REINFORCED SUSTAINABLY-PRODUCED ARTICLES
20260078553 ยท 2026-03-19
Inventors
- Eric Davis (Aurora, CO, US)
- Rick Welle (Aurora, CO, US)
- Vincent Powell (Aurora, CO, US)
- Geoffrey R. Quinter (Aurora, CO, US)
Cpc classification
International classification
Abstract
A sustainable article including a waste material and a binder is provided. The binder is mixed with the waste material and configured to bind the waste material to form the sustainable article. The binder may include a catalyst configured to enable the binder to bind the waste material to form the sustainable article. The sustainable article further includes a reinforcement system.
Claims
1. A sustainable article comprising: a waste material; a binder mixed with the waste material and configured to bind the waste material to form the sustainable article; and a reinforcement system.
2. The sustainable article of claim 1, wherein the reinforcement system comprises at least one tube attached to a side of the sustainable article.
3. The sustainable article of claim 1, wherein the reinforcement system comprises a plurality of tubes attached to a side of the sustainable article.
4. The sustainable article of claim 3, wherein the plurality of tubes comprises three tubes.
5. The sustainable article of claim 3, wherein the plurality of tubes are attached to the sustainable article with fasteners.
6. The sustainable article of claim 3, wherein the plurality of tubes comprises a plurality of metal tubes.
7. The sustainable article of claim 3, wherein the plurality of tubes are attached to at least two sides of the sustainable article.
8. The sustainable article of claim 1, wherein the reinforcement system comprises at least one tube overmolded into the sustainable article
9. The sustainable article of claim 1, wherein the reinforcement system comprises a plurality of tubes overmolded into the sustainable article.
10. The sustainable article of claim 9, wherein the plurality of tubes comprises three tubes.
11. The sustainable article of claim 9, wherein the plurality of tubes comprises a plurality of metal tubes.
12. The sustainable article of claim 1, wherein the reinforcement system comprises at least one tube attached to a side of the sustainable article by at least one connector.
13. The sustainable article of claim 1, wherein the reinforcement system comprises a plurality of tubes attached to a side of the sustainable article by two connectors.
14. The sustainable article of claim 13, wherein the plurality of tubes comprises three tubes.
15. The sustainable article of claim 13, wherein the two connectors attach the plurality of tubes to a connection system of the sustainable article.
16. The sustainable article of claim 13, wherein the two connectors comprise two plates each defining a plurality of connection holes and a plurality of tube holes.
17. The sustainable article of claim 1, wherein the reinforcement system comprises at least one tube attached positioned within a groove of the sustainable article, and wherein the reinforcement system further comprises at least one plate overmolded into the sustainable article.
18. The sustainable article of claim 1, wherein the reinforcement system comprises at least one Thrie beam attached to a side of the sustainable article.
19. A sustainable article comprising: a waste material; and a binder mixed with the waste material and configured to bind the waste material to form the sustainable article; and a reinforcement system, wherein the sustainable article is capable of being certified under the MASH TL3 certification test.
20. A sustainable article comprising: a waste material; and a binder mixed with the waste material and configured to bind the waste material to form the sustainable article; and a reinforcement system, wherein the reinforcement system comprises at least one tube attached to a side of the sustainable article, and wherein the sustainable article is capable of being certified under the MASH TL3 certification test.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] A further understanding of the nature and advantages of the embodiments may be realized by reference to the following drawings. In the appended figures, similar components or features may have the same reference label.
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[0149] While the embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the exemplary embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the instant disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.
DETAILED DESCRIPTION
[0150] The systems and methods disclosed herein relate to, among other things sustainable articles such as a sustainable barrier that may be used for a variety of purposes including use as a traffic barrier. The sustainable barriers described herein are formed of a waste material and a binder that binds the waste material into a specific shape for a specific use. Additionally, the waste material and the binder may be combined in different ratios with different compositions such that the material that forms the sustainable barrier may be tailored to specific uses. Moreover, the shape of the barriers may be tailored to a specific shape to suit a specific function. Accordingly, the sustainable barriers described herein are formed of a sustainable material with a tailored composition and shape to suit a specific function.
[0151] Specifically, in the illustrated embodiments, the waste material used to form the sustainable barriers described herein is used tires. In alternative embodiments, the waste material may be any material including, but not limited to, recycled plastics, recycled wood, and/or any other sustainable or recyclable material. The binder includes a polyurethane binder, an optional colorant, an optional catalyst, and a small amount of water. The used tires are ground to form a crumb rubber and the binder is formulated to bind the crumb rubber into a formed sustainable barrier. Specifically, the binder has been formulated to bind the crumb rubber into the sustainable barrier without using heat. More specifically, the catalyst within the binder quickly forms the sustainable barrier such that heat is not required.
[0152] The properties of the waste material and/or the processing conditions may be varied to tune or specify the final properties of the sustainable barrier. Specifically, a specific type of waste material may be selected to achieve a desired physical property within the sustainable barrier. For example, a denser waste material may be selected such that the sustainable barrier is denser and/or harder. The denser/harder sustainable barrier may be useful for specific uses or harsh environments. For example, the denser/harder sustainable barriers may be tailored such that the density is greater than the density of water and may be useful for flood control. Additionally, the denser/harder sustainable barriers may be useful for barriers in high traffic/high speed highways where collisions may cause damage to softer/less dense barriers.
[0153] Conversely, a less dense waste material may be selected such that the sustainable barrier is less dense and/or softer. The less dense/softer sustainable barrier may be useful for specific uses or specific environments. For example, the less dense/softer sustainable barriers may be useful for situations where a barrier is needed but the barrier needs to give to protect the object impacting the barrier. For example, barriers at bumper car facilities or go-cart racetracks need to stop the bumper car or go-cart without hurting the occupant or damaging the bumper car or go-cart. Certain waste materials are denser than others and may be suitable for specific situations. For example, tires suitable for large commercial vehicles (such as constructions vehicles and tractor trailers) are typically denser/harder than tires for residential vehicles and bicycles. The density of the sustainable barrier may be tuned by selecting the material the sustainable barrier is made from based on the materials density. Additionally, the density of the sustainable barrier may also be varied based on the compression pressure used to form the barrier. A higher compression pressure increases the density of the sustainable barrier and a lower compression pressure decreases the density of the sustainable barrier.
[0154] Furthermore, different mixtures of materials may form different parts of the same barrier with different densities to perform different functions. For example, a first uncured batter (combination of the waste material and the binder in an uncured slurry) may be poured into a mold to form a core of the barrier. The first uncured batter may be tailored to have a high density such that the core provides structural support for the barrier. A second uncured batter may be poured around the core to form a skin of the barrier. The second uncured batter may be tailored to have a lower density such that the skin gives upon impact with the barrier. As such, the densities of the sustainable materials use to form the barriers may be tailored to a specific use for the barrier.
[0155] The shape of the sustainable barriers may also be tailored to different uses. That is, the mold used to cure the batter may be configured to have different shapes such that the sustainable barriers are useful for other applications. For example, the sustainable barriers may have the traditional Jersey Barrier shape for use as a traffic divider. In other embodiments, the sustainable barriers may be blocks instead of the traditional Jersey style barrier. The blocks may be stackable on each other such that the sustainable barriers can be formed into a makeshift wall. In still other embodiments, the sustainable barriers may resemble the traditional Jersey Barrier but may have different angles to deflect vehicles in different directions upon impact. As such, the shape of the sustainable barriers may be tailored to different configurations depending on their use.
[0156] Furthermore, because the sustainable barriers are made from a waste material (in this case recycled tires), the sustainable barriers are substantially less brittle than traditional concrete barriers and are substantially less likely to break or chip when moved. As describe above, traditional concrete barriers often chip or even break when moved at a construction site. The barriers described herein do not break or chip like traditional concrete barriers. Specifically, the recycled tires used to form the sustainable barriers are flexible and, as such, the sustainable barriers typically bounce or temporarily deform when impacted or dropped. That is, the sustainable barriers described herein do not break or chip like traditional concrete barriers. Accordingly, the sustainable barriers described herein may be more robust than traditional concrete barriers.
[0157] Because the sustainable barriers are formed of less brittle, more flexible materials, the sustainable barriers may be stacked on top of each other several levels high for storage or for creating larger barrier structures. For example, the sustainable barriers may be sized and shaped such that the barriers are stacked several levels high on top of each other to form a makeshift wall. In contrast, the traditional Jersey Barriers cannot be stacked to form tall structures that are several levels high.
[0158] The sustainable barriers described herein may also include connectors that enable the sustainable barriers to be connected to each other. In some embodiments, the connectors include loops of rebar that extend out from a side of the sustainable barrier and are capable of interfacing with connectors of other sustainable barriers to form an extended barrier structure. The material of the connectors may also reinforce the structure of the barrier. For example, the rebar may extend into the body of the barrier such that the rebar also acts as a barrier if the sustainable barrier is struck by a vehicle. In some embodiments, the connectors may include shaped ends with corresponding shapes that interconnect with each other to interlock. In some embodiments, the connectors may include a shaped connector that interlocks with identical shaped ends of the sustainable barrier.
[0159] In some embodiments, the rebar of the connector extends from one side of the sustainable barrier to the other. More specifically, the connectors may include a rebar loop that extends from a connector on one side of the sustainable barrier to a connector on the other side of the sustainable barrier. As such, the rebar loop forms an extra structural component that strengthens the barrier.
[0160] In alternative embodiments, the rebar connectors may not extend throughout the sustainable barrier. Rather, the rebar connector only extends into the sustainable barrier a short distance. In this embodiment, the connector does not provide as much structural reinforcement as the rebar loop embodiment described above and may be designed to separate in the event of an impact. In this embodiment, the rebar connector may be sized and shaped to maintain the connector within the sustainable barrier. For example, the ends of the connector may be turned up or may be twisted to create a tortuous pull-out path in the event of an impact.
[0161] Accordingly, the embodiments of sustainable barriers described herein are formed of a sustainable material that may be tailored to a specific use. Specifically, the density of the material may be tailored such that the relative hardness of the material of portions of the sustainable barriers may be tailored for different uses. Furthermore, the shape of the sustainable barriers may also be tailored for different uses. As such, the sustainable barriers described herein may be tailored for different uses and are entirely sustainable.
[0162]
[0163] As shown in
[0164] In the illustrated embodiment, the sustainable barrier 100 has a wide base 110 and a narrow top 102. The two broad sides 106 are angled to shape both the wide base 110 and the narrow top 102. The narrow top 102 is substantially flat to facilitate stacking a plurality of sustainable barriers 100 on top of each other. The two narrow sides 104 are substantially flat to facilitate aligning a plurality of sustainable barriers 100 in a row to form a long, continuous barrier. For example, a plurality of sustainable barriers 100 may be arranged by aligning one of the narrow sides 104 of a first sustainable barrier 100 with one of the narrow sides 104 of a second sustainable barrier 100 and the other of the narrow sides 104 of the first sustainable barrier 100 with one of the narrow sides 104 of a third sustainable barrier 100 to form a row in the median of a road. This long, continuous barrier in the middle of the road reduces the risk of head on collisions and improves the overall safety of traveling on the road.
[0165] As shown in
[0166] In the illustrated embodiment, the two broad sides 106 each include a vertical base 116 and an angled top 118. The vertical base 116 extends substantially vertically from the bottom 108 and the angle top 118 extends at an angle a relative to grade or a horizontal line 120 parallel to grade from the vertical base 116 to the top 102. The two broad sides 106 each define a sustainable barrier height 122, the two vertical bases 116 each define a vertical base height 124, and the two angle tops 118 each define an angled top height 126. In the illustrated embodiment, the sustainable barrier height 122 is approximately 30 inches to approximately 42 inches high, the vertical base height 124 is approximately 0 inches to approximately 12 inches high, the angled top height 126 is approximately 0 inches to approximately 42 inches high, and the angle a is approximately 70 to approximately 90. More specifically, in the illustrated embodiment, the sustainable barrier height 122 is 30, 32, 36, or 40 inches high, the vertical base height 124 is 8 inches high, the angled top height 126 is 24 inches high, and the angle a is 76. In alternative embodiments, the sustainable barrier height 122, the vertical base height 124, the angled top height 126, and the angle a may be any height or angle that enables the sustainable barrier 100 to operate as described herein.
