Patent Publication Number: US-2019177099-A1

Title: Loading dock seal

Description:
RELATED APPLICATIONS 
     This application claims the benefit of provisional application Ser. No. 62/596,238 filed 8 Dec. 2017. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention pertains to loading docks, particularly loading docks commonly found on commercial or industrial buildings and warehouses for use by trucks for loading and unloading transported items. A typical loading dock includes several components including a seal member. The seal member creates a seal between a transport vehicle (such as a truck or trailer) and the building on which the loading dock is located. Most loading dock seals share common attributes although there are several variants. The usual and customary method of constructing a loading dock seal consists of securing a large piece of foam to a backer mount (wood or steel backers are common), fully wrapped in vinyl or another fabric which can withstand the operating environment. 
     In use, a truck/trailer backs into the loading dock, and compresses the seal between the truck/trailer and the building wall, to thereby create a seal that prevents foreign material (dust, rain, air, etc.) from entering or leaving the building. During loading and unloading, as a forklift or other transport vehicle passes from the loading dock into the trailer (or vice versa) the trailer typically moves up and down, with the back of the trailer sliding against the stationary seal, causing wear of the fabric. Eventually this wear causes the fabric to wear through, tear, or in cases where it maintains integrity, it may become dirty and frayed. The seal must then be repaired or replaced for optimal performance. Typically, the decision to repair or replace a worn seal is made by observation of the loading dock users. The user then must contact a seal provider or seal repair provider to put the dock back into service. Typically, replacement is required. Thus, known seals are put into service at a loading dock and used until they wear out or are damaged to the point at which they don&#39;t function properly, and need to be replaced in their entirety rather than having the worn portions replaced. This takes time, causing the dock to be unusable for service, and may be costly when a full replacement is necessary. Thus there exists a need for an automated use meter, wherein metrics concerning use and wear are measured and transmitted to a provider, to communicate the need for repair prior to failure and need for total replacement. Moreover, a use meter may further predict when replacement is needed to thereby reduce dock downtime, since replacement may be coordinated with other planned downtime or allow full coordination of replacement parts prior to actual part failure. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a system and method for monitoring and measuring docking events of a loading dock seal. The system includes a loading dock seal having at least one monitoring device, such as a sensor, and a counting device. The sensors, or other monitoring devices measure predetermined metrics, for which the cycles of use and degree of wear of the loading dock seal may be detected locally, communicated with a cloud platform and then monitored remotely, thus enabling coordination of service or replacement of the loading dock seal without disturbing the end-user. Alternatively, the sensor may connect to an externally mounted counting device rather than a cloud platform. The invention envisions use of sensors or other monitoring devices to detect loading dock events such detecting motion and/or air pressure, temperature, and/or humidity, by way of non-limiting examples. The invention further contemplates a solution for computing service, engineering, and manufacturing activities through the use of loading dock event metrics. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vehicle nearing a loading dock seal. 
         FIG. 1A  is an enlarged side view of a portion of  FIG. 1  and showing the loading dock seal in non-compressed state and extending away from the wall a distance greater than the bumper. 
         FIG. 2  is a view similar to that of  FIG. 1 , but showing the vehicle backed into the loading dock seal and the seal compressed. 
         FIG. 2A  is a view similar to that of  FIG. 1A , but showing the loading dock seal in compressed condition and extending away from the wall a distance similar to the bumper. 
         FIG. 3  is a view of a loading dock seal according to the present invention with a partial cut away, and showing component parts. 
         FIG. 4  is a schematic view showing sensors on the loading dock seal with sensors interfacing with an Internet of Things and transmitted to an end user. 
         FIG. 4A  is a view similar to that of  FIG. 4 , but illustrating the system having an external counter reader. 
         FIG. 4B  is a view similar to that of  FIGS. 4 and 4A , but illustrating the system having an external counter reader and external sensors. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention which, is defined by the claims. 
