Smooth transition dock leveler lip

Abstract

A dock leveler includes a vehicle-engaging pivotal lip extending from the front end of a pivotal deck, wherein the lip has one or more unique features that provide a smooth transition for forklifts traveling between the lip and a trailer bed upon which the lip is resting. The smooth transition minimizes jolting and vibration of the forklift and its driver as the forklift wheels pass over the leading edge of the lip. The special features of the lip may include one or more of the following: a curved traffic-bearing surface terminating at a sharp or blunt leading edge, a traffic-bearing surface that includes both flat and curved sections, a multifaceted traffic-bearing surface that approximates a curved surface, a rubber or plastic shock absorbing element, an articulated nose piece at the lip's leading edge, and a main lip plate that is coplanar with the deck's traffic surface (i.e., zero crown angle).

1 . A dock leveler, comprising:
 a deck that includes a front edge and a rear edge, the deck is pivotal about the rear edge to selectively raise and lower the front edge; and   a lip that includes a leading edge, a hinged edge and a traffic-bearing surface extending therebetween, the hinged edge is pivotally coupled to the front edge of the deck such that the leading edge can selectively rise and descend relative to the front edge of the deck, the traffic-bearing surface includes a first approach surface, a second approach surface and a final approach surface such that:   a) the first approach surface is adjacent to the leading edge of the lip;   b) the first approach surface is between the leading edge of the lip and the second approach surface; and   c) the final approach surface is adjacent to the hinged edge of the lip, and the final approach surface is between the second approach surface and the hinged edge, wherein each of the first approach surface, the second approach surface and the final approach surface are at an incline relative to each other.   
   
   
       2 . The dock leveler of  claim 1 , wherein each of the first approach surface, the second approach surface and the final approach surface are substantially flat. 
   
   
       3 . The dock leveler of  claim 1 , wherein at least one of the first approach surface and the second approach surface is curved. 
   
   
       4 . The dock leveler of  claim 1 , wherein a curved surface exists between the first approach surface and the second approach surface. 
   
   
       5 . The dock leveler of  claim 1 , wherein a curved surface exists between the second approach surface and the final approach surface. 
   
   
       6 . The dock leveler of  claim 1 , wherein the leading edge provides a generally flat surface that lies at an angle greater than zero degrees relative to the first approach surface. 
   
   
       7 . The dock leveler of  claim 1 , wherein the leading edge is a substantially sharp line. 
   
   
       8 . The dock leveler of  claim 1 , wherein the traffic-bearing surface includes a polymeric element carried by the lip. 
   
   
       9 . The dock leveler of  claim 8 , wherein the polymeric element includes the leading edge of the lip. 
   
   
       10 . The dock leveler of  claim 8 , wherein the polymeric element is between the leading edge and the final approach surface. 
   
   
       11 . The dock leveler of  claim 8 , wherein the polymeric element includes a curved surface. 
   
   
       12 . A dock leveler comprising:
 a deck that includes a front edge and a rear edge, the deck is pivotal about the rear edge to selectively raise and lower the front edge; and   a lip that includes a leading edge, a hinged edge and a traffic-bearing surface extending therebetween, the hinged edge is pivotally coupled to the front edge of the deck such that the leading edge can move vertically relative to the front edge of the deck, the traffic-bearing surface includes a curved surface.   
   
   
       13 . The dock leveler of  claim 12 , wherein the leading edge provides a generally flat surface that lies at an angle greater than zero degrees relative to the curved surface. 
   
   
       14 . The dock leveler of  claim 12 , wherein the leading edge is a substantially sharp line. 
   
   
       15 . The dock leveler of  claim 12 , wherein the traffic-bearing surface includes a polymeric element carried by the lip. 
   
   
       16 . The dock leveler of  claim 15 , wherein the polymeric element extends to the leading edge of the lip. 
   
   
       17 . A dock leveler comprising:
 a deck that includes a front edge and a rear edge, the deck is pivotal about the rear edge to selectively raise and lower the front edge; and   a lip assembly comprising a main piece and a leading edge piece, the main piece is pivotally coupled to the front edge of the deck, the leading edge piece is defectively coupled to the main piece.   
   
   
       18 . The dock leveler of  claim 17 , wherein the main piece is between the leading edge piece and the front edge of the deck. 
   
   
       19 . The dock leveler of  claim 17 , wherein the leading edge piece includes a leading edge that is generally a sharp straight line, the leading edge is a portion of the leading edge piece that is farthest away from the main piece of the lip assembly. 
   
   
       20 . The dock leveler of  claim 17 , further comprising a first hinge at the rear edge of the deck, a second hinge at the front edge of the deck, and a third hinge between the leading edge piece and the main piece of the lip assembly. 
   
   
       21 . The dock leveler of  claim 17 , wherein the leading edge piece extends substantially a full length along the front edge. 
   
   
       22 . The dock leveler of  claim 17 , wherein the lip assembly includes a plurality of leading edge pieces that are distributed along the main piece. 
   
   
       23 . The dock leveler of  claim 17 , wherein the leading edge piece is at least partially comprised of a polymeric material. 
   
   
       24 . The dock leveler of  claim 17 , wherein the leading edge piece includes a curved surface. 
   
   
       25 . The dock leveler of  claim 17 , further comprising an adhesive that bonds the leading edge piece to the main piece. 
   
   
       26 . The dock leveler of  claim 17 , further comprising a fastener that holds the leading edge piece in place. 
   
   
       27 . The dock leveler of  claim 17 , wherein the leading edge piece includes an interlocking feature that helps hold the leading edge piece in place. 
   
   
       28 . The dock leveler of  claim 17 , wherein the main piece has a main traffic surface, the deck has a deck traffic surface, and the main piece can pivot to a position where the main traffic surface and the deck traffic surface are substantially coplanar. 
   
   
       29 . A dock leveler comprising:
 a deck that includes a front edge and a rear edge, the deck is pivotal about the rear edge to selectively raise and lower the front edge;   a lip that includes a leading edge, a hinged portion and a traffic-bearing surface extending therebetween, the hinged portion is pivotally coupled to the front edge of the deck such that the leading edge can move vertically relative to the front edge of the deck; and   a polymeric piece that provides a least a portion of the traffic bearing surface.   
   
   
       30 . A dock leveler comprising:
 a deck that includes a front edge and a rear edge, the deck is pivotal about the rear edge to selectively raise and lower the front edge; and   a lip assembly comprising a main piece and a leading edge piece, the main piece is pivotally coupled to the front edge of the deck, the leading edge piece is pivotally coupled to the main piece such that the main piece is between the leading edge piece and the front edge of the deck.