[0167] As shown in
[0168] The drainage slots 128 facilitate water drainage from one side of the sustainable barrier 100 to the other. In alternative embodiments the drainage slot 128 may extend along a length of the sustainable barrier rather than across the width of the sustainable barrier. Additionally, the drainage slots 128 may also be used to facilitate movement of the sustainable barrier 100. More specifically, in the illustrated embodiment, the drainage slots 128 are positioned to enable a forklift (not shown) or some other equipment to pick up and move the sustainable barrier 100. More specifically, in the illustrated embodiment, the drainage slots 128 each define a drainage slot bottom width 130, a drainage slot top width 132, a drainage slot height 134, and a drainage slot length 136. In the illustrated embodiment, the drainage slot length 136 is equal to the bottom width 112 such that the drainage slots 128 each extend through the wide base 110 of the sustainable barrier 100. Additionally, the drainage slot widths 130 and 132 and the drainage slot height 134 are each sized and shaped to enable water to drain from one side of the sustainable barrier 100 to the other and to enable the prongs of a forklift to be inserted into the drainage slots 128 for picking up the sustainable barrier 100. In the illustrated embodiment, the drainage slot bottom width 130 is approximately 12 inches to approximately 24 inches wide, the drainage slot top width 132 is approximately 12 inches to approximately 26 inches wide, the drainage slot height 134 is approximately 3 inches to approximately 6 inches high, and the drainage slot length 136 is approximately 18 inches to approximately 24 inches long. More specifically, for a sustainable barrier with a length 127 of approximately 6 feet, the drainage slot bottom width 130 is 11 inches wide, the drainage slot top width 132 is 10 inches wide, the drainage slot height 134 is 3.5 inches high, and the drainage slot length 136 is 24 inches long. Additionally, for a sustainable barrier with a length 127 of approximately 8 feet, the drainage slot bottom width 130 is 26 inches wide, the drainage slot top width 132 is 25 inches wide, the drainage slot height 134 is 3.5 inches high, and the drainage slot length 136 is 18 inches long. In alternative embodiments, the drainage slot bottom width 130, the drainage slot top width 132, the drainage slot height 134, and the drainage slot length 136 may be any length that enables the sustainable barrier 100 to operate as described herein.
[0169] As discussed above, the sustainable barriers 100 described herein are formed of a waste material and a binder that binds the waste material into a specific shape for a specific use. The waste material and the binder may be combined in different ratios with different compositions such that the material that forms the sustainable barrier 100 may have portions with different densities. Additionally, the shape of the sustainable barriers 100 may be tailored to a specific shape to suit a specific function. Accordingly, the sustainable barriers 100 described herein are formed of a sustainable material with a tailored composition and shape to suit a specific function.
[0170] Specifically, in the illustrated embodiments, the waste material used to form the sustainable barriers 100 described herein is used tires. In alternative embodiments, the waste material may be any material including, but not limited to, recycled plastics, recycled wood, and/or any other sustainable or recyclable material. The used tires are ground to form a crumb rubber and the binder is formulated to bind the crumb rubber into a formed sustainable barrier 100. In the illustrated embodiments, the waste material is approximately 90% to approximately 99% by weight of the sustainable barrier 100, approximately 91% to approximately 99% by weight of the sustainable barrier 100, approximately 92% to approximately 99% by weight of the sustainable barrier 100, approximately 93% to approximately 99% by weight of the sustainable barrier 100, approximately 94% to approximately 99% by weight of the sustainable barrier 100, approximately 95% to approximately 99% by weight of the sustainable barrier 100, or approximately 95% to approximately 98% by weight of the sustainable barrier 100. In alternative embodiments, the composition of the waste material in the sustainable barriers 100 described herein may be any amount that enables the sustainable barriers 100 to operate as described herein.
[0171] The properties of the waste material and/or the processing conditions may be varied to tune or specify the final properties of the sustainable barrier. Specifically, a specific type of waste material may be selected to achieve a desired physical property within the sustainable barrier. For example, a denser waste material may be selected such that the sustainable barrier is denser and/or harder. The denser/harder sustainable barrier may be useful for specific uses or harsh environments. For example, the denser/harder sustainable barriers may be tailored such that the density is greater than the density of water and may be useful for flood control. Additionally, the denser/harder sustainable barriers may be useful for barriers in high traffic/high speed highways where collisions may cause damage to softer/less dense barriers. In some embodiments, the waste material may be crumb rubber including 10/20 mesh size granules, 10 mesh size granules, 20 mesh size granules, and/or any size granules.
[0172] Conversely, a less dense waste material may be selected such that the sustainable barrier is less dense and/or softer. The less dense/softer sustainable barrier may be useful for specific uses or specific environments. For example, the less dense/softer sustainable barriers may be useful for situations where a barrier is needed but the barrier needs to give to protect the object impacting the barrier. For example, barriers at bumper car facilities or go-cart racetracks need to stop the bumper car or go-cart without hurting the occupant or damaging the bumper car or go-cart. Certain waste materials are denser than others and may be suitable for specific situations. For example, tires suitable for large commercial vehicles (such as constructions vehicles and tractor trailers) are typically denser/harder than tires for residential vehicles and bicycles. The density of the sustainable barrier may be tuned by selecting the material the sustainable barrier is made from based on the materials density. Additionally, the density of the sustainable barrier may also be varied based on the compression pressure used to from the barrier. A higher compression pressure increases the density of the sustainable barrier and a lower compression pressure decreases the density of the sustainable barrier.
[0173] The binder includes a polyurethane binder, an optional colorant, a catalyst, and a small amount of water. The binder has been formulated to bind the crumb rubber into the sustainable barriers 100 described herein without using heat. More specifically, the catalyst within the binder quickly forms the sustainable barriers 100 such that heat is not required to cure the sustainable barriers 100. In the illustrated embodiments, the binder is approximately 10% to approximately 1% by weight of the sustainable barrier 100, approximately 9% to approximately 1% by weight of the sustainable barrier 100, approximately 8% to approximately 1% by weight of the sustainable barrier 100, approximately 7% to approximately 1% by weight of the sustainable barrier 100, approximately 6% to approximately 1% by weight of the sustainable barrier 100, approximately 5% to approximately 1% by weight of the sustainable barrier 100, or approximately 5% to approximately 2% by weight of the sustainable barrier 100. In alternative embodiments, the composition of the binder in the sustainable barriers 100 described herein may be any amount that enables the sustainable barriers 100 to operate as described herein.
[0174] The polyurethane binder includes a polyurethane adhesive. In the illustrated embodiment, the polyurethane binder includes an aromatic polyurethane binder. More specifically, the polyurethane binder may include Stobicoll R 1142, Stobicoll R 359, Stobicoll R 1129, Stobicoll R 382, Stobicoll R 401, Stobicoll R 1160, Polyval GN416, Polyval GN418, and/or Poly Tree Fusion. In the illustrated embodiments, the polyurethane binder is approximately 10% to approximately 1% by weight of the waste material, approximately 10% to approximately 1.5% by weight of the waste material, approximately 9% to approximately 1% by weight of the waste material, approximately 8% to approximately 1% by weight of the waste material, approximately 7% to approximately 1% by weight of the waste material, approximately 6% to approximately 1% by weight of the waste material, approximately 5% to approximately 1% by weight of the waste material, or approximately 2.5% to approximately 2% by weight of the waste material. In alternative embodiments, the composition of the polyurethane binder in the sustainable barriers 100 described herein may be any amount that enables the sustainable barriers 100 to operate as described herein.
[0175] The colorant includes any material configured to dye the waste material and the binder a color. In the illustrated embodiments, the colorant is approximately 10% to approximately 1% by weight of the waste material, approximately 10% to approximately 1.5% by weight of the waste material, approximately 9% to approximately 1% by weight of the waste material, approximately 8% to approximately 1% by weight of the waste material, approximately 7% to approximately 1% by weight of the waste material, approximately 6% to approximately 1% by weight of the waste material, approximately 5% to approximately 1% by weight of the waste material, or approximately 5% to approximately 2.5% by weight of the waste material. In alternative embodiments, the composition of the colorant in the sustainable barriers 100 described herein may be any amount that enables the sustainable barriers 100 to operate as described herein.
[0176] The catalyst or accelerant includes a polyether polyol-based catalyst configured increase polyurethane reactivity. In the illustrated embodiment, the catalyst or accelerant includes Stobiblend Z 952.50, Stobiblend Z 1959, and/or Polyval 910624. In the illustrated embodiments, the catalyst is approximately 1% to approximately 0.001% by weight of the waste material, approximately 0.5% to approximately 0.001% by weight of the waste material, approximately 0.1% to approximately 0.001% by weight of the waste material, approximately 0.05% to approximately 0.001% by weight of the waste material, approximately 0.01% to approximately 0.001% by weight of the waste material, approximately 0.005% to approximately 0.001% by weight of the waste material, approximately 0.003% to approximately 0.001% by weight of the waste material, or approximately 0.002% by weight of the waste material. In alternative embodiments, the composition of the catalyst in the sustainable barriers 100 described herein may be any amount that enables the sustainable barriers 100 to operate as described herein. In some embodiments, the catalyst may not be included in the sustainable barrier 100. Rather, environmental conditions such as temperature and humidity levels will determine if catalyst is used, and how much catalyst is used.
[0177] In the illustrated embodiments, water is approximately 1% to approximately 0.01% by weight of the waste material, approximately 0.5% to approximately 0.01% by weight of the waste material, approximately 0.1% to approximately 0.01% by weight of the waste material, approximately 0.05% to approximately 0.01% by weight of the waste material, approximately 0.04% to approximately 0.01% by weight of the waste material, approximately 0.03% to approximately 0.01% by weight of the waste material, approximately 0.02% to approximately 0.01% by weight of the waste material, or approximately 0.02% by weight of the waste material. n alternative embodiments, the composition of water in the sustainable barriers 100 described herein may be any amount that enables the sustainable barriers 100 to operate as described herein. In some embodiments, water may not be included in the sustainable barrier 100. Rather, environmental conditions such as temperature and humidity levels will determine if water is used, and how much catalyst is used.
[0178] The waste material and the binder are combined into a batter. The batter is put into a mold and the mold cures the batter into the sustainable barriers 100 described herein at high pressure. The sustainable barrier 100 is then removed from the mold. In the illustrated embodiment, the catalyst enables the sustainable barrier 100 to be cured without the use of heat to cure the binder, substantially reducing costs and the complexity of the manufacturing process.
[0179] The sustainable barrier 100 may be cured from a single batter. However, in some embodiments, the sustainable barrier 100 may be formed of more than one batter. For example, as shown in
[0180]
[0181] As described above, the sustainable barriers 100, 600, and 700 may be designed for different uses. For example, a motorcycle racetrack may require a barrier with a softer outer skin and a harder core. Riders may crash into the barriers and the softer outer skin may improve the safety of the motorcycle racetrack. However, a racetrack for traditional vehicles may require a barrier with a harder outer skin and a softer core to improve the durability of the barriers while also allowing the barriers to be flexible and absorb impacts. As such, the composition of the waste material and the binder may be tuned to produce layers or entire barriers with different properties that have different uses.
[0182]
[0183] The groove 840 defines a groove height 844, a groove depth 846, and a groove width 848. Additionally, the loops 842 each define a loop length 850. The groove depth 846 and the loop length 850 are configured to enable the loops 842 of a first barrier 800 to be inserted into the groove 840 of a second barrier 800 such that the narrow side 804 of the first barrier 800 is flush with the narrow side 804 of the second barrier 800 to form a longer, extend barrier. The loops 842 are each positioned at different heights such that each loop 842 cannot interfere with another loop 842 when the loops 842 are inserted into the grooves 840. Additionally, a connector (not shown) is inserted into the loops 842 of both the first barrier 800 and the second barrier 800 to hold the two barriers together. As such, the connector system 838 enables the sustainable barriers 800 to be connected to each other to strengthen the connected barriers.
