Abstract
A flexible substrate for adhering reflective film and attaching to highway guardrails, guardrail end sections, barrier walls, and cable barrier systems. The flexible material permits the reflector to flex and/or move on impact and thus can withstand impact without breaking or suffering significant damage. The reflectors of the present invention can also increase highway safety and reduce highway maintenance costs.
Claims
1. A highway reflector that can withstand impact without breaking, the reflector formed of a flexible cross-reinforced UV resistant polypropylene substrate and comprising a retroreflective sheeting applied to one or both sides of the reflector.
2. The reflector of claim 1, wherein the reflector is shaped to nest inside the web of conventional W-beam guardrail.
3. The reflector of claim 1, further comprising first and second fastening members for fastening the reflector to a conventional W-beam guardrail.
4. The reflector of claim 1, further comprising a first fastening member for fastening the reflector to a conventional concrete barrier wall.
5. The reflector of claim 1, wherein the reflector is circular in shape and includes a cut line for separating/opening and attaching the reflector to a cable barrier.
6. The reflector of claim 5, wherein cut line comprises a locking tab.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 depicts a flexible bolt-mounted W-beam guardrail reflector constructed in accordance with a preferred embodiment of the present invention;
[0008] FIG. 2 depicts the 1 or 2-sided guardrail reflector of FIG. 1 installed on a guardrail in accordance with a preferred embodiment of the present invention;
[0009] FIG. 3 depicts a flexible 1 or 2-sided concrete barrier wall reflector constructed in accordance with a preferred embodiment of the present invention;
[0010] FIG. 4 depicts the reflector of FIG. 3 installed on a guardrail in accordance with a preferred embodiment of the present invention;
[0011] FIG. 5 depicts a flexible raised asphalt pavement reflector constructed in accordance with a preferred embodiment of the present invention;
[0012] FIG. 6 depicts the reflector of FIG. 5 installed in accordance with a preferred embodiment of the present invention;
[0013] FIG. 7 depicts a flexible cable barrier reflector constructed in accordance with a preferred embodiment of the present invention;
[0014] FIG. 8 depicts the reflector of FIG. 7 installed in accordance with a preferred embodiment of the present invention;
[0015] FIG. 9 depicts the reflector of FIG. 7 being installed on a cable in accordance with a preferred embodiment of the present invention;
[0016] FIG. 10 depicts a flexible cable barrier reflector with a locking tab constructed in accordance with a preferred embodiment of the present invention;
[0017] FIG. 11 depicts a; flexible bolt-mounted W-beam guardrail reflector constructed in accordance with a preferred embodiment of the present invention;
[0018] FIG. 12 depicts the reflectors of FIG. 1 and FIG. 12 installed on a guardrail in accordance with a preferred embodiment of the present invention;
[0019] FIG. 13 depicts the reflectors of FIG. 1 and FIG. 12 installed on a guardrail in accordance with a preferred embodiment of the present invention;
[0020] FIG. 14 depicts a flexible 2-sided concrete barrier wall tent reflector constructed in accordance with a preferred embodiment of the present invention;
[0021] FIG. 15 depicts the reflectors of FIG. 3 and FIG. 15 installed on a concrete barrier in accordance with a preferred embodiment of the present invention; and
[0022] FIG. 16 depicts enlarged views of a cross-reinforced polypropylene substrate material for use in connection with the reflectors of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0024] As stated above, conventional reflectors used on highway guardrails, guardrail end sections and on barrier walls are often destroyed when impacted, for example by vehicles and snow and ice removal operations and equipment. In addition, conventional devices are limited for installation in some areas and specific locations of guardrails and barriers and are also often made of metals and hard plastic materials which bend, break, and have potential to cause damage or injury on impact.
[0025] The present invention is directed at improvements to the currently available products. In a preferred embodiment, the present invention is directed towards a flexible substrate for adhering various reflective films and attaching to highway guardrails, guardrail end sections, barrier walls, and cable barriers. The flexible material permits the reflector to flex/move on impact and thus can withstand impact without breaking or suffering significant damage. The reflectors of the present invention can also increase highway safety and reduce highway maintenance costs.
