CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the priority benefit of U.S. Provisional Patent Application Serial Number 62/745,160 filed October 12, 2018, incorporated herein by reference in its entirety

FIELD OF ENDEAVOR

[0002] The invention relates to lift platforms, and more particularly to lift platforms with a core interior structure.

BACKGROUND

[0003] Lifts such as lift gates and accompanying lift platforms are typically mounted at a structure such as an opening at a rear of a vehicle to lift payloads on the lift platform from one level (e.g., ground level) up to another level (e.g., the bed of the vehicle), or vice versa. Operation of a lifting mechanism may rotate the lift platform into an inverted, stowed position beneath the vehicle body. Actuators, such as hydraulic actuators and electric actuators, are used to provide lifting force for moving the lift platform.

SUMMARY

[0004] A core lift platform panel embodiment may include: a top layer; a core layer comprising: a repeating series of cells, where the cells comprise a fixed shape throughout the core layer, and where the fixed shape may be orientated substantially perpendicular to the top layer such that at least one face of the cell may be adjacent to the top layer; and a first adhesive component disposed between at least a portion of the top layer and the core layer, where the core layer may be adhered to the top layer by the first adhesive component.

[0005] Additional core lift platform panel embodiments may include: a bottom layer; where the fixed shape of the repeating series of cells may be orientated substantially perpendicular to the bottom layer such that at least one face of the cell may be adjacent to the bottom layer. Additional core lift platform panel embodiments may include: a second adhesive component disposed between at least a portion of the bottom layer and the core layer, where the core layer may be adhered to the bottom layer by the first adhesive component. Additional core lift platform panel embodiments may include: one or more covers, where the one or more cover are disposed at an edge of the core layer between at least a portion of the top layer and the bottom layer, and where the one or more covers protect the core layer.

[0006] In additional core lift platform panel embodiments, the cells of the core layer may comprise honeycomb-shaped cells, rectangular-shaped cells, and/or square-shaped cells. In additional core lift platform panel embodiments, the core layer may comprises at least one of: metal, foam, Styrofoam, and paper. In additional core lift platform panel embodiments, the top layer may comprise at least one of: aluminum, Nomex, Balsa wood, Tedlar, polyester, Nylon, and Phenolic. In additional core lift platform panel embodiments, the core lift platform panel may comprise a generally rectangular body with a variable thickness.

[0007] In additional core lift platform panel embodiments, the first adhesive component may comprise a weld applied to a perimeter of at least a portion of the top layer and the core layer. In additional core lift platform panel embodiments, the first adhesive component may comprise a layer of epoxy applied across at least a portion of the top layer and the core layer. Additional core lift platform panel embodiments may include: a filler component disposed in at least a portion of the repeating series of cells of the core layer. In additional core lift platform panel embodiments, the filler component provides strength, noise dampening, and thermal insulation to the core layer.

[0008] A system embodiment may include: a foldable section of a lift platform, where the foldable section comprises: a foldable section top layer; a foldable section core layer, where at least a portion of the foldable section core layer comprises a repeating series of cells, where the cells comprise a fixed shape throughout the core layer, and where the fixed shape may be orientated substantially perpendicular to the foldable section top layer such that at least one face of the cell may be adjacent to the foldable section top layer; and a first adhesive component disposed between at least a portion of the foldable section top layer and the foldable section core layer, where the foldable section core layer may be adhered to the foldable section top layer by the first adhesive component.

[0009] Additional system embodiments may further include: a platform section of the lift platform, where the foldable section may be pivotally connected to the platform section via one or more interlocking units, where the one or more interlocking units pivotally connect the foldable section and the platform section in a manner that allows for a folding of the folding section underneath the platform section. Additional system embodiments may further include: a platform section top layer; a platform section core layer, where at least a portion of the platform section core layer comprises a repeating series of cells, where the cells comprise a fixed shape throughout the core layer, and where the fixed shape may be orientated substantially perpendicular to the platform section top layer such that at least one face of the cell may be adjacent to the platform section top layer; and a first adhesive component disposed between at least a portion of the platform section top layer and the platform section core layer, where the platform section core layer may be adhered to the platform section top layer by the first adhesive component.

[0010] Another system embodiment may include: at least one extruded platform segment, where multiple extruded platform segments may be connected in parallel to form a platform; and one or more connectors of each extruded platform segment, where each of the one or more connectors may connect with one or more complementary connectors of another extruded platform segment. In additional system embodiments, a top portion of the at least one extruded platform segment comprises a plurality of extruded grooves to increase grip. In additional system embodiments, the at least one extruded platform segment, may be connected in parallel with another extruded platform segment by at least one of: a weld, an adhesive, and at least one nut and bolt.

