Modular and Impactable Frame with Integrated Leveler

A modular and impactable frame which includes an integrated dock leveler. The frame includes opposing front plates, opposing side members, opposing base members and an integral bracing structure which connects each side member to a respective base member, the base members each have a base plate and a pair of front and back supporting legs, each base plate is secured to the grade and is adjustable in a side-to-side direction as well as adjustable in a front-to-back direction so as to securely conform to and attach to the contour of the grade.

FIELD OF THE INVENTION

This invention relates to dock levelers and more particularly to a dock leveler which is integrated into a modular frame and is able to withstand and transfer an impact from a vehicle.

BACKGROUND OF THE INVENTION

A variety of dock levelers both with and without surrounding structural frames have been devised to adjust the height of different trailers to properly match the deck of the trailer to the height of the dock. By aligning the height of the trailer and the dock the loading and unloading of cargo is facilitated.

One such device is seen in U.S. Pat. No. 4,624,446 to Gould which discloses a reinforced platform pivotally mounted to the ground at one end and includes a support assembly having hydraulic cylinders. In operation the rear wheels of a truck trailer are backed onto the platform and then the non-mounted end of the platform is lifted by the hydraulic cylinders until the deck of the trailer is equal to the height of the dock.

A similar device is disclosed in U.S. Pat. No. 4,765,792 to Cherry, et al. which also discloses a pivotally-mounted and hydraulically-raised platform. In addition to the disclosure of Gould, the device includes mounting the hydraulics inwardly from the non-mounted end of the platform and an aperture in the non-mounted end of the platform to accommodate a truck restraining device.

Another design is disclosed in U.S. Pat. No. 6,368,043 to Leum, et al. which teaches a low-profile truck leveler. In this design a low-profile leveler is enabled through the use of a raised rear beam and two lateral beams that extend above the upper surface of the platform. In addition, a central beam adds further to the leveler's strength and rigidity.

Some dock levelers of the prior art include surrounding frame structure, however, none of these levelers include the leveler being integrated into a frame which is modular, impactable and highly adjustable for added safety. It is to this need that this invention is drawn.

This device overcomes certain problems and shortcomings in the prior art, including those mentioned above and others, and provides advantages for a dock leveler integrated into a modular, impactable and adjustable frame not previously provided.

SUMMARY OF THE INVENTION

A modular and impactable frame which includes an integrated dock leveler with a planar member, the frame has opposing front plates, opposing side members, opposing base members and an integral bracing structure connecting each side member to a respective base member. It is highly preferred that the base members each have a base plate and a pair of front and back supporting legs, each base plate being secured to the grade and being adjustable in a side-to-side direction as well as adjustable in a front-to-back direction so as to securely attach to the grade.

The frame is able to be very precisely adjusted in multiple directions given the space between the adjustment structure. Specifically there are gaps in the base plate so that the screws are able to move in all directions so as to allow for multi-directional adjustment, including being adjustable in a side-to-side direction and a front-to-back direction. Once the base plate is in the desired, adjusted position it can be temporarily or permanently secured in the desired position so it doesn't shift or rotate once it has been secured. If the frame is later moved to a different location, the base plate can be adjusted to securely attach to the contour of the new grade.

It is highly preferred that each base plate is able to be adjusted independent of the opposing base plate. Preferably, the base plate includes one or more adjustment structures, the adjustment structure has a locking bolt, top nut and a bottom.

It is preferable that the front plates absorb impact from a vehicle and transfer an impact load to the integral bracing structure and base plate. In some applications it is preferable that a dock housing be secured to the planar member or frame. In other applications it is preferable that the frame be bolted to a mobile loading dock or a loading platform.

In preferred embodiments, the base plate is secured to the grade by one or more bolts and the frame includes a back plate which can be bolted to a wall of a building.

The term “impactable” as used herein refers to a frame which can withstand and transfer an impact load from a vehicle.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1-9illustrate an impactable and modular frame10with an integrated hinged dock leveler12. Frame10is self-standing (it can operate as a stand alone platform and does not need any other structure to function) but frame10is versatile as well as modular as it can also be used with any platform, ramp, dock housing or an existing building.

Frame10includes integrated dock leveler12which is a planar member14. Frame10also includes opposing front plates16, opposing side members18, opposing base members20and an integral bracing structure22connecting each side member18to a respective base member20as can be seen inFIGS. 1-4.

Opposed front plates16act as bumpers (seeFIGS. 1 and 3) to protect frame10from impact with a vehicle and also to protect dock leveler12from impact should a vehicle back up too far and bump into frame10. Opposed front plates if impacted absorb the impact from a vehicle and transfers the impact load to both integral bracing structure22and base plate24.

FIG. 2illustrates the location of dock leveler12in the middle section of frame10. Next to dock leveler12on each side are flat side portions (not claimed) which function to provide a larger work area on top of frame10for use when loading or unloading cargo. These flat side portions can also provide an area to secure additional structures, such as a dock housing40to frame10as seen inFIG. 7.