[0184] In the illustrated embodiment, the groove height 844 is about 30 inches to about 42 inches, the groove depth 846 is about 1 inch to about 2 inches, the groove width 848 is about 3 inches to about 5 inches, and the loop length 850 is about 2 inches to about 4 inches. Specifically, in the illustrated embodiment, the groove height 844 is about 30 inches, the groove depth 846 is about 1.375 inches, the groove width 848 is about 3.5 inches, and the loop length 850 is about 3.25 inches. In alternative embodiments, the groove height 844, the groove depth 846, the groove width 848, and the loop length 850 may be any length that enables the sustainable barriers 800 described herein to operate as described herein.
[0185] To strengthen the connections between the barriers 800, the loops 842 may be set into the batter before the batter is cured into the sustainable barriers 800. As such, the connections between the barriers 800 are strengthened because the sustainable barriers 800 are cured around the loops 842 and the binder adheres the loops 842 to the rest of the sustainable barriers 800. However, to further strengthen the connections between the barriers 800, shape of the loops 842 within the sustainable barriers 800 may be varied to improve the strength of the loops 842 and the bond between the loops 842 and the sustainable barriers 800.
[0186] For example,
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[0191] In alternative embodiments, the sustainable barrier 100 may have a different shape than the shape illustrated in
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[0202] The sustainable barriers 3800 described herein are capable of being certified under the Manual for Assessing Safety Hardware (MASH) guidelines. MASH is a criteria created by AASHTO (American Association of State Highway and Transportation Officials) that presents uniform guidelines for crash testing permanent and temporary highway safety features and recommends evaluation criteria to assess test results. Specifically, in the illustrated embodiment, the sustainable barriers 3800 are capable of being certified under MASH Test Level-2 (TL-2) Criteria. More specifically, the sustainable barriers 3800 have been tested and have been certified under MASH TL-2 Criteria.
[0203] MASH includes 6 test levels which increase in test speed and vehicle size as the test level increases. Test Levels are determined by the in-field application of the traffic safety device being tested (city roads, rural roads, highways, etc.). To achieve a rating, the physical crash test of a traffic safety device must have met certain criteria regarding where the car ended up, how it got there and what kind of damage occurred. The basic differences per test level are noted below: [0204] TL-1: cars and pick-up trucks at 31 miles per hour (mph) [0205] TL-2: cars and pick-up trucks at 44 mph [0206] TL-3: cars and pick-up trucks at 62 mph [0207] TL-4: cars, pick-up trucks, and single unit trucks at 62 mph and 56 mph respectively [0208] TL-5: cars, pick-up trucks, and tractor trailers at 62 mph and 50 mph respectively [0209] TL-6: cars, pick-up trucks, and tractor tank trailers at 62 mph and 50 mph respectively
[0210] Specifically, MASH TL-2 certification test includes: [0211] 1. Connecting the sustainable barriers 3800 in a straight line using a quantity to satisfy the Length-of-Need. [0212] 2. Impacting the connected sustainable barriers 3800 with a passenger car of approximately 1,100 kilograms (kg) at an angle of approximately 25 degrees from parallel to the connected sustainable barriers 3800 at a speed of approximately 44 mph. [0213] 3. Impacting the connected sustainable barriers 3800 with a pick-up truck of approximately 2,270 kg at an angle of approximately 25 degrees from parallel to the connected sustainable barriers 3800 at a speed of approximately 44 mph.
[0214] The connected sustainable barriers must satisfy the following conditions to pass MASH TL-2 certification test: [0215] 1. The connected sustainable barriers 3800 must contain and redirect the vehicle or bring the vehicle to a controlled stop. The vehicle should not penetrate, underride, or overrider the installation. [0216] 2. The vehicle should remain upright during and after the collision, with a maximum roll and pitch angle not to exceed 75 degrees. [0217] 3. Occupant impact velocities, both longitudinal and lateral, may not exceed 12.2 meters per second (m/s). [0218] 4. Occupant ride down acceleration, both longitudinal and lateral, may not exceed 20.49 G.
[0219] As described below, the sustainable barrier 3800 described herein include a connector system 3838 configured to connect the sustainable barriers 3800 together during the MASH TL-2 certification test and during use.
[0220] The sustainable barriers 3800 were tested under the MASH TL-2 certification parameters listed above and were certified under MASH TL-2. Specifically, the physical characteristics of the sustainable barriers 3800 enabled the sustainable barriers 3800 to be certified under MASH TL-2. More specifically, as described below, the sustainable barriers 3800 described herein include substantially vertical broad sides 3806 that at least partially enabled the sustainable barriers 3800 to be certified under MASH TL-2. In alternative embodiments, the broad sides 3806 may not need to be substantially vertical for the sustainable barriers 3800 to be certified under MASH TL-2. For example, the angle of the broad sides 3806 may be between 80 and 100 relative to grade and the sustainable barriers 3800 may still be capable of being certified under MASH TL-2.
[0221] Additionally, the sustainable barrier height 3822 of the sustainable barrier 3800 also enabled the sustainable barriers 3800 to be certified under MASH TL-2. In the illustrated embodiments, the sustainable barrier height 3822 is 30, 32, 34.5, 36, or 40 inches high. The sustainable barriers 3800 having a height of at least 30 inches enables the sustainable barriers 3800 to be certified under MASH TL-2.
[0222] During the certification test the sustainable barriers 3800 were free standing and were not physically attached to the ground in any way. Even without physical attachments to the ground, the sustainable barriers 3800 were certified under MASH TL-2. In alternative embodiments, the sustainable barriers 3800 may be attached to the ground by pinning, gluing, and/or any other attachments. Attaching the sustainable barriers 3800 to the ground during the test would also enable the sustainable barriers 3800 to be certified under MASH TL-2.
[0223] Finally, the wide base of the sustainable barriers 3800 enables the sustainable barriers 3800 to be certified under MASH TL-2. That is, the bottom width 3812 of the sustainable barrier 3800 also enabled the sustainable barriers 3800 to be certified under MASH TL-2. In the illustrated embodiments, the bottom width 3812 is approximately 18 inches to approximately 26 inches wide or approximately 22.5 inches wide. The sustainable barriers 3800 having a bottom width 3812 of at least 20 inches enables the sustainable barriers 3800 to be certified under MASH TL-2.
[0224] In alternative embodiments, the sustainable barriers 3800 are also capable of being certified under the MASH TL-3 certification test without any modifications. The requirements of the MASH TL-3 certification test are the same as the MASH TL-2 certification test except that the passenger car and the pick-up truck impact the sustainable barriers 3800 at a speed of approximately 62 mph. In some embodiments, the sustainable barriers 3800 are also capable of being certified under the MASH TL-3 certification test without any modifications. In other embodiments, the sustainable barriers 3800 are also capable of being certified under the MASH TL-3 certification test with minor modifications. For example, the sustainable barriers 3800 may be modified by increasing the sustainable barrier height 3822 of the sustainable barrier 3800, pinning the sustainable barriers 3800 to the ground, strengthening the connector system 3838 of the sustainable barriers 3800 by increasing the number of loops 3842 or increasing the amount of rebar in the connector system 3838, adding reinforcing elements, and/or increasing the tensile modulus, compressive modulus, and/or the flexural modulus of the sustainable barriers 3800 to ensure the sustainable barriers 3800 are capable of being certified under the MASH TL-3 certification test.
[0225] The sustainable barriers 3800 have performance advantages over traditional concrete barriers, and purpose built metal stands, in a load rated applications. More specifically, traditional concrete barriers are not designed to support large loads upon them because they offer no benefits over purpose built stands or supports and may be too brittle. Metal load rated stands are typically rated for up to 20,000 pounds and can damage the equipment placed upon them due to the hard metal surface. In contrast, the sustainable barrier 3800 described herein has a maximum load rating of at least 25,000 pounds with a safety factor of 3 for total load for a barrier 3800 that is at least 6 ft in length. In some embodiments, the maximum load rating may be at least 32,000 pounds with a safety factor of 3 for total load for a barrier 3800 that is at least 8 ft in length. Additionally, the sustainable barrier 3800 described herein has a maximum surface pressure rating of at least 150 pound per square inch with a safety factor of 4 for pressure. Furthermore, the sustainable barrier 3800 described herein have undergone further testing and have withstood a surface pressure of over 600 pound per square inch and a total load of over 80,000 pounds without any signs of damage. Furthermore, the sustainable barriers 3800 are also capable of supporting a substantial load for an extended period of time (more than a month) without sustaining any damage.
[0226] As such, the sustainable barriers 3800 may be used to support equipment, like industrial saw horses do, because the sustainable barriers 3800 have a high load rating. Specifically, the sustainable barriers 3800 have a maximum load rating of at least 25,000 pounds (greater than 10 tons) and, because the sustainable barriers 3800 are made of softer waste materials, the sustainable barriers 3800 do not damage the other equipment, they contour to the load, and have high friction against the load.
[0227] Additionally, the sustainable barriers 3800 also have a maximum elongation at failure of at least approximately 50 percent. Specifically, the sustainable barriers 3800 have a maximum elongation at failure of at least approximately 50 percent to at least approximately 200 percent. In the illustrated embodiment, the sustainable barriers 3800 have a maximum elongation at failure of at least approximately 50 percent to at least approximately 74 percent or approximately 62 percent. Having a higher maximum elongation of the sustainable barrier 3800 allows for larger deformations without failure. Increasing the maximum elongation increases the ability to absorb energy over a longer duration, which could allow for higher speed impacts without risk of failure of the sustainable barrier 3800. If an equivalent amount of energy is absorbed over a longer duration, then the peak deacceleration of the object impacting the sustainable barrier 3800 would be reduced, which is generally safer. Having a low maximum elongation to failure value, as is typical in materials like concrete, results in a more brittle, sudden failure with very little deformation. Successful use of a sustainable barrier 3800 with a minimal maximum elongation at failure value allows for simplification in the manufacturing process since higher elongation values are more challenging to achieve. A broader set of materials can be used with lower elongation targets.
[0228] Additionally, the sustainable barriers 3800 also have a maximum tensile strength of, at least, approximately 450 kPa to approximately 1 GPa. Specifically, the sustainable barriers 3800 have a maximum tensile strength of, at least, approximately 450 kPa to approximately 590 kPa or approximately 520 kPa. The maximum tensile strength provides a number of benefits related to the ability to resist damage to the sustainable barrier 3800. Upon impact, a higher maximum tensile strength would lead to less rupture, cracking, and tearing. With less damage incurred, the sustainable barrier 3800 has a greater chance of being reused after an impact. Greater maximum tensile strength allows for higher speed impacts before failing. Successful use of a sustainable barrier 3800 with a minimal maximum tensile strength allows for simplification in the manufacturing process since higher maximum tensile strength values are more challenging to achieve. A broader set of materials can be used with lower maximum tensile strength targets.
[0229] In addition, the sustainable barriers 3800 also have a tensile modulus of at least approximately 1,000 kPa to approximately 1 GPa. Specifically, the sustainable barriers 3800 have a tensile modulus of at least approximately 1,000 kPa to approximately 1,300 kPa or approximately 1,150 kPa. The tensile modulus enables the sustainable barriers 3800 to resist lengthening when stuck by an object, most noticeably when attached to subsequent sustainable barriers 3800, forming a chain of sustainable barriers 3800. A higher tensile modulus in the sustainable barrier 3800 would provide more resistance to deforming when pulled on, which would engage adjacent connect barriers more rapidly, allowing a system of barriers 3800 to deform less upon impact. This would be beneficial in preventing people or objects behind the barriers 3800 from being struck. Higher tensile modulus would also more fully resist internal rebar components, such as loop ends, from being removed from the barrier 3800. Using a sustainable barrier 3800 with the lowest tensile modulus possible provides a softer impact for the object, which in the case of a vehicle, means a safer impact for occupants.
[0230] Moreover, the sustainable barriers 3800 also have a compressive modulus of at least approximately 5,900 kPa to approximately 1 GPa. Specifically, the sustainable barriers 3800 have a compressive modulus of at least approximately 5,900 kPa to approximately 6,600 kPa or approximately 6,250 kPa. The compressive modulus is related to how far an object will deform into the sustainable barrier 3800 with a given load. A higher modulus would imply less deformation into the sustainable barrier 3800 with a given impact, and more redirection of the object. Using a sustainable barrier 3800 with the lowest compressive modulus possible provides a softer impact for the object, which in the case of a vehicle, means a safer impact for occupants.