     With attention to the Figures, a loading dock  20  having a seal  22  and at least one sensor  11  may be seen. As shown in  FIG. 1 , with no transport vehicle  4  at the loading dock  20 , the dock seal  22  is at a resting position.  FIG. 1  shows a Foam Pad (FP) compression-type seal  22  surrounding a loading dock door opening  6 , and mounted on a building wall  5 . While an FP type seal  22  is shown in these views, it is to be understood that other types of seals may be utilized with the present invention and method, as will be discussed. The FP seal  22  of these views includes a right side pad  2 , a left side pad  7 , and a head pad  3 . As seen particularly in the view of  FIG. 1A , the seal  22  projects outwardly from the building wall  5  at a distance greater than the bumper  1 . As mentioned other loading dock seals  22  may be used with the present system without departing from the invention. For example, while not specifically shown in the Figures, a non-limiting list of seal examples includes: 
     Foam Pad (FP) seal having side pads  2 ,  7  and head pad  3  constructed of vinyl-wrapped foam mounted on a backer. The vehicle  4  backs into and compresses the foam to create a seal. 
     Foam Pad with Hood (FPH) seal having side pads  2 ,  7  of vinyl-wrapped foam with a head portion  3  being a vinyl hood. The vehicle  4  compresses the side pads  2 ,  7 , while the hood is in sliding contact with the roof of the vehicle  4  to create a seal. 
     Foam side pads having an L-shaped cross section (FPU) including a foam-filled “curtain” that wipes against the side of the vehicle  4  to create a seal. This allows full access to the rear of the vehicle  4  while the top of the vehicle  4  compresses a foam-filled head pad  3 . 
     Foam side pads having an L-shaped cross section (FPHU). Similar to FHU, but instead of a foam-filled head pad  3 , the seal includes a hood which is arranged for sliding contact with the vehicle  4  roof. 
     A Rigid Frame Shelter (RF) includes rigid frames sides mounted to a building wall  5 , with fabric side curtains arranged for sliding contact with the vehicle  4  sides to create a seal. A fabric head curtain contacts vehicle  4  roof to make a seal. 
     A Soft Sided Shelter (SS). Similar to the RF Shelter, but with vinyl-wrapped foam side frames which compress. This reduces damage when a vehicle  4  backs in off-center. 
     A Gap Sealing Shelter (GS). Similar to SS, but having a semi-rigid full-length hook extrusion which are arranged to capture the rear sides of a vehicle  4  having a rear swinging door. The arrangement reduces airflow through the gap created by door hinges. 
     A Flex Frame (FF) is similar to the RF Shelter, having mechanically flexible side frames. The arrangement reduces damage when a vehicle  4  backs in off-center. 
     An inflatable Shelter (IS) includes vinyl-wrapped seals inflated with air pressure rather than foam to compress to form a seal between the vehicle  4  and building wall  5 . The IS type is often used at railcar docks as well as truck docks. 
     Other loading dock seal  22  styles may be envisioned, but the system and method described herein may be utilized with all types of loading docks and seals. Operating results are similar regardless of the specific loading dock seal  22  used because when a vehicle  4  makes contact with the seal  22 , relative motion between the vehicle  4  and the seal  22  causes wear and tear. 
     As further shown in  FIGS. 1 and 2 , a vehicle  4  backs to the loading dock  20  and travels until it rests against the loading dock  20  bumpers  1 . Initially, the dock seal pads  2 ,  3 ,  7 , project out from the wall  5  at a greater distance than the bumper  1 . Once in docking position, and as seen in  FIG. 2A , the seal pads  2 ,  3 ,  7  are compressed to a projection roughly equal to the bumper  1  projection. While the seal pads  2 ,  3 ,  7  are compressed, the pressure within the seal pads  2 ,  3 ,  7  rises slightly until air entrapped within the fabric-covered pad  2 ,  3 ,  7  escapes through the grommets  12  or other openings (see  FIG. 3 ). Once the trapped air has escaped, the seal pads  2 ,  3 ,  7  normalize at the local ambient barometric pressure. 