[0026] The traffic safety reflector products of the present invention comprise several unique designs as well as unlimited size variations that utilize a flexible cross-reinforced and/or corrugated polypropylene substrate. Products that can be made in accordance with preferred embodiments of the present invention include, but are not limited to, Barrier Wall Reflectors, Guardrail Reflectors, Cable Barrier System Reflectors, and Temporary HMA (hot mix asphalt) raised pavement markers. These products can be installed similarly to conventional products with adhesive or mechanical fasteners. They are aligned to reflect back light from motorist headlights and warn them of various roadside hazards that the reflectors are mounted to.
[0027] The material used for the reflector substrate is not brittle and can survive impacts from snow and ice removal operations. Reflectors made in accordance with preferred embodiments of the present invention will remain functional when impacted by snow removal operations and have the potential to save lives.
[0028] As described herein, and as seen in accompanying FIGS. 1-16, the primary components of the present invention comprise a substrate comprising extruded and thermal formed flexible plastic sheet, a reflective top coating on the substrate, and one or more fastening devices.
[0029] FIG. 1 depicts a W-beam guardrail reflector 10 constructed in accordance with a preferred embodiment of the present invention. Reflector 10 comprises a main reflector body 12 and a first and second fastening members 14. In a preferred embodiment, reflector body 12 is formed of a cross reinforced UV resistant polypropylene substrate, which is flexible enough to withstand impact without breaking. Retroreflective sheeting is applied to one or both sides of reflective body 12 polypropylene substrate. In a preferred embodiment, retroreflective sheeting meets various state department of transportation (DOT) specifications and includes Pressure Sensitive Adhesive for applying the sheeting to reflector body 12 and accommodates bending without breaking upon impact. In a preferred embodiment, the shape of reflector body 12 is die cut to nest inside the web of conventional W-beam guardrail and can be attached with self-taping screws 18 as depicted in FIG. 2. Score lines 16 aid in bending and shaping the fastening members 14 for attachment to the guardrail 20. In a preferred embodiment, the corners of reflective body 12 are rounded to help reduce sharp edges.
[0030] Installing reflector 10 comprises first folding fastener members 14 along score lines 16 towards the reverse side of the reflector 10. Reflector 10 can then be positioned on guardrail 20 such that reflector 10 nests tightly in the appropriate section of guardrail 20 (see FIG. 2, by way of example). Next, reflector 10 should be visually aligned so that it is vertical and perpendicular to traffic viewpoint. Reflector 10 can then be attached to guardrail 20 with self-taping screws 18, with screws 18 tightened until firm contact is made between the screws and reflector 10 and guardrail 20.
[0031] FIG. 3 depicts a flexible concrete barrier wall reflector 30 constructed in accordance with a preferred embodiment of the present invention. Reflector 30 is designed to install quickly and easily at any point along the length of a concrete, steel or wood barrier wall or railing. Reflector 30 comprises a cross-reinforced UV resistant polypropylene substrate that is flexible enough to withstand impact without breaking and includes retroreflective sheeting (per DOT specifications) on one or both sides of the reflector 30. Such reflectors 30 can be installed on top of or on the sides of concrete barrier walls 34 on Interstates, highways, or country roads (see FIG. 4, by way of example), or on concrete, steel or wood barrier walls and railing, and in a preferred embodiment, should be spaced per DOT specifications to enhance nighttime visibility.
[0032] In a preferred embodiment, reflector 30 comprises a score line 32 that allows reflector 30 to bend of flex when impacted. In an alternative embodiment, reflector 30 can be a flat sheet that can be attached to the side of guardrail post 111 (FIG. 13).
[0033] Installing reflector 30 comprises first ensuring that dirt and dust have been removed from the concrete, steel or wood mounting surface. Next, an appropriate construction adhesive suitable for the barrier should be applied to the rear surface of reflector 30, and reflector 30 should be positioned as the desired location along barrier wall 34. Pressure should be applied, and reflector 30 moved side to side to ensure adequate adhesive contact is achieved. In addition, a mechanical fastener (not shown) may be used.
[0034] FIGS. 5 and 6 depict a temporary HMA raised pavement marker 40 constructed in accordance with a preferred embodiment of the present invention. Marker 40 allows for immediate marking of centerlines and lane lines on freshly laid HMA (Hot Mix Asphalt) and can be installed quicky and easily behind paving machines before the first pass of the roller machine.
[0035] In a preferred embodiment, marker 40 comprises a corrugated polypropylene substrate that is flexible enough to withstand impact without breaking and includes a retroreflective sheeting in accordance with DOT specifications on one or both sides of the reflector 40. Reflector 40 comprises a score line 42 so that marker 40 will flex when roller machine and subsequent tires from traffic roll over it (see FIG. 6). Marker 40 has a melting point exceeding the recommended installation temperature for HMA, is durable and will flex under traffic.