[0231] Moreover, the sustainable barriers 3800 also have a flexural modulus of at least approximately 2,000 kPa to approximately 1 GPa. Specifically, the sustainable barriers 3800 also have a flexural modulus of at least approximately 2,000 kPa to approximately 2,400 kPa or approximately 2,200 kPa. The flexural modulus enables the sustainable barriers 3800 to resist bending when stuck by an object, most noticeably when struck in the mid-span of a long section. A higher flexural modulus in the sustainable barrier 3800 would provide more resistance to deforming when struck, providing a greater ability to redirect the object. Using a sustainable barrier 3800 with the lowest flexural modulus possible provides a softer impact for the object, which in the case of a vehicle, means a safer impact for occupants.
[0232] As shown in
[0233] In the illustrated embodiment, the sustainable barrier 3800 has a wide base 3810 and a narrow top 3802. The two broad sides 3806 are substantially vertical to shape both the wide base 3810 and the narrow top 3802. The narrow top 3802 has a substantially flat portion 3860 and two sloped side portions 3862 to facilitate stacking a plurality of sustainable barriers 3800 on top of each other. The two narrow sides 3804 are substantially flat to facilitate aligning a plurality of sustainable barriers 3800 in a row to form a long, continuous barrier. For example, a plurality of sustainable barriers 3800 may be arranged by aligning one of the narrow sides 3804 of a first sustainable barrier 3800 with one of the narrow sides 3804 of a second sustainable barrier 3800 and the other of the narrow sides 3804 of the first sustainable barrier 3800 with one of the narrow sides 3804 of a third sustainable barrier 3800 to form a row in the median of a road, on the shoulder of the road, or to block off an existing lane. Additionally, the row of sustainable barriers 3800 may be used to protect construction workers on or near a roadway during maintenance or construction. This long, continuous barrier in the middle of the road reduces the risk of head on collisions and improves the overall safety of traveling on the road.
[0234] As shown in
[0235] In the illustrated embodiment, the two broad sides 3806 each include a vertical base 3816 and a vertical top 3818 separated by a curved shoulder 3864. The vertical base 3816 extends substantially vertically from the bottom 3808, the curved shoulder 3864 extends vertically and curves inward from the vertical base 3816, and the vertical top 3818 extends vertically from the curved shoulder 3864 to the top 3802. The two broad sides 3806 each define a sustainable barrier height 3822, the two vertical bases 3816 each define a vertical base height 3824, and the two vertical tops 3818 each define a vertical top height 3826. In the illustrated embodiment, the sustainable barrier height 3822 is approximately 30 inches to approximately 42 inches high, the vertical base height 3824 is approximately 0 inches to approximately 12 inches high, and the vertical top height 3826 is approximately 0 inches to approximately 42 inches high. More specifically, in the illustrated embodiment, the sustainable barrier height 3822 is 30, 32, 34.5, 36, or 40 inches high, the vertical base height 3824 is 5 inches high, and the vertical top 3818 is 29.5 inches high. In alternative embodiments, the sustainable barrier height 3822, the vertical base height 3824, and the vertical top 3818 may be any height or angle that enables the sustainable barrier 3800 to operate as described herein.
[0236] As shown in
[0237] The drainage slots 3828 facilitate water drainage from one side of the sustainable barrier 3800 to the other. In alternative embodiments the drainage slot 3828 may extend along a length of the sustainable barrier rather than across the width of the sustainable barrier. Additionally, the drainage slots 3828 may also be used to facilitate movement of the sustainable barrier 3800. More specifically, in the illustrated embodiment, the drainage slots 3828 are positioned to enable a forklift (not shown) or some other equipment to pick up and move the sustainable barrier 3800. More specifically, in the illustrated embodiment, the drainage slots 3828 each define a drainage slot width 3830, a drainage slot height 3834, a drainage slot length 3836, and a drainage slot total width 3866. In the illustrated embodiment, the drainage slot length 3836 is equal to the bottom width 3812 such that the drainage slots 3828 each extend through the wide base 3810 of the sustainable barrier 3800. Additionally, the drainage slot widths 3830 and 3832 and the drainage slot height 3834 are each sized and shaped to enable water to drain from one side of the sustainable barrier 3800 to the other and to enable the prongs of a forklift to be inserted into the drainage slots 3828 for picking up the sustainable barrier 3800. In the illustrated embodiment, the drainage slot bottom width 3830 is approximately 12 inches to approximately 36 inches wide, the drainage slot top width 3832 is approximately 12 inches to approximately 36 inches wide, the drainage slot height 3834 is approximately 3 inches to approximately 8 inches high, the drainage slot length 3836 is approximately 18 inches to approximately 26 inches wide or approximately 22.5 inches wide long, and the drainage slot total width 3866 is approximately 12 inches to approximately 36 inches wide. More specifically, for a sustainable barrier with a length 3827 of approximately 8 feet, the drainage slot bottom width 3830 is 26 inches wide, the drainage slot top width 3832 is 25 inches wide, the drainage slot height 3834 is 3.5 inches high, the drainage slot length 3836 is 22.5 inches long, and the drainage slot total width 3866 is 62 inches long. In alternative embodiments, the drainage slot bottom width 3830, the drainage slot top width 3832, the drainage slot height 3834, the drainage slot length 3836, and the drainage slot total width 3866 may be any length that enables the sustainable barrier 3800 to operate as described herein.
[0238] As discussed above, the sustainable barriers 3800 described herein are formed of a waste material and a binder that binds the waste material into a specific shape for a specific use. The waste material and the binder may be combined in different ratios with different compositions such that the material that forms the sustainable barrier 3800 may have portions with different densities. Additionally, the shape of the sustainable barriers 3800 may be tailored to a specific shape to suit a specific function. Accordingly, the sustainable barriers 3800 described herein are formed of a sustainable material with a tailored composition and shape to suit a specific function.
[0239] Specifically, in the illustrated embodiments, the waste material used to form the sustainable barriers 3800 described herein is used tires. In alternative embodiments, the waste material may be any material including, but not limited to, recycled plastics, recycled wood, shingles, composite materials (fiberglass and/or carbon fiber), and/or any other sustainable or recyclable material. The used tires are ground to form a crumb rubber and the binder is formulated to bind the crumb rubber into a formed sustainable barrier 3800. In the illustrated embodiments, the waste material is approximately 90% to approximately 99% by weight of the sustainable barrier 3800, approximately 91% to approximately 99% by weight of the sustainable barrier 3800, approximately 92% to approximately 99% by weight of the sustainable barrier 3800, approximately 93% to approximately 99% by weight of the sustainable barrier 3800, approximately 94% to approximately 99% by weight of the sustainable barrier 3800, approximately 95% to approximately 99% by weight of the sustainable barrier 3800, or approximately 95% to approximately 98% by weight of the sustainable barrier 3800. In alternative embodiments, the composition of the waste material in the sustainable barriers 3800 described herein may be any amount that enables the sustainable barriers 3800 to operate as described herein.
[0240] The properties of the waste material and/or the processing conditions may be varied to tune or specify the final properties of the sustainable barrier. Specifically, a specific type of waste material may be selected to achieve a desired physical property within the sustainable barrier. For example, a denser waste material may be selected such that the sustainable barrier is denser and/or harder. The denser/harder sustainable barrier may be useful for specific uses or harsh environments. For example, the denser/harder sustainable barriers may be tailored such that the density is greater than the density of water and may be useful for flood control. Additionally, the denser/harder sustainable barriers may be useful for barriers in high traffic/high speed highways where collisions may cause damage to softer/less dense barriers.
[0241] Conversely, a less dense waste material may be selected such that the sustainable barrier is less dense and/or softer. The less dense/softer sustainable barrier may be useful for specific uses or specific environments. For example, the less dense/softer sustainable barriers may be useful for situations where a barrier is needed but the barrier needs to give to protect the object impacting the barrier. For example, barriers at bumper car facilities or go-cart racetracks need to stop the bumper car or go-cart without hurting the occupant or damaging the bumper car or go-cart. Certain waste materials are denser than others and may be suitable for specific situations. For example, tires suitable for large commercial vehicles (such as constructions vehicles and tractor trailers) are typically denser/harder than tires for residential vehicles and bicycles. The density of the sustainable barrier may be tuned by selecting the material the sustainable barrier is made from based on the materials density. Additionally, the density of the sustainable barrier may also be varied based on the compression pressure used to from the barrier. A higher compression pressure increases the density of the sustainable barrier and a lower compression pressure decreases the density of the sustainable barrier.
[0242] The binder includes a polyurethane binder, an optional colorant, a catalyst, and a small amount of water. The binder has been formulated to bind the crumb rubber into the sustainable barriers 3800 described herein without using heat. More specifically, the catalyst within the binder quickly forms the sustainable barriers 3800 such that heat is not required to cure the sustainable barriers 3800. In the illustrated embodiments, the binder is approximately 10% to approximately 1% by weight of the sustainable barrier 3800, approximately 9% to approximately 1% by weight of the sustainable barrier 3800, approximately 8% to approximately 1% by weight of the sustainable barrier 3800, approximately 7% to approximately 1% by weight of the sustainable barrier 3800, approximately 6% to approximately 1% by weight of the sustainable barrier 3800, approximately 5% to approximately 1% by weight of the sustainable barrier 3800, or approximately 5% to approximately 2% by weight of the sustainable barrier 3800. In alternative embodiments, the composition of the binder in the sustainable barriers 3800 described herein may be any amount that enables the sustainable barriers 3800 to operate as described herein.
[0243] The polyurethane binder includes a polyurethane adhesive. In the illustrated embodiment, the polyurethane binder includes an aromatic polyurethane binder. More specifically, the polyurethane binder may include Stobicoll R 1142, Stobicoll R 359, Stobicoll R 1129, Stobicoll R 382, Stobicoll R 401, Stobicoll R 1160, Polyval GN416, Polyval GN418, and/or Poly Tree Fusion. In the illustrated embodiments, the polyurethane binder is approximately 10% to approximately 1% by weight of the waste material, approximately 10% to approximately 1.5% by weight of the waste material, approximately 9% to approximately 1% by weight of the waste material, approximately 8% to approximately 1% by weight of the waste material, approximately 7% to approximately 1% by weight of the waste material, approximately 6% to approximately 1% by weight of the waste material, approximately 5% to approximately 1% by weight of the waste material, or approximately 2.5% to approximately 2% by weight of the waste material. In alternative embodiments, the composition of the polyurethane binder in the sustainable barriers 3800 described herein may be any amount that enables the sustainable barriers 3800 to operate as described herein.
[0244] The colorant includes any material configured to dye the waste material and the binder a color. In the illustrated embodiments, the colorant is approximately 10% to approximately 1% by weight of the waste material, approximately 10% to approximately 1.5% by weight of the waste material, approximately 9% to approximately 1% by weight of the waste material, approximately 8% to approximately 1% by weight of the waste material, approximately 7% to approximately 1% by weight of the waste material, approximately 6% to approximately 1% by weight of the waste material, approximately 5% to approximately 1% by weight of the waste material, or approximately 5% to approximately 2.5% by weight of the waste material. In alternative embodiments, the composition of the colorant in the sustainable barriers 3800 described herein may be any amount that enables the sustainable barriers 3800 to operate as described herein.
[0245] The catalyst or accelerant includes a polyether polyol-based catalyst configured increase polyurethane reactivity. In the illustrated embodiment, the catalyst or accelerant includes Stobiblend Z 952.50, Stobiblend Z 1959, and/or Polyval 910624. In the illustrated embodiments, the catalyst is approximately 1% to approximately 0.001% by weight of the waste material, approximately 0.5% to approximately 0.001% by weight of the waste material, approximately 0.1% to approximately 0.001% by weight of the waste material, approximately 0.05% to approximately 0.001% by weight of the waste material, approximately 0.01% to approximately 0.001% by weight of the waste material, approximately 0.005% to approximately 0.001% by weight of the waste material, approximately 0.003% to approximately 0.001% by weight of the waste material, or approximately 0.002% by weight of the waste material. In alternative embodiments, the composition of the catalyst in the sustainable barriers 3800 described herein may be any amount that enables the sustainable barriers 3800 to operate as described herein. In some embodiments, the catalyst may not be included in the sustainable barrier 3800. Rather, environmental conditions such as temperature and humidity levels will determine if catalyst is used, and how much catalyst is used.