[0011] Another system embodiment may include: a top layer; a bottom layer; a core layer comprising: a repeating series of cells, where the cells comprise a fixed shape throughout the core layer, and where the fixed shape is orientated substantially perpendicular to the top layer and to the bottom layer such that at least one face of the cell is adjacent to the top layer and at least one face of the cell is adjacent to the bottom layer; a first adhesive component disposed between at least a portion of the top layer and the core layer, where the core layer is adhered to the top layer by the first adhesive component; and a second adhesive component disposed between at least a portion of the bottom layer and the core layer, where the core layer is adhered to the bottom layer by the first adhesive component.

[0012] Additional system embodiments may include: one or more covers, where the one or more cover may be disposed at an edge of the core layer between at least a portion of the top layer and the bottom layer, and where the one or more covers may protect the core layer. Additional system embodiments may include: a filler component disposed in at least a portion of the repeating series of cells of the core layer, where the filler component may provide strength, noise dampening, and thermal insulation to the core layer.

BRIEF DESCRIPTION OF THE DRAWINGS [0013] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principals of the invention. Like reference numerals designate corresponding parts throughout the different views. Embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which:

[0014] FIG. 1 depicts a perspective view of an extrusion lift platform, in accordance with an embodiment of the invention.

[0015] FIG. 2 depicts a side view of an extrusion lift platform, in accordance with an embodiment of the invention.

[0016] FIG. 3 is a perspective view of a composite core lift platform, in accordance with an embodiment of the invention.

[0017] FIG. 4 is a side view of a lift platform system with an unfolded lift platform, in accordance with an embodiment of the invention.

[0018] FIG. 5 is a side view of a lift platform system with a folded lift platform, in accordance with an embodiment of the invention.

[0019] FIG. 6 is a perspective view of a lift gate system, wherein the composite core lift platform is in a raised position, in accordance with an embodiment of the invention.

[0020] FIG. 7 is a perspective view of a single honeycomb-shaped cell, in accordance with an embodiment of the invention.

[0021] FIG. 8 is a perspective cutaway view of a composite core layer, in accordance with an embodiment of the invention.

[0022] FIG. 9 is a perspective cutaway view of a honeycomb-shaped cell composite core lift platform, in accordance with an embodiment of the invention.

[0023] FIG. 10 is a perspective cutaway view of a rectangular-shaped cell composite core lift platform, in accordance with an embodiment of the invention.

[0024] FIG. 11 A is a perspective view of a lift platform frame, in accordance with an embodiment of the invention.

[0025] FIG. 11B is a top view of the lift platform frame of FIG. 11 A, in accordance with an embodiment of the invention.

[0026] FIG. 11C is a cross-section view of the lift platform frame of FIG. 11B along line A-A, in accordance with an embodiment of the invention.

[0027] FIG. 12 depicts a side view of an extruded platform segment, in accordance with an embodiment of the invention. [0028] FIG. 13 depicts a side view of two extruded platform segments connected in parallel to form a platform, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

[0029] The following description is made for the purpose of illustrating the general principles of the embodiments discloses herein and is not meant to limit the concepts disclosed herein. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations. Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the description as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc.

[0030] Embodiments include a core lift platform panel. The core lift panel may include a top layer, a bottom layer, and a core layer. The core layer may include a repeating series of cells. The cells may have a fixed shape throughout the core layer. The fixed shape may be orientated substantially perpendicular to the top layer and the bottom layer such that at least one face of the cell is adjacent to the top layer and/or at least one face of the cell is adjacent to the bottom layer. A first adhesive component may be disposed between the top layer and the core layer. In some embodiments, the first adhesive component may be a weld applied to the perimeter of at least a portion of the top layer and/or the core layer. In other embodiments, the first adhesive component may be a layer of epoxy applied across at least a portion of the top layer and/or the core layer. The core layer may be adhered to the bottom layer by a second adhesive component. The second adhesive component may be disposed between the bottom layer and the core layer. The core layer may be adhered to the bottom layer by the second adhesive component. The cells of the core layer may comprise honeycomb-shaped cells, rectangular-shaped cells, and/or square-shaped cells. The core layer may be made of at least one of: metal, Styrofoam, and paper. In another embodiment, the core layer may be welded to the top layer and to the bottom layer. Other forms of adherence of the core layer may be welded to the top layer and to the bottom layer are possible and contemplated.

[0031] With reference to FIG. 1, the disclosed system may include an extrusion lift platform 100 The extrusion lift platform 100 may be configured for mounting at a mounting structure such as, but not limited to, a rear frame of a vehicle, such as a truck. For example, the extrusion lift platform 100 may be attached to a rear opening of a vehicle bed of a vehicle, where the vehicle may include an extension plate. The load-carrying surfaces of the lift gate can comprise said extrusion lift platform 100. The extrusion lift platform 100 may typically be square or rectangular in shape and include a rectangular platform section 110 and a rectangular foldable section 120, also known as a“flipover”. The platform section 110 may have a top surface made of multiple extruded platform segments 111, which may be made of extruded metal and may be generally thin rectangular slats that lie along the length of the platform section 110. Similar extruded platform segments may also cover the bottom of the platform section 110. The foldable section 120 may also have a top surface that has multiple extruded platform segments 121.