[0036] Reflector 40 can be installed after placement of HMA by the paving machine and before the first pass of the roller machine. Reflector 40 is designed to be installed into freshly laid pavement at an approximate installation angle of 45 degrees with the pointed end inserted down into the freshly laid pavement and opposite the direction of traffic (see FIG. 6, by way of example). For best results, marker 40 should be installed approximately 4 to 6 inches from the edge of the pavement joint to prevent damage from the paving machine when paving the adjacent lane. The roller should operate normally, rolling over marker 40 to firmly set it in place.
[0037] FIGS. 7-10 depict a universal cable barrier reflector 60 constructed in accordance with a preferred embodiment of the present invention. Reflector 60 is simple and unique, installs quicky and easily at any point along the length of a standard inch cable barrier system 80, and no tool or special hardware is required for installation. In a preferred embodiment, reflector 60 comprises a cross-reinforced UV resistant polypropylene substrate that is flexible enough to withstand impacts without breaking and includes retroreflective sheeting in accordance with DOT specifications (such as 3M Series 3930) on one or both sides of the reflector 60. Reflector 60 comprises a cut line 62 that can be separated for easy installation over a cable barrier 80 (see FIG. 9, by way of example). In an alternative embodiment, cut line 62 can be replaced with a locking tab 64 (see FIG. 10).
[0038] Installing reflector 60 comprises selecting an installation location, opening reflector 60 along cut line 62 (or 64) to create a gap to slip reflector 60 over cable 80. Reflector 60 can then be positioned as desired along the length of the cable.
[0039] FIG. 11 depicts a flexible bolt-mounted W-beam guardrail reflector 100 constructed in accordance with a preferred embodiment of the present invention. Reflector 100 comprises a main reflector body 102 and a fastening member 104. In a preferred embodiment, reflector body 102 is formed of a cross reinforced UV resistant polypropylene substrate, which is flexible enough to withstand impact without breaking. Retroreflective sheeting is applied to one or both sides of reflective body 102 polypropylene substrate. In a preferred embodiment, the retroreflective sheeting meets DOT specifications and includes Pressure Sensitive Adhesive for applying the sheeting to reflector body 102 and accommodates bending without breaking upon impact. In a preferred embodiment, the shape of reflector body 102 is die cut to nest inside the web of conventional W-beam guardrail and can be attached with a -inch attachment bolt 110 as depicted in FIGS. 12 and 13. Score line 106 aids in bending and shaping the fastening member 104 for attachment to the guardrail 108. In a preferred embodiment, the corners of reflective body 100 are rounded to help reduce sharp edges.
[0040] Installing reflector 100 comprises loosening bolt 110, inserting fastener member 104 under loosened bolt 110, visually aligning reflector 100 so that it is vertical and perpendicular to traffic, and then tightening bolt 110 until firm contact is made between fastener member 110 and guardrail 108.
[0041] FIG. 14 depicts a flexible 2-sided concrete barrier wall tent reflector 200 constructed in accordance with a preferred embodiment of the present invention. Reflector 200 is designed to install quickly and easily at any point along the length of a concrete, steel or wood barrier wall or railing (see FIG. 15, by way of example). Reflector 200 comprises a cross-reinforced UV resistant polypropylene substrate that is flexible enough to withstand impact without breaking and includes retroreflective sheeting in accordance with DOT specifications on one or both sides of the reflector 200. Such reflectors 200 can be installed on top of or on the sides of concrete barrier walls 220 on Interstates, highways, or country roads (see FIG. 15, by way of example), or on concrete, steel or wood barrier walls and railing, and in a preferred embodiment, should be spaced per DOT specifications to enhance nighttime visibility.
[0042] In a preferred embodiment, reflector 200 comprises two end score lines 210 and a center score line 208 that allows reflector 200 to bent and formed into a tent shape for installation (see FIG. 15, by way of example).
[0043] FIG. 16 depicts an example of a cross-reinforced polypropylene substrate suitable for the reflectors described and depicted herein. In this embodiment, substrate 80 is a co-extruded board made of three layers sold under the name Prime Bubble-X by Primex Plastics.
[0044] While the primary use of the reflectors of the present invention is intended for highway safety warning, the devices may also be used in Industrial facilities for employee safety.
[0045] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