[0246] In the illustrated embodiments, water is approximately 1% to approximately 0.01% by weight of the waste material, approximately 0.5% to approximately 0.01% by weight of the waste material, approximately 0.1% to approximately 0.01% by weight of the waste material, approximately 0.05% to approximately 0.01% by weight of the waste material, approximately 0.04% to approximately 0.01% by weight of the waste material, approximately 0.03% to approximately 0.01% by weight of the waste material, approximately 0.02% to approximately 0.01% by weight of the waste material, or approximately 0.02% by weight of the waste material. n alternative embodiments, the composition of water in the sustainable barriers 3800 described herein may be any amount that enables the sustainable barriers 3800 to operate as described herein. In some embodiments, water may not be included in the sustainable barrier 3800. Rather, environmental conditions such as temperature and humidity levels will determine if water is used, and how much catalyst is used.
[0247] The waste material and the binder are combined into a batter. The batter is put into a mold and the mold cures the batter into the sustainable barriers 3800 described herein at high pressure. The sustainable barrier 3800 is then removed from the mold. In the illustrated embodiment, the catalyst enables the sustainable barrier 3800 to be cured without the use of heat to cure the binder, substantially reducing costs and the complexity of the manufacturing process.
[0248] The sustainable barrier 3800 may be cured from a single batter. However, in some embodiments, the sustainable barrier 3800 may be formed of more than one batter. For example, the sustainable barrier 3800 may be formed of more than one batter as shown in
[0249] As described above, the sustainable barrier 3800 may be designed for different uses. For example, a motorcycle racetrack may require a barrier with a softer outer skin and a harder core. Riders may crash into the barriers and the softer outer skin may improve the safety of the motorcycle racetrack. However, a racetrack for traditional vehicles may require a barrier with a harder outer skin and a softer core to improve the durability of the barriers while also allowing the barriers to be flexible and absorb impacts. As such, the composition of the waste material and the binder may be tuned to produce layers or entire barriers with different properties that have different uses.
[0250] As shown in
[0251] The groove 3840 defines a groove height 3844, a groove depth 3846, and a groove width 3848. Additionally, the loops 3842 each define a loop length 3850. The groove depth 3846 and the loop length 3850 are configured to enable the loops 3842 of a first barrier 3800 to be inserted into the groove 3840 of a second barrier 3800 such that the narrow side 3804 of the first barrier 3800 is flush with the narrow side 3804 of the second barrier 3800 to form a longer, extend barrier. The loops 3842 are each positioned at different heights such that each loop 3842 cannot interfere with another loop 3842 when the loops 3842 are inserted into the grooves 3840. Additionally, a connector (not shown) is inserted into the loops 3842 of both the first barrier 3800 and the second barrier 3800 to hold the two barriers together. As such, the connector system 3838 enables the sustainable barriers 3800 to be connected to each other to strengthen the connected barriers.
[0252] In the illustrated embodiment, the groove height 3844 is about 30 inches to about 42 inches, the groove depth 3846 is about 1 inch to about 2 inches, the groove width 3848 is about 3 inches to about 5 inches, and the loop length 3850 is about 2 inches to about 4 inches. Specifically, in the illustrated embodiment, the groove height 3844 is about 34.5 inches, the groove depth 3846 is about 1.375 inches, the groove width 3848 is about 3.5 inches, and the loop length 3850 is about 3.25 inches. In alternative embodiments, the groove height 3844, the groove depth 3846, the groove width 3848, and the loop length 3850 may be any length that enables the sustainable barriers 3800 described herein to operate as described herein.
[0253] To strengthen the connections between the barriers 3800, the loops 3842 may be set into the batter before the batter is cured into the sustainable barriers 3800. As such, the connections between the barriers 3800 are strengthened because the sustainable barriers 3800 are cured around the loops 3842 and the binder adheres the loops 3842 to the rest of the sustainable barriers 3800. However, to further strengthen the connections between the barriers 3800, shape of the loops 3842 within the sustainable barriers 3800 may be varied to improve the strength of the loops 3842 and the bond between the loops 3842 and the sustainable barriers 3800.
[0254] For example,
[0255] Additionally,
[0256] Additionally,
[0257] Additionally,
[0258] Additionally,
[0259] Additionally,
[0260]
[0261]
[0262] As such, the sustainable barriers 7700 may be used to support equipment, like industrial saw horses do, because the sustainable barriers 7700 have a high load rating. Specifically, the sustainable barriers 7700 have a maximum load rating of at least 25,000 pounds (greater than 10 tons) and, because the sustainable barriers 7700 are made of softer waste materials, the sustainable barriers 7700 do not damage the other equipment, they contour to the load, and have high friction against the load.
[0263] Furthermore, as shown in
[0264] Additionally, the sustainable barriers 7700 also have a maximum elongation at failure of at least approximately 52 percent. Having a higher maximum elongation of the sustainable barrier 7700 allows for larger deformations without failure. Increasing the maximum elongation increases the ability to absorb energy over a longer duration, which could allow for higher speed impacts without risk of failure of the sustainable barrier 7700. If an equivalent amount of energy is absorbed over a longer duration, then the peak deacceleration of the object impacting the sustainable barrier 7700 would be reduced, which is generally safer. Having a low maximum elongation to failure value, as is typical in materials like concrete, results in a more brittle, sudden failure with very little deformation. Successful use of a sustainable barrier 7700 with a minimal maximum elongation at failure value allows for simplification in the manufacturing process since higher elongation values are more challenging to achieve. A broader set of materials can be used with lower elongation targets.
[0265] Additionally, the sustainable barriers 7700 also have a maximum tensile strength of, at least, approximately 450 kPa. The maximum tensile strength provides a number of benefits related to the ability to resist damage to the sustainable barrier 7700. Upon impact, a higher maximum tensile strength would lead to less rupture, cracking, and tearing. With less damage incurred, the sustainable barrier 7700 has a greater chance of being reused after an impact. Greater maximum tensile strength allows for higher speed impacts before failing. Successful use of a sustainable barrier 7700 with a minimal maximum tensile strength allows for simplification in the manufacturing process since higher maximum tensile strength values are more challenging to achieve. A broader set of materials can be used with lower maximum tensile strength targets.
[0266] In addition, the sustainable barriers 7700 also have a tensile modulus of at least approximately 1,000 kPa. The tensile modulus enables the sustainable barriers 7700 to resist lengthening when stuck by an object, most noticeably when attached to subsequent sustainable barriers 7700, forming a chain of sustainable barriers 7700. A higher tensile modulus in the sustainable barrier 7700 would provide more resistance to deforming when pulled on, which would engage adjacent connect barriers more rapidly, allowing a system of barriers 7700 to deform less upon impact. This would be beneficial in preventing people or objects behind the barriers 7700 from being struck. Higher tensile modulus would also more fully resist internal rebar components, such as loop ends, from being removed from the barrier 7700. Using a sustainable barrier 7700 with the lowest tensile modulus possible provides a softer impact for the object, which in the case of a vehicle, means a safer impact for occupants.
[0267] Moreover, the sustainable barriers 7700 also have a compressive modulus of at least approximately 5,900 kPa. The compressive modulus is related to how far an object will deform into the sustainable barrier 7700 with a given load. A higher modulus would imply less deformation into the sustainable barrier 7700 with a given impact, and more redirection of the object. Using a sustainable barrier 7700 with the lowest compressive modulus possible provides a softer impact for the object, which in the case of a vehicle, means a safer impact for occupants.
[0268] Moreover, the sustainable barriers 7700 also have a flexural modulus of at least approximately 2,000 kPa. The flexural modulus enables the sustainable barriers 7700 to resist bending when stuck by an object, most noticeably when struck in the mid-span of a long section. A higher flexural modulus in the sustainable barrier 7700 would provide more resistance to deforming when struck, providing a greater ability to redirect the object. Using a sustainable barrier 7700 with the lowest flexural modulus possible provides a softer impact for the object, which in the case of a vehicle, means a safer impact for occupants.
[0269]
[0270] In the illustrated embodiment, the barrier jacket 8100 described herein includes sheet material. Specifically, in some embodiments, the barrier jacket 8100 includes plastic formed in a specific configuration such that the barrier jacket 8100 is folded to conform to the shape of the barrier 100. In some embodiments, the barrier jacket 8100 includes a twin wall plastic sheet formed of polypropylene. In alternative embodiments, the barrier jacket 8100 may be formed of any material that enables the barrier jacket 8100 to operate as described herein. For example, the barrier jacket 8100 may be formed of metal that can be folded into a shape conforming to the shape of the barrier 100 or a single wall plastic sheet that can also be folded into a shape conforming to the shape of the barrier 100.
[0271] In the illustrated embodiment, the barrier jacket 8100 is folded into three sections to conform to the shape of the barrier 100. Specifically, the barrier jacket 8100 includes a first section 8102, a second section 8104, and a third section 8106. The first section 8102 and the third section 8106 are configured to be attached to the angled tops 118 of the barrier 100 and the second section 8104 is configured to be attached to the top 102 of the barrier 100. At least the first section 8102 and the third section 8106 each include at least one or a plurality of holes 8108 configured to receive at least one or a plurality of fasteners 8110 configured to attach the barrier jacket 8100 to the barrier 100. In the illustrated embodiment, the fasteners 8110 include screws. In alternative embodiments, the barrier jacket 8100 may be attached to the barrier 100 using any type of fastener including, but not limited to, nails, staples, adhesives, and/or any other fastener.
[0272] Additionally, as shown in
[0273] During assembly and installation, the barrier jackets 8100 are removed from a pallet and, if any knockouts 8120 are included in the barrier jackets 8100, the knockouts 8120 are removed. The barrier jackets 8100 are bent along the partial cutouts 8118 and positioned on top of the barrier 100. The fasteners 8110 are inserted into the holes 8108 in the barrier jacket 8100 and into the barrier 100 to attach the barrier jacket 8100 to the barrier 100 and to maintain the barrier jacket 8100 in position on the barrier 100. Accordingly, the barrier jackets 8100 described herein enable the barriers 100 to be modified as need in a quick and economical manner, reducing labor and manufacturing costs.
[0274]
[0275]
[0276] In the illustrated embodiment, the sign 8400 described herein includes a sheet material with a display printed on the sheet material. More specifically, in some embodiments, the sign 8400 includes plastic formed in a specific configuration such that the sign 8400 conforms to the shape of the barrier 100. In some embodiments, the sign 8400 includes a twin wall plastic sheet formed of polypropylene. In alternative embodiments, the sign 8400 may be formed of any material that enables the sign 8400 to operate as described herein including, but not limited to, metal, wood, and/or any other material. Additionally, the sign 8400 includes at least one or a plurality of holes 8402 configured to receive at least one or a plurality of fasteners 8404 that attach the sign 8400 to the barrier 100. In the illustrated embodiment, the fasteners 8404 include screws. In alternative embodiments, the sign 8400 may be attached to the barrier 100 using any type of fastener including, but not limited to, nails, staples, adhesives, and/or any other fastener.
[0277]
[0278] In the illustrated embodiment, the sign 8600 described herein includes a sheet material with a display printed on the sheet material. More specifically, in some embodiments, the sign 8600 includes vinyl formed in a specific configuration such that the sign 8600 conforms to the shape of the barrier 100. In the illustrated embodiment, the sign 8600 is a flexible, vinyl sign that is attached to the barrier 100 using an adhesive. More specifically, the adhesive may include a pressure-sensitive, high tack adhesive attached to a vinyl sign. The sign 8600 may be wrapped around the corners of the barrier 100 because the sign 8600 is made of a flexible material. In alternative embodiments, the sign 8600 may be formed of any material that enables the sign 8600 to operate as described herein including, but not limited to, metal, wood, and/or any other material.