     The present system includes a loading dock seal  22  and at least one sensor  11  on the loading dock seal  22 . The system further includes a counter reader  28 , or other means for gathering information collected by the sensor  11 . The sensors  11  allow the end user to monitor certain predetermined conditions of the seal  22 , such as cycles of use, wear, and the like. One example of a sensors  11  for use with the present system may include those used to monitor displacement of the dock seal  22  working surfaces  2 ,  3 ,  7 . Other information such as ambient pressure, humidity, and/or temperature may be registered and monitored if desired. It is to be understood that while sensors  11  mounted on the seal  22  are illustrated, it is within the scope of the invention to include other devices for monitoring docking events, including those mounted externally, as seen in  FIG. 4B . Further, it is to be understood that any sensor  11  able to gather the docking or undocking event external to the seal  22  may be utilized by the present invention. Examples include, but are not limited to, photoelectric sensors, mechanical displacement clickers, or motion sensors mounted externally to count docking events (see  FIG. 4B ). 
     As shown in  FIGS. 2 and 4 , a vehicle  4  backs into the seal  22 , and a sensor  11  records the docking event. The information measured by the sensor  11  may be transmitted to an Internet of Things (IoT) Platform  24  via Wi-Fi, cellular communication, or other acceptable means. The Internet of Things (IoT) platform  24  stores and utilizes the gathered information. The gathered information corresponds to the predetermined conditions selected by the user and the sensor  11  used on a particular seal  22 . Alternatively, and as seen in  FIGS. 4A, 4B , the sensor  11  may not transmit to an Internet of Things (IoT) Platform  24 , rather a sensor  11  may comprise a mechanical clicker or counter, such as those commercially available from electronics and instrumentation supply houses, and the information is gathered by, for example, a counter reader  28 . As mentioned, various sensors  11  may be employed by the present system and may vary according to the desired data to be collected. Non-limiting types of sensors to be used on a selected dock seal  22  or shelter include those used to measure or count pressure, humidity, temperature, or displacement. 
     It is to be understood that while an ultrasonic distance sensor  11  is illustrated herein, any sensor  11  able to gather information pertaining to predetermined conditions selected by the user may be utilized by the present system and method. For example proximity sensors or pressure sensors, as will be discussed. Moreover, it is envisioned that multiple sensors  11  may be utilized by a single loading dock  20 , depending on the needs of the user. Several downstream uses of the information gathered by the sensor  11  may be utilized. Non-limiting examples of such uses include:
         Invoicing of customer for seal based on a “per use” fee rather than up-front expenditure.   Reporting to end user whether there is a vehicle at the specific loading dock.   Monitoring wear and tear of the seal based on usage. May lead to better product design.   Predicting when service and replacement is needed based on known usage levels and wear-out rates. Enabling a predictable production schedule for replacement products.   Allowing the manufacturer to level load production schedules during slow periods with planned replacements.   For the distributor, providing predictable repeat business, enabling scheduling service calls aligned with when the product needs service.
 
The information gathered by the system provides the original equipment manufacturer (OEM), distributor, and end customer with an understanding of the customer base and assets associated with each.
       

     As mentioned, and with attention to  FIG. 4 , the sensor  11  is preferably connected to an Internet of Things (IoT)  24  platform with the gathered information transmitted via Wi-Fi, cellular (or other means which may be developed from time to time), to provide the gathered information to the user  26 . The user  26  may utilize the information in ways previously mentioned, for example to provide a new sales model such as a subscription-based selling of dock seals to lower costs for end user, or to enhance repeat business for the OEM and distributor whereby the end user has reduced costs over time. Another aspect of the system and method is the development of business logic, business rules and notifications that deliver directed activities/work to the parties, for example, OEM, distributor, or end customer. In addition, cycles of use may be counted, the information transmitted to the OEM, and compiled by the OEM to proactively produce replacement seal covers for installation by the distributor. This enables prediction of seal life, and when combined with a subscription-based sales model, allows repair/replacement of seals prior to wear-out and at a lower cost than traditional methods. 