[0032] Similarly, the bottom of the foldable section 120 may also be covered with extruded platform segments 121. The platform segments 121 may be made from extruded aluminum while the interior of the ramp may be supported with a spaced internal structure wall structure. In some embodiments, the extruded platform segments 111 of the platform section and the extruded platform segments 121 of the foldable section 120 may be identical. The platform section 110 and foldable section 120 may be connected via a number of interlocking units 130 that may pivotally connect the sections in a manner that allows for folding of the folding section 120 underneath the platform section 110. The extrusion lift platform 100 may be used to lift payloads from one level, e.g., proximate the ground, up to another level, e.g., the vehicle bed of a vehicle, or vice versa. The lift gate system may be a stow away system and the foldable section 120 may be folded onto the platform section 110 during stowing of the extrusion lift platform 100. The extrusion lift platform 100 may be substantially aligned with the other parts of the lift gate system including, but not limited to, an extension plate. A ramp lip 140 can be positioned at one end of the foldable section 120 such that the ramp 140 may be attached to an end of the foldable section 120 distal from the platform section 110. The ramp lip 140 may provide a ramping incline from a ground level to a top surface of the foldable section 120 and a top surface of the platform section 110.

[0033] FIG. 2 depicts a side view of a lift platform 200. The lift platform 200 may include a platform section 210, and a foldable section 220 similar to the section described in the discussion of FIG. 1. The platform section 210 and foldable section 220 may be connected via one or more interlocking units 230 that may be similar to interlocking units 130 in FIG. 1, which may pivotally connect the sections 210, 220 in a manner that allows for folding of the folding section 220 underneath the platform section 210. In some

embodiments, at least a portion of a side of the lift platform 200 may be open and expose the internal supports of the platform section 210 and foldable section 220. Internal gaps 240 may be present that allow for lighter weight construction which results in increased fuel efficiency for vehicles that have the platform 200 attached. A ramp lip 250 may be positioned at one end of the foldable section 220 such that the ramp lip 250 may provide a ramping incline from a ground level to the top of the foldable section 220 and the platform section 210. In another embodiment, the lift platform 200 may be a single-piece platform, being comprised of either the platform section 210 or the foldable section 220. In another embodiment, the lift platform 200 may be a multi-piece platform with at least one section in addition to the platform section 210 and the foldable section 220. In some embodiments, at least a portion of the side of the lift platform 200 may be closed.

[0034] With reference to FIG. 3, the present embodiments include a composite core lift platform 300. In many embodiments, the composite core lift platform 300 may be configured for mounting at a mounting structure such as, but not limited to, a rear frame of a vehicle, such as a truck. By way of example and not limitation, the composite core lift platform 300 may be attached to a rear opening of a vehicle bed of a vehicle, where the vehicle may include an extension plate. In various embodiments, the load-carrying surfaces of the lift platform may comprise at least one top layer 310, 320, at least one bottom layer (not pictured), and an interior composite core layer (not pictured) that may comprise a repeating series of cells of various shapes. In more embodiments, the top layers 310, 320 and/or bottom layers may be affixed to the composite core layer by a first adhesive component and/or a second adhesive component (See FIG. 8) between the composite core layer and the top 310, 320 and bottom layers, respectively. In a number of embodiments, the composite core lift platform 300 may include a platform section 310 and a foldable section 320 (also known as a“flipover”). In further additional embodiments, the platform section 350 may comprise an internal layer of composite core cells (not pictured) with a solid external layer on the top 310 and bottom of the platform section 350 with similar external covers on the sides of the platform section 350.

[0035] Similarly, the foldable section 360 may comprise an internal layer of composite core cells (not pictured) with a solid external layer on the top 320 and bottom (not pictured) of the foldable section 360 with similar external covers on the sides of the foldable section 360. In further embodiments, the platform section 350 and foldable section 360 may be connected via a number of interlocking units 330 that may pivotally connect the sections 350, 360 in a manner that allows for folding of the folding section 360 underneath the platform section 350. In certain embodiments, the interlocking pieces may be male rods that couple with female holes present on both the platform section 350 and foldable section 360.