[0279]
[0280]
[0281] In the illustrated embodiment, the protective coverings 9000 are formed of sheet metal formed into sheets that are then formed into a shape that corresponds to the shape of the barrier 100. In alternative embodiments, the protective coverings 9000 may be formed of any material that protects the barrier 100 including, but not limited to, plastic, rubber, wood, and/or any other material.
[0282] The two top corner coverings 9002 each include a single sheet of metal that has been folded to correspond to the shape of the corner of the top 102 of the barrier 100. Similarly, the four side corner coverings 9004 each also include a single sheet of metal that has been folded to correspond to the shape of the corner of the sides 104 of the barrier 100. The four side corner coverings 9004 may also include cutouts 9010 that enable the sheet of metal to be bent to correspond to the shape of the corner along the entire height of the barrier 100.
[0283] As discussed above, the first and second drainage slot coverings 9006 and 9008 protect the drainage slots 128 during repeated lifting. The first and second drainage slot coverings 9006 and 9008 each include a base plate 9012 and two vertical plates 9014 extending from an end of the base plate 9012. The base plate 9012 protects the under side of the barrier 100 during lifting and the two vertical plates 9014 protect the side of the barrier 100 as the forklift is engaging the drainage slots 128. The first drainage slot covering 9006 may further include two side plates 9016 that are configured to protect the sides of the drainage slots 128 during lifting.
[0284] Each of the protective coverings 9000 include at least one or a plurality of holes 9018 configured to receive at least one or a plurality of fasteners 9020 that attach the protective coverings 9000 to the barrier 100. In the illustrated embodiment, the fasteners 9020 include screws. In alternative embodiments, the protective coverings 9000 may be attached to the barrier 100 using any type of fastener including, but not limited to, nails, staples, adhesives, and/or any other fastener.
[0285]
[0286] The accessory attachment unit 9200 includes at least one tube 9204 overmolded into the barrier 100. Specifically, the tube 9204 is positioned in the mold and the batter is poured around the tube 9204. The batter hardens into the barrier 100 around the tube 9204 and the tube 9204 remains in place. The tube 9204 defines an opening in the barrier 100 that is then configured to receive the accessory 9202 (such as a fence post, a sign post, cabling, and/or any other accessory). The accessory attachment unit 9200 may further include at least one grommet 9206 positioned in the tube 9204 and configured to position and secure the fence post and/or sign post in the tube 9204 if the diameters of the tube 9204 and the posts are significantly different.
[0287]
[0288] The accessory attachment unit 9500 includes at least one tube 9504 overmolded into the barrier 100. Specifically, the tube 9504 is positioned in the mold and the batter is poured around the tube 9504. The batter hardens into the barrier 100 around the tube 9504 and the tube 9504 remains in place. The tube 9504 defines two openings in the barrier 100 that is then configured to receive the accessory (such as a fence post, a sign post, cabling, and/or any other accessory) and/or is configured to enable drainage through the barrier 100.
[0289]
[0290] The accessory attachment unit 9600 includes at least one tube 9604 overmolded into the barrier 100. Specifically, the tube 9604 is positioned in the mold and the batter is poured around the tube 9604. The batter hardens into the barrier 100 around the tube 9604 and the tube 9604 remains in place. The tube 9604 defines two openings in the barrier 100 that is then configured to receive the accessory (such as a connection system, a fence post, a sign post, cabling, and/or any other accessory) and/or is configured to enable drainage through the barrier 100.
[0291]
[0292]
[0293] The used tires are ground to form a crumb rubber and the binder is formulated to bind the crumb rubber into a formed barrier 9800. In the illustrated embodiments, the waste material is approximately 80% to approximately 90% by weight of the barrier 9800, approximately 81% to approximately 89% by weight of the barrier 9800, approximately 82% to approximately 88% by weight of the barrier 9800, approximately 83% to approximately 87% by weight of the barrier 9800, approximately 84% to approximately 86% by weight of the barrier 9800, or approximately 85% by weight of the barrier 9800. In alternative embodiments, the composition of the waste material in the barrier 9800 described herein may be any amount that enables the barrier 9800 to operate as described herein.
[0294] In the illustrated embodiments, the polyurethane binder is approximately 10% to approximately 20% by weight of the barrier 9800, approximately 11% to approximately 19% by weight of the barrier 9800, approximately 12% to approximately 18% by weight of the barrier 9800, approximately 13% to approximately 17% by weight of the barrier 9800, approximately 14% to approximately 16% by weight of the barrier 9800, and/or approximately 15% by weight of the barrier 9800. In alternative embodiments, the composition of the polyurethane binder in the barrier 9800 described herein may be any amount that enables the barrier 9800 to operate as described herein.
[0295] In the illustrated embodiment, the barrier 9800 has a length 9802 of approximately 1.83 meters (m), a height 9804 of approximately 810 millimeters (mm), a width 9806 of approximately 610 mm, and a mass of approximately 400 kilograms. In alternative embodiments, the length 9802 may be approximately 0.5 meters to approximately 8 meters, the height 9804 may be approximately 0.5 meters to approximately 2 meters, the width 9806 may be approximately 0.2 meters to approximately 2 meters, and the mass may be approximately 100 kilograms to approximately 2,000 kilograms.
[0296]
[0297] In the illustrated embodiment, the reinforcement system 10004 includes at least one tube 10006 attached to the barrier 10002. In some embodiments, the reinforcement system 10004 may include a single tube 10006 attached to the barrier 10002. In the illustrated embodiment, the reinforcement system 10004 includes a plurality of tubes 10006 attached to the barrier 10002. Specifically, in the illustrated embodiment, the reinforcement system 10004 includes three tubes 10006 attached to the barrier 10002. In alternative embodiments, the reinforcement system 10004 may include any number of tubes 10006 attached to the barrier 10002 including one, two, three, four, or more tubes 10006 attached to the barrier 10002.
[0298] In the embodiments illustrated in
[0299] In the illustrated embodiment, the tubes 10006 are hollow, square tubes. In alternative embodiments, the tubes 10006 may have any shape and may be solid rather than hollow. For example, in alternative embodiments, the tubes 10006 may have a circular cross-section, may be I-beams, or may be solid. Additionally, in the illustrated embodiment, the tubes 10006 are metal tubes. The metal tubes may include steel tubes, aluminum tubes, or any other type of metal tubes. In alternative embodiments, the tubes 10006 may be made of any material that increases the stiffness of the barrier 10002. For example, the tubes 10006 may be made of wood, plastic, plastic composite material, fiberglass, or carbon fiber.
[0300] In the illustrated embodiment, a length of the tubes 10006 corresponds to a length of the barrier 10002 such that the tubes 10006 and the barrier 10002 have substantially the same length. In alternative embodiments, the tubes 10006 may be shorter or longer than the barrier 10002. If the tubes 10006 are longer than the barrier 10002, the tubes 10006 may be configured to span multiple barriers 10002 to interconnect and stiffen the barrier system 10000 including at least two barrier 10002. That is, the tubes 10006 may each be attached to at least two barriers 10002, or may be attached to more than two barriers 10002, to interconnect and stiffen elements of the barrier system 10000.
[0301] As discussed above, the reinforcement system 10004 is configured to stiffen the barrier 10002 to increase the barrier's 10002 ability to withstand an impact. For example, the reinforcement system 10004 enables the sustainable barrier 10002 to be certified under the MASH TL-3 certification test as described herein. As shown in
[0302] The barrier system 10000 described herein is capable of being certified under the Manual for Assessing Safety Hardware (MASH) guidelines. MASH is a criteria created by AASHTO (American Association of State Highway and Transportation Officials) that presents uniform guidelines for crash testing permanent and temporary highway safety features and recommends evaluation criteria to assess test results. Specifically, in the illustrated embodiment, the barrier systems 10000 are capable of being certified under MASH Test Level-2 (TL-2) Criteria. More specifically, the barrier systems 10000 have been tested and have been certified under MASH TL-2 Criteria.
[0303] MASH includes 6 test levels which increase in test speed and vehicle size as the test level increases. Test Levels are determined by the in-field application of the traffic safety device being tested (city roads, rural roads, highways, etc.). To achieve a rating, the physical crash test of a traffic safety device must have met certain criteria regarding where the car ended up, how it got there and what kind of damage occurred. The basic differences per test level are noted below: [0304] TL-1: cars and pick-up trucks at 31 miles per hour (mph) [0305] TL-2: cars and pick-up trucks at 44 mph [0306] TL-3: cars and pick-up trucks at 62 mph [0307] TL-4: cars, pick-up trucks, and single unit trucks at 62 mph and 56 mph respectively [0308] TL-5: cars, pick-up trucks, and tractor trailers at 62 mph and 50 mph respectively [0309] TL-6: cars, pick-up trucks, and tractor tank trailers at 62 mph and 50 mph respectively
[0310] Specifically, MASH TL-2 certification test includes: [0311] 1. Connecting the barrier systems 10000 in a straight line using a quantity to satisfy the Length-of-Need. [0312] 2. Impacting the connected barrier systems 10000 with a passenger car of approximately 1,100 kilograms (kg) at an angle of approximately 25 degrees from parallel to the connected barrier systems 10000 at a speed of approximately 44 mph. [0313] 3. Impacting the connected barrier systems 10000 with a pick-up truck of approximately 2,270 kg at an angle of approximately 25 degrees from parallel to the connected barrier systems 10000 at a speed of approximately 44 mph.
[0314] The connected sustainable barriers must satisfy the following conditions to pass MASH TL-2 certification test: [0315] 1. The connected barrier systems 10000 must contain and redirect the vehicle or bring the vehicle to a controlled stop. The vehicle should not penetrate, underride, or overrider the installation. [0316] 2. The vehicle should remain upright during and after the collision, with a maximum roll and pitch angle not to exceed 75 degrees. [0317] 3. Occupant impact velocities, both longitudinal and lateral, may not exceed 12.2 meters per second (m/s). [0318] 4. Occupant ride down acceleration, both longitudinal and lateral, may not exceed 20.49 G.
[0319] The barrier systems 10000 are capable of being certified under the MASH TL-2 certification parameters listed above. Additionally, the barrier systems 10000 are also capable of being certified under the MASH TL-3 certification test without any modifications. The requirements of the MASH TL-3 certification test are the same as the MASH TL-2 certification test except that the passenger car and the pick-up truck impact the barrier systems 10000 at a speed of approximately 62 mph. In some embodiments, the barrier systems 10000 are also capable of being certified under the MASH TL-3 certification test without any modifications. In other embodiments, the barrier systems 10000 are also capable of being certified under the MASH TL-3 certification test with minor modifications.
[0320] Furthermore, the barrier systems 10000 described herein may also satisfy the requirements of guidelines/criteria required for certification in other jurisdictions. For example, in the European Union, the European Committee for Standardization publishes European Standard 1317 and, more specifically, 1317-2 titled Road restraint systemsPart 2: Performance classes, impact test acceptance criteria and test methods for safety barriers including vehicle parapets, which is incorporated by reference in its entirety. While there are differences between the MASH TL-2 and MASH TL-3 certification tests and the certification tests for European Standard 1317-2, the tests are substantially similar such that the barrier systems 10000 described herein also satisfy the conditions of at least one test for European Standard 1317-2. Specifically, the barrier systems 10000 described herein satisfy the conditions of at least level N2 of European Standard 1317-2. Similarly, the barrier systems 10000 described herein may also satisfy the requirements of guidelines/criteria required in: Austroads AS/NZS 3845.1:2015 for Australia and New Zealand; JTG B05-01 for China; MLIT for Japan; KATRI/MOLIT for South Korea; IRC: SP:84-2019 and IRC:119 for India; and NCHRP 350 where it still applies which are all incorporated by reference in their entirety.
[0321] Accordingly, the barrier system 10000 described herein includes a reinforcement system 10004 that increases the barrier's 10002 ability to withstand an impact.