     The present system provides lower expenses to the end user  26  over the course of time compared to the cost of traditional seal replacements. The system and method further ensures that loading dock seals  22  are in operating condition due to regularly scheduled replacement in response to information gathered by the sensor  11  regarding cycles of use. This results in optimal loading dock  20  usability. The manufacturer benefits from repeat business and is able to plan production accordingly, thereby enabling higher efficiency use of resources. The distributor benefits from repeat business and is able to plan service calls well in advance. 
     By way of non-limiting example, when the sensor  11  used is an ultrasonic distance sensor, the sensor  11  monitors a change in seal compression between the seal  22  at rest and the seal  22  when compressed (see  FIGS. 1A and 2A ). The sensor  11  records the change as a cycle of operation indicating the presence of a vehicle  4  at the loading dock  20  door. Later, when the vehicle  4  departs, the dock seal  22  expands to its original dimension. During this expansion, the pad  2 ,  3 ,  7  stabilizes to its original shape and size. When the sensor  11  to be used is a pressure sensor, the pressure drop and stabilization back to ambient pressure of the pad  2 ,  3 ,  7  is monitored. A pressure drop indicates that a vehicle  4  has departed the loading dock  20 . 
     With attention to  FIG. 3 , typical seal  22  construction may be seen. An FP seal  22  is shown as including a wood or metal frame backer  10 , with a foam pad  8  attached to it, and wrapped with fabric  9  which is attached to the backer  10 . Grommets  12  or other openings in the pad  8  allow air and water to escape the pad  8 . As shown, a sensor  11  may be mounted on the backing board  10 . In this configuration the side pads  2 ,  7  and head pad  3  are constructed of vinyl-wrapped foam mounted on a backer  10 , into which a vehicle  4  backs. When backed into, the foam pad  8  compresses to create a seal. Other examples of seals  22  have been previously described, including FPH (not shown), and it is to be understood that the FP seal  22  is illustrated by way of non-limiting example. As shown in  FIG. 3 , the FP seal  22  includes vinyl-wrapped foam side pads  2 ,  7  and a head portion  3  being a vinyl hood. 
     It is to be understood that there are various types and grades of fabric used in the construction of loading dock seals. In this document they are referred to as “vinyl” because that is most common, but other fabrics are also used and are to be included herein. Likewise, here are many grades and weights of vinyl used in the construction of loading dock seals, all of which are included in the description of “vinyl”. Lower grades and lighter weights of vinyl (such as 22 ounce) tend to wear out faster than heavier weights (such as 40 ounce). Additionally, some loading dock seals are outfitted with protective layers of fabric in a variety of styles, including single-layer known as scuff guard, or multiple layers cascading from top to bottom of side pads or head pads or hoods, typically known as wear pleats. These protective layers tend to extend the wear-out process, providing longer seal life. 
     With attention to  FIGS. 4, 4A, and 4B  it may be seen that a system according to the present invention may include a power source  30 . For example, when the sensors  11  communicate with an IfT platform  24  (see  FIG. 4 ), the sensors  11  may be battery charged through solar power. Alternatively, the power source  30  may include a rechargeable battery, wired connection to dock building  5  (see  FIGS. 4A, 4B ), or any other acceptable source. 
     The present invention includes a method of gathering information from a loading dock seal  22  including the steps of: 
     providing a loading dock  20 ; 
     providing said loading dock  20  with a loading dock seal  22 ; 
     providing said loading dock seal  22  with at least one sensor  11 ; 
     moving said loading dock seal  22  to a compressed position, said sensor  11  detecting said compressed position as information; and 
     transmitting said information to a counter reader, wherein said counter reader may be an externally mounted dedicated device  28 , or an IoT Platform  24 . 
     The present invention is a system for gathering information from a loading dock seal  22  including: a loading dock  20 ; a loading dock seal  22  located on said loading dock  20 ; at least one sensor  11  proximate to said loading dock seal  22 ; and a counter reader. The counter reader for the system may be an externally mounted dedicated device  28 , or an Internet of Things Platform  24 . 
     The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.