In still further embodiments, the composite core lift platform 300 may be used to lift payloads from one level, e.g., proximate the ground, up to another level, e.g., the vehicle bed of a vehicle, or vice versa. In additional embodiments, the lift gate system utilizing the composite core lift platform 300 may be a stow away system and the foldable section 360 may be folded onto the platform section 350 during stowing of the composite core lift platform 300. In still additional embodiments, the composite core lift platform 300 can be substantially aligned with the other parts of the lift gate system including, but not limited to, an extension plate. In certain embodiments, a ramp lip 340, comprising a single piece of supporting metal, or other material, can be positioned at one end of the foldable section 360 along its width such that the ramp 340 provides a ramping incline from the ground level to the top of the foldable section 360 and platform section 350. The ramp lip 340 may be disposed distal from the platform section 350 when the foldable section 360 is unfolded. In one embodiment, the composite core cells (not pictured) may be at least partially filled with a filler component (956, FIG. 9) such as foam or other similar materials to provide strength, noise dampening which may be caused by movement of the composite core cells (not pictured) within the composite core lift platform 300, and thermal insulation.

[0036] While a variety of composite core lift platforms are described above with reference to FIG. 3, the specific configurations and structures of the composite core lift platforms may be varied based upon the requirements of specific applications. For example, it can be appreciated by those skilled in the art that the sizes of the composite core lift platforms can be variable depending on the type and size of vehicle or structure that it may be utilized for. Additionally, the thickness and/or internal structure of the composite core lift platforms may be changed based upon the types of weights that will need to be lifted and/or the number of duty cycles that are expected of the composite core lift platform. A discussion of a lift platform system with a folding assistant arm is below.

[0037] With reference to FIG. 4, the present embodiments include a lift platform system 400 and folding assisting aluminum retention ramp assembly with an unfolded lift platform in accordance with an embodiment of the invention. In a number of embodiments, the lift platform 435 is lowered and substantially horizontal relative to the ground. In certain embodiments, the foldable section 432, which is a generally rectangular body with a variable thickness and a set of interconnecting parts on one side that allows it to flip over onto a platform section 431 of the lift platform 435 can be unfolded. In additional embodiments, the foldable section 432 may be in the unfolded position during lifting operations, such as shown in FIG. 4. In further embodiments, to stow the lift platform 435 underneath the body of a vehicle or within another body, an operator may first remove any load from the lift platform 435 and manually fold the foldable section 432 over onto the platform section 431. In some embodiments, the platform section 431 may be a generally rectangular body with a variable thickness. In additional embodiments, the foldable section 432 may be hinged to the platform section 431, allowing the foldable section 432 to be folded over onto the platform section 431. The lift platform 435 may be attached to the rest of the lift gate system 400 by a pivot connection 430 that allows for the folding and stowing of the lift platform 435. In certain embodiments, the foldable section 432 may comprise a composite core with a top and bottom layer, while the platform section 431 may be composed of traditional materials. In other embodiments, the foldable section 432 and the platform section 431 may comprise a partially composite core. In other embodiments, the foldable section 432 may be composed of traditional materials and the platform section 431 may comprise a partially composite core.

[0038] With reference to FIG. 5, the present embodiments include the lift gate system 400 with a partially folded lift platform 435. In many embodiments, the lift gate system 400 is ready for stowing when the foldable section 432 is folded against the platform section 431. In more embodiments, the operator can push a switch to initiate stowing of the lift platform 435. In a number of embodiments, the lift platform 435 may require manual rotation of the foldable section 432 relative to the platform section 431 before the switch can be pressed to initiate stowing. The lift platform 435 may be attached to the rest of the lift gate system 400 by the pivot connection 430 that allows for the folding and stowing of the lift platform 435.

In certain embodiments, the foldable section 432 may comprise a composite core with a top and bottom layer, while the platform section 431 may be composed of traditional materials.

[0039] With reference to FIG. 6, the present embodiments include a lift gate system 400, where the lift platform 435 is in a raised position. In many embodiments, a lifting mechanism 660 may move the lift platform 435 between a raised position and a fully lowered position. In a number of embodiments, when the lift platform 435 is in the raised position, the lift platform 435 may be substantially aligned with an extension plate 611 mounted at a bed 650 of a truck opening 651. In additional embodiments, the lift gate system 400 is configured for mounting at a structure such as a rear frame of a vehicle, such as a truck 670. By way of example and not limitation, the lift gate 435 may be attached to the rear opening 651 of a vehicle bed 650 of the vehicle 670, having the extension plate 611. In still further embodiments, the extension plate 611 may be coupled, e.g., fixedly welded and/or removably connected with screws or nuts and bolts, adjacent to a rear face of the vehicle bed 650 for extending the depth, i.e., reach, of the vehicle bed 650 beyond the truck opening 651. In a similar embodiment depicted in FIGS. 4-5, the lift platform 435 may comprise a foldable section 432 and/or a platform section 431. The foldable section 432, platform section 431, and/or the lift platform 435 may comprise a composite core layer with a top and bottom layer.