[0322]
[0323] In the illustrated embodiment, the reinforcement system 10304 includes at least one tube 10306 overmolded into the barrier 10302. In some embodiments, the reinforcement system 10304 may include a single tube 10306 overmolded into the barrier 10302. In the illustrated embodiment, the reinforcement system 10304 includes a plurality of tubes 10306 overmolded into the barrier 10302. Specifically, in the illustrated embodiment, the reinforcement system 10304 includes three tubes 10306 overmolded into the barrier 10302. In alternative embodiments, the reinforcement system 10304 may include any number of tubes 10306 overmolded into the barrier 10302 including one, two, three, four, or more tubes 10306 overmolded into the barrier 10302. Specifically, the tubes 10306 are positioned in the mold and the batter is poured around the tubes 10306. The batter hardens into the barrier 10302 around the tubes 10306 and the tubes 10306 remain in place. In the illustrated embodiment, the tubes 10306 may define an opening in the barrier 10302 that is then configured to receive an accessory 9202 (such as cabling, wiring, connectors, electronics including impact sensors, and/or any other accessory).
[0324] In the embodiment shown in
[0325] In the illustrated embodiment, the tubes 10306 are hollow, square tubes. In alternative embodiments, the tubes 10306 may have any shape and may be solid rather than hollow. For example, in alternative embodiments, the tubes 10306 may have a circular cross-section as shown in
[0326] As discussed above, the reinforcement system 10304 is configured to stiffen the barrier 10302 to increase the barrier's 10302 ability to withstand an impact. As shown in
[0327]
[0328] In the illustrated embodiment, the reinforcement system 10904 includes at least one tube 10906 attached to the barrier 10902 by at least one connector 10908. In some embodiments, the reinforcement system 10904 may include a single tube 10906 attached to the barrier 10902 by at least one connector 10908. In the illustrated embodiment, the reinforcement system 10904 includes a plurality of tubes 10906 attached to the barrier 10902 by at least one connector 10908. Specifically, in the illustrated embodiment, the reinforcement system 10904 includes three tubes 10906 attached to the barrier 10902 by at least one connector 10908. In alternative embodiments, the reinforcement system 10904 may include any number of tubes 10906 attached to the barrier 10902 including one, two, three, four, or more tubes 10906 attached to the barrier 10902 by at least one connector 10908. Additionally, in the illustrated embodiment, the reinforcement system 10904 includes two connectors 10908. In alternative embodiments, the reinforcement system 10904 may include any number of connectors 10908 that enable the reinforcement system 10904 to operate as described herein including one, two, three, or more connectors 10908.
[0329] In the illustrated embodiment, the connectors 10908 include plates that define a plurality of receiving holes 10910 and a plurality of connection holes 10912. The receiving holes 10910 are configured to receive and hold the tubes 10906 and the connection holes 10912 are configured to attach the connectors 10908 to the barrier 10902. Specifically, in the illustrated embodiment, the connection holes 10912 are configured to correspond with a connection system, such as connector system 838, and the connection holes 10912 receive a portion of the connection system to attach the connectors 10908 and the tubes 10906 to the barrier 10902. However, some existing barriers may not include a connection system and the connectors 10908 may be attached to the barrier 10902 with fasteners including screws, nails, bolts, or adhesives. Additionally, the tubes 10906 may be attached to the connectors 10908 with fasteners or by welding for added stability. Attaching the tubes 10906 to the barrier 10902 with the connectors 10908 enables existing barriers to be retrofitted with the reinforcement system 10904 to stiffen the existing barriers.
[0330] In the embodiment shown in
[0331] In the illustrated embodiment, the tubes 10906 are hollow, square tubes. In alternative embodiments, the tubes 10906 may have any shape and may be solid rather than hollow. For example, in alternative embodiments, the tubes 10906 may have a circular cross-section or may be solid. Additionally, in the illustrated embodiment, the tubes 10906 are metal tubes. The metal tubes may include steel tubes, aluminum tubes, or any other type of metal tubes. In alternative embodiments, the tubes 10906 may be made of any material that increases the stiffness of the barrier 10902. For example, the tubes 10906 may be made of wood, plastic, plastic composite material, fiberglass, or carbon fiber.
[0332] In the illustrated embodiment, a length of the tubes 10906 corresponds to a length of the barrier 10902 such that the tubes 10906 and the barrier 10902 have substantially the same length. In alternative embodiments, the tubes 10906 may be shorter or longer than the barrier 10902. If the tubes 10906 are longer than the barrier 10902, in some instances, the tubes 10906 may be configured to span multiple barriers 10902 to stiffen and/or to interconnect elements of the barrier system 10900 including at least two barriers 10902. That is, the tubes 10906 may each be attached to at least two barriers 10902, or may be attached to more than two barriers 10902, to stiffen and/or to interconnect elements of the barrier system 10900.
[0333] As discussed above, the reinforcement system 10904 is configured to stiffen the barrier 10902 to increase the barrier's 10902 ability to withstand an impact. As shown in
[0334]
[0335] In the illustrated embodiment, the reinforcement system 11204 includes at least one tube 11206 attached to the barrier 11202. In some embodiments, the reinforcement system 11204 may include a single tube 11206 attached to the barrier 11202. In the illustrated embodiment, the reinforcement system 11204 includes a plurality of tubes 11206 attached to the barrier 11202. Specifically, in the illustrated embodiment, the reinforcement system 11204 includes two tubes 11206 attached to the barrier 11202. In alternative embodiments, the reinforcement system 11204 may include any number of tubes 11206 attached to the barrier 11202 including one, two, three, four, or more tubes 11206 attached to the barrier 11202.
[0336] In the illustrated embodiment, the tubes 11206 are each attached to a top and a bottom of the barrier 11202. Specifically, in the illustrated embodiment, the barrier 11202 defines a top groove 11208 and a bottom groove 11210 each configured to receive a tube 11206. In some embodiments, the tubes 11206 are overmolded into the grooves 11208 and 11210 as the barrier 11202 is formed. In some embodiments, the barrier 11202 is molded with the grooves 11208 and 11210 and the tubes 11206 are positioned within the grooves 11208 and 11210 and secured within the grooves 11208 and 11210 with fasteners 11212 including screws bolts, nails, or adhesives. In the illustrated embodiment, the fasteners 11212 include bolts that extend through two tubes 11206 and the barrier 11202 to increase the stiffness of the barrier 11202.
[0337] Additionally, in the illustrated embodiment, the reinforcement system 11204 includes connectors 11214 attached to each end of the tubes 11206. The connectors 11214 are configured to connect the ends of the tubes 11206 of a first barrier to the ends of the tubes 11206 of a second barrier. As such, the reinforcement system 11204 described herein includes a connection system configured to connect a plurality of barriers 11202 together such that the barrier system's 11200 ability to withstand impacts is increased. In the illustrated embodiment, the connectors 11214 are attached to each end of the tubes 11206 by fasteners 11216 including screws bolts, nails, or adhesives. In the illustrated embodiment, the fasteners 11216 include bolts that extend through two tubes 11206 and two connectors 11214 to increase the stiffness of the barrier system 11200.
[0338] In the illustrated embodiment, the reinforcement system 11204 may further include at least one plate 11218 overmolded into the barrier 11202. In some embodiments, the reinforcement system 11204 may include a single plate 11218 overmolded into the barrier 11202. In the illustrated embodiment, the reinforcement system 11204 includes a plurality of plates 11218 overmolded into the barrier 11202. Specifically, in the illustrated embodiment, the reinforcement system 11204 includes a single plate 11218 overmolded into the barrier 11202. In alternative embodiments, the reinforcement system 11204 may include any number of plates 11218 overmolded into the barrier 11202 including one, two, three, four, or more plates 11218 overmolded into the barrier 11202. Specifically, the plates 11218 are positioned in the mold and the batter is poured around the plates 11218. The batter hardens into the barrier 11202 around the plates 11218 and the plates 11218 remain in place.
[0339] In the illustrated embodiment, the tubes 11206 are hollow, square tubes. In alternative embodiments, the tubes 11206 may have any shape and may be solid rather than hollow. For example, in alternative embodiments, the tubes 11206 may have a circular cross-section, may be solid, or may have various cross-sections including I-beams, C-channel, L-brackets, and/or any other cross-section. Additionally, in the illustrated embodiment, the tubes 11206 are metal tubes. The metal tubes may include steel tubes, aluminum tubes, or any other type of metal tubes. In alternative embodiments, the tubes 11206 may be made of any material that increases the stiffness of the barrier 11202. For example, the tubes 11206 may be made of wood, plastic, plastic composite material, fiberglass, or carbon fiber. Similarly, in the illustrated embodiment, the plates 11218 are metal plates. The metal plates may include steel plates, aluminum plates, or any other type of metal plates. In alternative embodiments, the plates 11218 may be made of any material that increases the stiffness of the barrier 11202. For example, the plates 11218 may be made of wood, plastic, plastic composite material, fiberglass, or carbon fiber.
[0340] As discussed above, the reinforcement system 11204 is configured to stiffen the barrier 11202 to increase the barrier's 11202 ability to withstand an impact. The barrier system 11200 includes tubes 11206, a connection system, and at least one plate 11218 that each stiffen the barrier system 11200. Accordingly, the barrier system 11200 described herein includes a reinforcement system 11204 that increases the barrier's 11202 ability to withstand an impact.
[0341]
[0342] In the illustrated embodiment, the reinforcement system 11504 includes at least one Thrie beam or W-beam 11506 attached to the barrier 11502. In the illustrated embodiment, the reinforcement system 11504 includes a single Thrie beam 11506 attached to the barrier 11502. In the alternative embodiments, the reinforcement system 11504 may include a plurality of Thrie beams 11506 attached to the barrier 11502. In alternative embodiments, the reinforcement system 11504 may include any number of Thrie beams 11506 attached to the barrier 11502 including one, two, three, four, or more Thrie beams 11506 attached to the barrier 11502.
[0343] In the embodiment illustrated in
[0344] In the illustrated embodiment, the Thrie beams 11506 are formed of metal. The metal beams may include steel beams, aluminum beams, or any other type of metal beams. In alternative embodiments, the Thrie beams 11506 may be made of any material that increases the stiffness of the barrier 11502. For example, the Thrie beams 11506 may be made of wood, plastic, plastic composite material, fiberglass, or carbon fiber.
[0345] In some embodiments, a length of the Thrie beams 11506 corresponds to a length of the barrier 11502 such that the Thrie beams 11506 and the barrier 11502 have substantially the same length. In some embodiments, the Thrie beams 11506 may be shorter or longer than the barrier 11502. In the illustrated embodiment, the Thrie beams 11506 are longer than the barriers 11502. If the Thrie beams 11506 are longer than the barrier 11502, the Thrie beams 11506 may be configured to span multiple barriers 11502 to stiffen and/or interconnect elements of the barrier system 11500 including at least two barriers 11502. That is, the Thrie beams 11506 may each be attached to at least two barriers 11502, or may be attached to more than two barriers 11502, to stiffen and/or interconnect elements of the barrier system 11500.
[0346] As discussed above, the reinforcement system 11504 is configured to stiffen the barrier 11502 to increase the barrier's 11502 ability to withstand an impact. As shown in
[0347]
[0348] In the illustrated embodiment, the reinforcement system 11904 includes at least one tube 11906 attached to the bike lane barrier 11902. In some embodiments, the reinforcement system 11904 may include a single tube 11906 attached to the bike lane barrier 11902. In the illustrated embodiment, the reinforcement system 11904 includes a plurality of tubes 11906 attached to the bike lane barrier 11902. Specifically, in the illustrated embodiment, the reinforcement system 11904 includes two tubes 11906 attached to the bike lane barrier 11902. In alternative embodiments, the reinforcement system 11904 may include any number of tubes 11906 attached to the bike lane barrier 11902 including one, two, three, four, or more tubes 11906 attached to the bike lane barrier 11902.
[0349] In the illustrated embodiment, the tubes 11906 are each attached to either side of the bike lane barrier 11902. In alternative embodiments, the tubes 11906 may be attached to only one side of the bike lane barrier 11902. In the illustrated embodiment, the tubes 11906 are attached to the bike lane barrier 11902 with fasteners (not shown). In alternative embodiments, the tubes 11906 may be attached to the bike lane barrier 11902 using anything configured to attach the tubes 11906 to the bike lane barrier 11902 including screws, nails, bolts, or adhesives. Attaching the tubes 11906 to the bike lane barrier 11902 with a fastener enables existing barriers to be retrofitted with the reinforcement system 11904 to stiffen the existing barriers.
