel working near the loading dock, and further provide a barrier against the loss of heat or cooling from inside the building. An example of a dock seal is illustrated in U.S. Pat. No. 4,679,364, which is incorporated herein by reference in its entirety.
Current procedures for manufacturing dock seals involve wrapping a fabric cover around resilient foam. This process involves cutting and sewing the fabric cover so that it fits snugly around the foam. The fabric is commonly stapled or otherwise secured to a backing member, such as plywood or sheet metal.
SUMMARY OF THE INVENTION
The above-described process for producing dock seals is very labor intensive. In addition, the labor content increases with the complexity of the shape of the seal, with some shapes not being manufacturable due to an inability to apply the covers. Errors in cutting and sewing can lead to a sloppy fit between the cover and the foam, and can also result in waste fabric, rework and delays in shipment. Accordingly, it would be beneficial if there was an alternative process for applying a cover to foam to produce a dock seal. It would be particularly beneficial if cutting and sewing operations were reduced or eliminated.
The present invention provides an improved process for producing dock seals wherein the cover is applied to the foam in a liquid form. For example, the cover can comprise a plastic-type (e.g., urethane) coating that is sprayed, dipped, brushed, or poured onto the foam. After curing or drying, the coating provides a cover that fits perfectly to the foam without the need for sewing or cutting operations, and without waste fabric being produced. Additional properties, such as puncture resistance and structural reinforcement, can be provided by adding appropriate reinforcing materials (e.g., woven and unwoven fabrics, chopped fibers, impregnates or meshes) to the coating/foam assembly. The reinforcing materials can be strategically positioned in the desired locations so that reinforcing materials are only used where needed.


REFERENCES:
patent: 3500599 (1970-03-01), Sciolino
patent: 3792559 (1974-02-01), Frommelt et al.
patent: 4711059 (1987-12-01), Layne
patent: 5741568 (1998-04-01), Rudy

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