[0040] While a variety of lift gate systems and lift platforms with composite cores are described above with reference to FIGS. 4-6, the specific configurations and structures of the lift platforms are largely dependent upon the requirements of specific applications. For example, it can be appreciated by those skilled in the art that the exact shape and

configuration of the lift gate can be modified depending on the shape and height of the lift to be performed. Specifically, the type of platform used in the lift gate system may contain either a uniform or non-uniform thickness. Each type of thickness may require a different manufacturing method and may be structurally similar even if the size and shape of the interior composite core cells are variable. Additionally, the thickness and/or internal structure of the lift platforms may be changed based upon the types of weights that will need to be lifted and/or the number of duty cycles that are expected of the lift platform. A discussion of shapes suitable for a composite core cell structure is below.

[0041] With reference to FIG. 7, the present embodiments include a plurality of single honeycomb-shaped composite core cell 700 structures. In various embodiments, the honeycomb-shaped composite core cell 700 and resulting composite core layer (950, FIG. 9) can be manufactured with a metal alloy. In certain embodiments, the honeycomb -shaped composite core cell 700 and composite core may be manufactured out of an aluminum alloy, such as a 3003 alloy. Other possible alloys for the honeycomb-shaped composite core cell 700 and composite core are possible and contemplated. In some embodiments, the composite core cell 700 may be a 3003, 5052, 5052N, and/or 5056 alloy. In some embodiments, the composite cell may comprise one or more aluminum alloys, such as the 3000, 5000, 6000, and/or 7000 series.

[0042] In additional embodiments, the cell height 730 (with respect to the Y-axis) of the honeycomb-shaped composite core cell 700 may be manufactured in various heights including 0.787 and 0.962 inches with a preferable height of 0.874 inches. In some embodiments, the cell height 730 may be anywhere from 0.5 to 4 inches. In certain embodiments, the cell height 730 of another style of honeycomb-shaped composite core cell 700 can be between 1.237 inches and 1.511 inches, with a preferable height 730 of 1.374 inches. In other embodiments, a height 730 of a third style of honeycomb -shaped composite core cell 700 may be between 1.687 and 2.061 inches with a preferable height 730 of 1.874 inches. Similarly, in more embodiments, the cell width or cell size 740 of a honeycomb- shaped composite core cell 700 may be between 0.125 and 1 inches with a preferable cell size 740 of 0.25 and 0.5 inches. In further additional embodiments, the cell wall thickness 750 may be between 0.001 and 0.005 inches with preferable cell wall thickness of 0.003 inches.

In more embodiments, the cell size 760 can be between 6.665 mm and 6.985 mm, but with a preferred cell size 760 of 6.35 mm. In some embodiments, the cell size 760, or density, may be anywhere from 1/8-5.7#, 1/8-4.5#, ¼-5.2#, 3/16-5.7#, 3/8-2.3#, ½-4.5#, and/or ½-2.3#, where X/X is cell size in inches and X.X# is honeycomb density in Pounds per Cubic Foot.

[0043] In further embodiments, the density of the honeycomb-shaped composite core cell 700 and composite core may be manufactured with a variety of densities. In some embodiments, the density of the honeycomb-shaped composite core cell 700 may be preferably between 2.47 and 2.97 g/cm3 for aluminum alloys. In yet further embodiments, the honeycomb structure 700 may be non-perforated.

[0044] With reference to FIG. 8, the present embodiments include a composite core layer 800. In many embodiments, a composite core layer 800 comprises a top layer 820, a bottom layer 810, and a composite cell layer 830 that may be a series of repeating composite core cells 700 arranged together on a layer. In a number of embodiments, the top and bottom of the composite cell layer 830 may be covered by flat metal sheets that make a bottom layer 810 and a top layer 820, respectively. In additional embodiments, the flat sheets may be made of aluminum. In still additional embodiments, the composite cell layer 830 may be made out of materials including, but not limited to, Aluminum, foam, Styrofoam, Nomex, Balsa,

Tedlar, Polyester, Nylon, and/or Phenolic. In certain embodiments, the bottom layer 810 and top layer 820 may be between 1/32 and ¼ inch in thickness.

[0045] In the embodiment shown in FIG. 8, the composite cell layer 830 comprises a series of honeycomb structures similar to the honeycomb structures described in the discussion of FIG. 7. Those skilled in the art will recognize that the composite cell layer 830 may comprise any number of composite cell shapes and sizes, including, but not limited to, a rectangular, triangular, and/or square shape as shown in the discussion of FIG. 10. In more embodiments, the top layer 820 and the bottom layer 810 may be adhered to the composite cell layer 830 by a layer of adhesive applied between each layer and the composite cell layer 830. The composite cell layer 830 may be affixed to the top layer 820 by a first adhesive component 870. The composite cell layer 830 may be affixed to the bottom layer 810 by a second adhesive component 860. In additional embodiments, the entire composite core layer height 840 can be calculated as the sum of the thickness of the bottom layer 810, composite core layer 830, top layer 820, and any adhesive components 860, 870. In still additional embodiments, the height of the composite cell layer 850 may be determined as the distance between the inner surfaces of the bottom layer 810 and top layer 820. The fixed shape of each cell 700 in the composite core layer 800 may be orientated substantially perpendicular to the top layer 820 and the bottom layer 810 such that at least one face 880 of the cell is adjacent to the top layer and bottom layer.