[0350] In the illustrated embodiment, the tubes 11906 are hollow, square tubes. In alternative embodiments, the tubes 11906 may have any shape and may be solid rather than hollow. For example, in alternative embodiments, the tubes 11906 may have a circular cross-section, may be I-beams, or may be solid. Additionally, in the illustrated embodiment, the tubes 11906 are metal tubes. The metal tubes may include steel tubes, aluminum tubes, or any other type of metal tubes. In alternative embodiments, the tubes 11906 may be made of any material that increases the stiffness of the bike lane barrier 11902. For example, the tubes 11906 may be made of wood, plastic, plastic composite material, fiberglass, or carbon fiber.
[0351] In the illustrated embodiment, a length of the tubes 11906 corresponds to a length of three bike lane barriers 11902. In alternative embodiments, the tubes 11906 may be shorter or longer than the bike lane barrier 11902 or the same length as the bike lane barriers 11902. If the tubes 11906 are longer than the bike lane barrier 11902, the tubes 11906 may be configured to span multiple barriers 10002 to interconnect and stiffen the bike lane barrier system 11900 including at least two bike lane barrier 11902. That is, the tubes 11906 may each be attached to at least two barriers 10002, or may be attached to more than two barriers 11902, to interconnect and stiffen elements of the bike lane barrier system 11900.
[0352] As discussed above, the reinforcement system 11904 is configured to stiffen the bike lane barrier 11902 to increase the barrier's 11902 ability to withstand an impact. As shown in
[0353] Accordingly, the bike lane barrier system 11900 described herein includes a reinforcement system 11904 that increases the barrier's 11902 ability to withstand an impact.
[0354] The systems and methods disclosed herein relate to, among other things, sustainable articles such as a sustainable barrier that may be used for a variety of purposes including use as a traffic barrier. The sustainable barriers described herein are formed of a waste material and a binder that binds the waste material into a specific shape for a specific use. Additionally, the waste material and the binder may be combined in different ratios with different compositions such that the material that forms the sustainable barrier may be tailored to specific uses. Moreover, the shape of the barriers may be tailored to a specific shape to suit a specific function. Accordingly, the sustainable barriers described herein are formed of a sustainable material with a tailored composition and shape to suit a specific function.
[0355] Specifically, in the illustrated embodiments, the waste material used to form the sustainable barriers described herein is used tires. In alternative embodiments, the waste material may be any material including, but not limited to, recycled plastics, recycled wood, and/or any other sustainable or recyclable material. The binder includes a polyurethane binder, an optional colorant, an optional catalyst, and a small amount of water. The used tires are ground to form a crumb rubber and the binder is formulated to bind the crumb rubber into a formed sustainable barrier. Specifically, the binder has been formulated to bind the crumb rubber into the sustainable barrier without using heat. More specifically, the catalyst within the binder quickly forms the sustainable barrier such that heat is not required.
[0356] The properties of the waste material and/or the processing conditions may be varied to tune or specify the final properties of the sustainable barrier. Specifically, a specific type of waste material may be selected to achieve a desired physical property within the sustainable barrier. For example, a denser waste material may be selected such that the sustainable barrier is denser and/or harder. The denser/harder sustainable barrier may be useful for specific uses or harsh environments. For example, the denser/harder sustainable barriers may be tailored such that the density is greater than the density of water and may be useful for flood control. Additionally, the denser/harder sustainable barriers may be useful for barriers in high traffic/high speed highways where collisions may cause damage to softer/less dense barriers.
[0357] Conversely, a less dense waste material may be selected such that the sustainable barrier is less dense and/or softer. The less dense/softer sustainable barrier may be useful for specific uses or specific environments. For example, the less dense/softer sustainable barriers may be useful for situations where a barrier is needed but the barrier needs to give to protect the object impacting the barrier. For example, barriers at bumper car facilities or go-cart racetracks need to stop the bumper car or go-cart without hurting the occupant or damaging the bumper car or go-cart. Certain waste materials are denser than others and may be suitable for specific situations. For example, tires suitable for large commercial vehicles (such as constructions vehicles and tractor trailers) are typically denser/harder than tires for residential vehicles and bicycles. The density of the sustainable barrier may be tuned by selecting the material the sustainable barrier is made from based on the materials density. Additionally, the density of the sustainable barrier may also be varied based on the compression pressure used to from the barrier. A higher compression pressure increases the density of the sustainable barrier and a lower compression pressure decreases the density of the sustainable barrier.
[0358] Furthermore, different mixtures of materials may form different parts of the same barrier with different densities to perform different functions. For example, a first uncured batter (combination of the waste material and the binder in an uncured slurry) may be poured into a mold to form a core of the barrier. The first uncured batter may be tailored to have a high density such that the core provides structural support for the barrier. A second uncured batter may be poured around the core to form a skin of the barrier. The second uncured batter may be tailored to have a lower density such that the skin gives upon impact with the barrier. As such, the densities of the sustainable materials use to form the barriers may be tailored to a specific use for the barrier.
[0359] The shape of the sustainable barriers may also be tailored to different uses. That is, the mold used to cure the batter may be configured to have different shapes such that the sustainable barriers are useful for other applications. For example, the sustainable barriers may have the traditional Jersey Barrier shape for use as a traffic divider. In other embodiments, the sustainable barriers may be blocks instead of the traditional Jersey style barrier. The blocks may be stackable on each other such that the sustainable barriers can be formed into a makeshift wall. In still other embodiments, the sustainable barriers may resemble the traditional Jersey Barrier but may have different angles to deflect vehicles in different directions upon impact. As such, the shape of the sustainable barriers may be tailored to different configurations depending on their use.
[0360] Furthermore, because the sustainable barriers are made from a waste material (in this case recycled tires), the sustainable barriers are substantially less brittle than traditional concrete barriers and are substantially less likely to break or chip when moved. As describe above, traditional concrete barriers often chip or even break when moved at a construction site. The barriers described herein do not break or chip like traditional concrete barriers. Specifically, the recycled tires used to form the sustainable barriers are flexible and, as such, the sustainable barriers typically bounce or temporarily deform when impacted or dropped. That is, the sustainable barriers described herein do not break or chip like traditional concrete barriers. Accordingly, the sustainable barriers described herein may be more robust than traditional concrete barriers.
[0361] Because the sustainable barriers are formed of less brittle, more flexible materials, the sustainable barriers may be stacked on top of each other several levels high for storage or for creating larger barrier structures. For example, the sustainable barriers may be sized and shaped such that the barriers are stacked several levels high on top of each other to form a makeshift wall. In contrast, the traditional Jersey Barriers cannot be stacked to form tall structures that are several levels high.
[0362] The sustainable barriers described herein may also include connectors that enable the sustainable barriers to be connected to each other. In some embodiments, the connectors include loops of rebar that extend out from a side of the sustainable barrier and are capable of interfacing with connectors of other sustainable barriers to form an extended barrier structure. The material of the connectors may also reinforce the structure of the barrier. For example, the rebar may extend into the body of the barrier such that the rebar also acts as a barrier if the sustainable barrier is struck by a vehicle. In some embodiments, the connectors may include shaped ends with corresponding shapes that interconnect with each other to interlock. In some embodiments, the connectors may include a shaped connector that interlocks with identical shaped ends of the sustainable barrier.
[0363] In some embodiments, the rebar of the connector extends from one side of the sustainable barrier to the other. More specifically, the connectors may include a rebar loop that extends from a connector on one side of the sustainable barrier to a connector on the other side of the sustainable barrier. As such, the rebar loop forms an extra structural component that strengthens the barrier.
[0364] In alternative embodiments, the rebar connectors may not extend throughout the sustainable barrier. Rather, the rebar connector only extends into the sustainable barrier a short distance. In this embodiment, the connector does not provide as much structural reinforcement as the rebar loop embodiment described above and may be designed to separate in the event of an impact. In this embodiment, the rebar connector may be sized and shaped to maintain the connector within the sustainable barrier. For example, the ends of the connector may be turned up or may be twisted to create a tortuous pull-out path in the event of an impact.
[0365] Accordingly, the embodiments of sustainable barriers described herein are formed of a sustainable material that may be tailored to a specific use. Specifically, the density of the material may be tailored such that the relative hardness of the material of portions of the sustainable barriers may be tailored for different uses. Furthermore, the shape of the sustainable barriers may also be tailored for different uses. As such, the sustainable barriers described herein may be tailored for different uses and are entirely sustainable.
[0366] The description set forth herein, in connection with the appended drawings, describes example configurations and does not represent all the examples that may be implemented or that are within the scope of the claims. The term exemplary used herein means serving as an example, instance, or illustration, and not preferred or advantageous over other examples. The detailed description includes specific details for the purpose of providing an understanding of the described techniques. These techniques, however, may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the described examples.
[0367] In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If just the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0368] The description herein is provided to enable a person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the scope of the disclosure. Thus, the disclosure is not limited to the examples and designs described herein, but is to be accorded the broadest scope consistent with the principles and novel features disclosed herein.
Terminology and Interpretative Conventions
[0369] Any methods described in the claims or specification should not be interpreted to require the steps to be performed in a specific order unless stated otherwise. Also, the methods should be interpreted to provide support to perform the recited steps in any order unless stated otherwise.
[0370] Spatial or directional terms, such as left, right, front, back, and the like, relate to the subject matter as it is shown in the drawings. However, it is to be understood that the described subject matter may assume various alternative orientations and, accordingly, such terms are not to be considered as limiting.
[0371] Articles such as the, a, and an can connote the singular or plural. Also, the word or when used without a preceding either (or other similar language indicating that or is unequivocally meant to be exclusivee.g., only one of x or y, etc.) shall be interpreted to be inclusive (e.g., x or ymeans one or both x or y).
[0372] The term and/or shall also be interpreted to be inclusive (e.g., x and/or y means one or both x or y). In situations where and/or or or are used as a conjunction for a group of three or more items, the group should be interpreted to include one item alone, all the items together, or any combination or number of the items.
[0373] The terms have, having, include, and including should be interpreted to be synonymous with the terms comprise and comprising. The use of these terms should also be understood as disclosing and providing support for narrower alternative embodiments where these terms are replaced by consisting or consisting essentially of.
[0374] Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, and the like, used in the specification (other than the claims) are understood to be modified in all instances by the term approximately. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term approximately should be construed in light of the number of recited significant digits and by applying ordinary rounding techniques.
[0375] All disclosed ranges are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed by each range. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).
[0376] All disclosed numerical values are to be understood as being variable from 0-100% in either direction and thus provide support for claims that recite such values or any and all ranges or subranges that can be formed by such values. For example, a stated numerical value of 8 should be understood to vary from 0 to 16 (100% in either direction) and provide support for claims that recite the range itself (e.g., 0 to 16), any subrange within the range (e.g., 2 to 12.5) or any individual value within that range (e.g., 15.2).
[0377] The terms recited in the claims should be given their ordinary and customary meaning as determined by reference to relevant entries in widely used general dictionaries and/or relevant technical dictionaries, commonly understood meanings by those in the art, etc., with the understanding that the broadest meaning imparted by any one or combination of these sources should be given to the claim terms (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of the combination of entries, etc.) subject only to the following exceptions: (a) if a term is used in a manner that is more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or (b) if a term has been explicitly defined to have a different meaning by reciting the term followed by the phrase as used in this document shall mean or similar language (e.g., this term means, this term is defined as, for the purposes of this disclosure this term shall mean, etc.). References to specific examples, use of i.e., use of the word invention, etc., are not meant to invoke exception (b) or otherwise restrict the scope of the recited claim terms. Other than situations where exception (b) applies, nothing contained in this document should be considered a disclaimer or disavowal of claim scope.
[0378] The subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any embodiment, feature, or combination of features described or illustrated in this document. This is true even if only a single embodiment of the feature or combination of features is illustrated and described in this document.