FIGS. 4-5illustrate that base members20each have a base plate24and a pair of front supporting legs26and a pair of back supporting legs28. As can be seen best inFIG. 5, each base plate24is secured to the grade30.FIGS. 4-5illustrate that base plate24is adjustable in a side-to-side direction (also referred to herein as “left-side to right-side direction”) as well as adjustable in a front-to-back direction so as to securely attach to grade30.

Arrows inFIG. 4indicate that the base plate can be adjusted in various directions based on the contour of grade30. It is important to note that each side of frame10has a base plate24and that base plates24on either side are able to adjusted independent of the other base plate24on the other side of frame10. Being able to adjust base plate24to the exact contour of grade30allows for a more secure attachment to grade30and greater stability of frame10. Base plate24can be secured to any type of grade30including but not limited to gravel, asphalt or concrete. It is important to note that frame10can secured to ground30by any known method and all such methods are within the scope of the application.

FIG. 4illustrates that for added structural support frame10has integral bracing structure22on each side of frame10.FIGS. 5-5Cshow in detail how either front supporting leg26or back supporting leg28are attached to base plate24and how base plate24can be adjusted. Front supporting leg26or back supporting leg28are secured to base plate24through the use of adjustment structures32. Adjustment structures32consist of several locking bolts34as well as a top nut36and a bottom nut38as seen inFIGS. 5-5C. This type of securement is used for each of the opposing front supporting legs26and back supporting legs28of frame10.

As seen inFIGS. 5-5C, frame10is able to be very precisely adjusted in multiple directions given the spaces50between parts of the adjustment structure. Specifically, as seen inFIG. 5Cthere are gaps/spaces50which allow locking bolts34to be able to move in all directions so as to allow for multi-directional adjustment, including side-to-side direction adjustability as well as front-to-back adjustability. The gaps allow for plenty of room for the structure to be adjusted in multiple directions and locking bolts34are only secured once base plate24is in the desired position. Once base plate24is in the desired, adjusted position it can be temporarily or permanently secured in the desired position so it doesn't shift or rotate once it has been secured. As seen best inFIGS. 5B and 5C, base plate24has a high degree of adjustability and is able to flex into different positions to accommodate an uneven surface or grade30. The side portion60of base plate24is one of the structures which is flexible and adjustable so as to match the contour of grade30.FIG. 5Bfor example, illustrates side portion60adjusted to an uneven, angled grade30. Each side portion60can be adjusted independent of a side portion60of the opposing base plate24as seen inFIGS. 5B and 5C. If frame10is later moved to a different location, base plate24including side portion60can be adjusted again to securely attach to the contour of the new grade30.

Top nut36and bottom nut38are only used once the entire frame10is set in place and adjusted to the contour of grade30, then top nut36and bottom nut38are used to secure the structure in place as seen inFIG. 5C. During installation, the process is to have the top nuts36loose with at least an inch or more of50between the locking bolts34and base plate24. Side clamping bolts, also referred to as locking bolts34, are all loose which allows base plates24to spring outward. Next, during installation, vertical height and leveling of frame10are set. The weight of frame10or multiple frames10help the structure to conform to the grade30. Once adjusted into the desired position and conforming with grade30, top nuts38are threaded down into contact with base plates24and locking bolts34lock it into place. The side-to-side rotation of side portion60allows for at least 30 degrees of adjustability (from one side to the other side) which combined with the front-to-back adjustability eliminates the need for a user to have to shim the structure in the field and also allows for a greater overall contact surface area with grade30and can be used on multiple surfaces including concrete, asphalt and gravel.

Frame10can be secured to the wall of a building46through the use of a back plate44as seen inFIG. 6. Back plate44is secured to frame10on one side and is secured to the wall of a building46on the other side.FIG. 6also illustrates how grade bolts42secure base plate24to grade30.FIG. 6shows a typical trailer or truck backed up to frame10for unloading and/or loading of cargo.

As seen inFIG. 7, a dock housing40can be used with frame10. Dock housing40is secured to frame10through the use of any type of securement device which would be known in the art.FIG. 8illustrates one such securement device and illustrates an example of how dock housing40can be secured to a top surface of frame10. Frame10can also include handrails for added safety as seen in the figures if a dock housing is not used.

FIG. 9illustrates that frame10can also be used with a mobile loading dock48. Frame10when in use with mobile loading dock48works in the same manner as when frame10is bolted to a wall of a building46or when it is free standing. When in use with a mobile loading dock48, frame10is still secured to grade30and can still be adjusted to securely attach to grade30as noted above. Frame10is secured (typically through the use of several bolts or other securement devices) to mobile loading dock48and can be used with mobile loading docks of any size or shape.

A lifting system is also incorporated into the leveler10of the first embodiment in the form of hydraulic lifts (not shown). The hydraulic lifts assist in lifting a section of the leveler10. However, any other lifting systems known in the art could be utilized as well.