[0046] With reference to FIG. 9, the present embodiments include the composite core lift platform 900, where the composite core lift platform 900 comprises multiple internally arranged honeycomb-shaped composite core cells 700. In many embodiments of the invention, the composite core lift platform 900 may be configured for attaching to a lift gate system, which thereby may be configured for mounting at a mounting structure such as, but not limited to, a rear frame of a vehicle (e.g., a truck). By way of example and not limitation, the composite core lift platform 900 may be installed on a lift gate system attached to a rear opening of a vehicle bed of a vehicle, where the vehicle may include an extension plate. In a number of embodiments, the composite core lift platform 900 comprises a platform section 910 and a foldable section 920 (also known as a“flipover”). In further embodiments, the platform section 910 and foldable section 920 may be connected via a number of interlocking units 930 that can pivotally connect the sections in a manner that allows for folding of the folding section 920 underneath the platform section 910. In still further embodiments, the composite core lift platform 900 may be used to lift payloads from one level, e.g., proximate the ground, up to another level, e.g., the vehicle bed of a vehicle, or vice versa.

[0047] In additional embodiments, the lift gate system utilizing the composite core lift platform 900 may be a stow away system and the foldable section 920 may be folded onto the platform section 910 during stowing of the composite core lift platform 900. In still additional embodiments, the composite core lift platform 900 may be substantially aligned with the other parts of the lift gate system including, but not limited to, an extension plate. In certain embodiments, a ramp lip 940 can be positioned at one end of the foldable section 920 such that the ramp lip 940 provides a ramping incline from the ground level to the top of the foldable section 920 and platform section 910. In still yet additional embodiments, a cutaway view of the internal honeycomb composite core 950 of the foldable section 920 is visible within the foldable section 920 allowing for visualization of how the honeycomb-shaped composite core cells 700 can be arranged and spaced in order to provide internal structural support for the composite core lift platform 900.

[0048] Similarly, a cutaway view of the internal honeycomb composite core layer 955 of the platform section 910 is visible within the platform section 910. Those skilled in the art can appreciate that although the current cutaway views show the honeycomb -shaped composite core layer 950, 955 within the platform section 910 and foldable section 920, similar structures are also placed in a similar fashion throughout the composite core lift platform 900. In still yet further embodiments, the honeycomb-shaped composite cell layer may provide increased efficiency in weight support on the composite core lift platform 900 while also being lighter than other internal structures, thus decreasing overall lift gate system weight and increasing fuel efficiency if the lift gate system is mounted on a vehicle.

[0049] In a variety of embodiments, the size of the platform may be manufactured to meet specific applications. By way of example and not limitation, a panel including a platform section 910 and/or a foldable section 920 may be between 0.9 and 1.1 inches thick, but preferably 1 inch thick. In some embodiments, a total panel thickness may be anywhere from 0.5 to 4 inches, plus a top and a bottom layer thickness. Adhesive component may add some thickness as well. In certain embodiments, a panel including a platform section 910 and/or a foldable section 920 may be between 1.50 and 2.00 inches thick, but preferably 1.75 inches thick. In certain other embodiments, a panel including a platform section 910 and/or a foldable section 920 may be manufactured to be between 1.8 and 2.2 inches thick, but preferably 2 inches thick. In many embodiments, the length of a panel including a platform section 910 and/or a foldable section 920 may be in a range between 31.84 - 38.92 inches but preferably 35.380 inches long.

[0050] In more embodiments, the width of a panel including a platform section 910 and/or a foldable section 920 may be between 79.01 inches and 96.67 inches, but preferably 87.860 inches wide. In some embodiments, the width and length of the panel may be the same as, or similar to, existing liftgate platform sizes. In one embodiment, the panel may have a 60” length total and a 85” width with a 30” main section and a 30” flip over. In one embodiment, the panel may have a 72” length total and a 85” width total with a 36” main section and a 36” flip over. In one embodiment, the panel may have a 72” length total and a 85” width total with a 42” main section and a 30” flip over. In one embodiment, the panel may have a 60” length total and a 80” width total. In one embodiment, the panel may have a 52” length total and a 86” width total with a 10” fixed ramp. In one embodiment, the panel may have a 60” length total and a 86” width total with a 10” fixed ramp. In one embodiment, the panel may have a 68” length total and a 86” width total with a 10” aluminum retention ramp assembly.

[0051] In yet additional embodiments, the top face sheet and bottom face sheet can be manufactured to be between 1/32 inch and 1/4 inch thick, but preferably is 1/8 inch. In some embodiments, the top and bottom layer thickness may differ. In still additional embodiments, the top and bottom layers may be made of an aluminum alloy including, but not limited to, 6061. In some embodiments, the top and bottom layer aluminum alloy may comprise Aluminum skins such as 2024-T3, 6061-T6 and/or 7075-T6). In some embodiments, the top and bottom layer may comprise unidirectional fiberglass reinforced epoxy facings/epoxy bonded. In some embodiments, the top and bottom layer may comprise aluminum grade - T3 or T6. Further, in still more embodiments, the type of aluminum alloy grade can vary depending on the application required, but can preferably be T6 grade aluminum. In yet still more embodiments, a film adhesive utilized between the top and bottom layer and the composite core layers 950, 955 may be applied to adhere the top and bottom layers to the internal composite core cells 700. In certain more embodiments, the adhesive can be a modified epoxy film adhesive. In more additional embodiments, the sides of the panels including the platform section 910 and/or the foldable section 920 may be covered with a solid aluminum bar to protect the interior of the panels. Some embodiments may include additional core/metal sheets (top & bottom) materials: Nomex, balsa (wood), Tedlar, polyester, Nylon, and/or Phenolic.

[0052] With reference to FIG. 10, the present embodiments include a composite core lift platform 1000, where the composite core lift platform 1000 comprises multiple internally arranged rectangular-shaped composite core cells 1050, 1055. In many embodiments of the invention, the composite core lift platform 1000 can be configured for attaching to a lift gate system, which thereby can be configured for mounting at a mounting structure such as, but not limited to, a rear frame of a vehicle, such as a truck. By way of example and not limitation, the composite core lift platform 1000 may be installed on a lift gate system attached to a rear opening of a vehicle bed of a vehicle, where the vehicle may include an extension plate. In a number of embodiments, the composite core lift platform 1000 comprises a platform section 1010 and a foldable section 1020 (also known as a“flipover”) similar to the platform and foldable sections 310, 320 of FIG. 3. In further embodiments, the platform section 1010 and foldable section 1020 may be connected via a number of interlocking units 1030 that may pivotally connect the sections in a manner that allows for folding of the folding section 1020 underneath the platform section 1010 in a similar manner to the interlocking units 330 described in FIG. 3. In still further embodiments, the composite core lift platform 1000 may be used to lift payloads from one level, e.g., proximate the ground, up to another level, e.g., the vehicle bed of a vehicle, or vice versa.

[0053] In additional embodiments, the lift gate system utilizing the composite core lift platform 1000 may be a stow away system and the foldable section 1020 may be folded onto the platform section 1010 during stowing of the composite core lift platform 1000. In still additional embodiments, the composite core lift platform 1000 may be substantially aligned with the other parts of the lift gate system including, but not limited to, an extension plate. In certain embodiments, a ramp lip 1040 can be positioned at one end of the foldable section 1020 such that the ramp lip 1040 provides a ramping incline from the ground level to the top of the foldable section 1020 and platform section 1010 similar to the ramp lip 340 in FIG. 3. In still yet additional embodiments, a cutaway view of the internal rectangular composite core 1050 of the foldable section 1020 is visible within the foldable section 1020 allowing for visualization of how the rectangular-shaped composite core cells can be arranged and spaced in order to provide internal structural support for the composite core lift platform 1000.

[0054] Similarly, a cutaway view of the internal rectangular composite core 1055 of the platform section 1010 is visible within the platform section 1010. Those skilled in the art can appreciate that although the current cutaway views show the rectangular-shaped composite cores 1050, 1055 within the platform section 1010 and foldable section 1020, similar structures are also placed in a similar fashion throughout the composite core lift platform 1000. In still yet further embodiments, the rectangular-shaped composite cell layer may provide increased efficiency in weight support on the composite core lift platform 1000 while also being lighter than other internal structures, thus decreasing overall lift gate system weight and increasing fuel efficiency if the lift gate system is mounted on a vehicle.

[0055] In a variety of embodiments, the size of the platform can be manufactured to meet specific applications. By way of example and not limitation, a panel including a platform section 1010 and/or a foldable section 1020 may be between 0.9 and 1.1 inches thick, but preferably 1 inch thick. In some embodiments, a total panel thickness may be anywhere from 0.5 to 4 inches, plus a top and a bottom layer thickness. Adhesive component may add some thickness as well. In certain embodiments, a panel including a platform section 1010 and/or a foldable section 1020 may be between 1.50 and 2.00 inches thick, but preferably 1.75 inches thick. In certain other embodiments, a panel including a platform section 1010 and/or a foldable section 1020 may be manufactured to be between 1.8 and 2.2 inches thick, but preferably 2 inches thick. In many embodiments, the length of a panel including a platform section 1010 and/or a foldable section 1020 can be in a range between 31.84 - 38.92 inches but preferably 35.380 inches long. In more embodiments, the width of a panel including a platform section 1010 and/or a foldable section 1020 can be between 79.01 inches and 96.67 inches, but preferably 87.860 inches wide. In yet additional embodiments, the top face sheet and bottom face sheet can be manufactured to be between 1/32 and 1/4 inches thick, but preferably is 1/8 inch. In still additional embodiments, the top and bottom layers may be made of an aluminum alloy including, but not limited to, 6061. Further, in still more embodiments, the type of aluminum alloy grade can vary depending on the application required, but can preferably be T6 grade aluminum.

[0056] In yet still more embodiments, a film adhesive utilized between the top and bottom layer and the composite core cell layers 1050, 1055 may be applied to adhere the top and bottom layers to the internal composite core cell layers 1050, 1055. In certain more embodiments, the adhesive may be a modified epoxy film adhesive. In more additional embodiments, the sides of the panels including the platform section 1010 and/or the foldable section 1020 may be covered by one or more covers 1065. The one or more covers 1065 may be made from a solid aluminum bar to protect the interior of the panels from dust, dirt, and/or the elements.

[0057] With reference to FIGS. 11 A-l 1C, the present embodiments include a lift platform frame 1100. The lift platform frame 1100 includes one or more substantially parallel slats 1102 and one more substantially parallel bars 1104. The one or more substantially parallel bars 1104 are substantially perpendicular to the one or more substantially parallel slats 1102. The one or more substantially parallel bars 1104 may be attached on top of and/or in an indentation in the one or more substantially parallel slats 1102. The present

embodiments include a lift platform frame 1100 with an interior composite core platform that may be attached to a truck. In a variety of embodiments, the composite core layer of a lift platform in a lift gate system may be placed within the frame of another type of lift platform. By way of example and not limitation, the embodiment depicted in FIG. 11 A comprises a composite cell layer 1106 encompassed by a left plate 1108, a right plate 1110, upper extrusions 1112, and lower extrusions 1114. In certain embodiments, the upper extrusions 1112 and/or the lower extrusions 1114 may be comprised of an aluminum alloy. Those skilled in the art will recognize that the frame that encompasses the composite cell layer 1106 may be made out of any suitable material that allows the lift gate system to operate more efficiently. In additional embodiments, the composite cell layer 1106 may be covered by solid plating on the top and/or bottom of the composite cell layer 1106.

[0058] With reference to FIGS. 12-13, the present embodiments include an extruded platform segment 1200, where multiple extruded platform segments 1200 may be connected 1302 in parallel to form a platform 1300. Each extruded platform segment 1200 may include a top portion 1202, a bottom portion 1204, and a middle portion 1206. Each platform segment may also include one or more connectors 1208, 1210, 1212, 1214 to connect with one or more complementary connectors 1208, 1210, 1212, 1214 on another extruded platform segment 1200. In some embodiments, a top surface 1216 of the top portion 1202 may include a plurality of extruded grooves or other features to increase grip. Two or more extruded platform sections 1200 may be connected 1302 in parallel to form a platform 1300. The connection 1302 may include welding adjacent extruded platform segments 1200 together. In some embodiments, the connection 1302 may include adhering adjacent extruded platform segments 1200 together via an adhesive, nuts and bolts, or the like. The extruded platform segments 1200 may be identical or vary in appearance, shape, cell structure, cell shape, and the like.

[0059] While a variety of composite core lift platforms are described above with reference to FIGS. 7 - 13, the specific configurations and structures of the composite core lift platforms are largely dependent upon the requirements of specific applications. For example, it can be appreciated by those skilled in the art that the exact size, shape, material, and configuration of the composite core cells can be modified depending on the material or manufacturing costs and/or potential lift platform weight limits needed.

[0060] The present invention has been described in considerable detail with reference to certain preferred versions thereof; however, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.

[0061] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0062] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

[0063] The above description presents the best mode contemplated for carrying out the present embodiments, and of the manner and process of practicing them, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which they pertain to practice these embodiments. The present embodiments are, however, susceptible to modifications and alternate constructions from those discussed above that are fully equivalent. Consequently, the present invention is not limited to the particular embodiments disclosed. On the contrary, the present invention covers all modifications and alternate constructions coming within the spirit and scope of the present disclosure. For example, the steps in the processes described herein need not be performed in the same order as they have been presented, and may be performed in any order(s). Further, steps that have been presented as being performed separately may in alternative embodiments be performed concurrently. Likewise, steps that have been presented as being performed concurrently may in alternative embodiments be performed separately.

[0064] It is contemplated that various combinations and/or sub-combinations of the specific features and aspects of the above embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments may be combined with or substituted for one another in order to form varying modes of the disclosed invention. Further, it is intended that the scope of the present invention herein disclosed by way of examples should not be limited by the particular disclosed embodiments described above.