Note: Descriptions are shown in the official language in which they were submitted.
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PORTABLE ROADWAY WARNING DEVICE WITH HIGH-DENSITY FILLER
AND ABSENT RIGID METAL BALLAST INSERTS
Related Applications
This application claims the benefit of U.S. Provisional Application No.
63/152,493 filed February 23, 2021, which is hereby incorporated herein by
reference in its entirety.
Technical Field
The present invention relates generally to a portable roadway warning
device including one or more portable rumble strips to alert an operator of
vehicle of an approaching condition, and more particularly to a portable
roadway
warning device having a portable rumble strip that provides a desired weight
and
road stability of the rumble strip without the use of conventional rigid metal
ballast inserts.
Background
Rumble strips are commonly used on roadways to provide a perceptible
noise and physical warning vibration to an operator of a vehicle when the
vehicle
drives over the rumble strip. Rumble strips can be used to slow traffic or
warn
vehicle operators of an approaching condition, such as a work site,
construction
site, slow speed zone, checkpoint, and the like, without adversely affecting
the
stability of the vehicle.
Some types of rumble strips are intended to be permanently installed for
long-term use, while others are intended to be temporary and portable for use
at
work zones and other applications of relatively short duration. Portable or
temporary rumble strips generally should be reusable and quick and easy to
deploy and remove. They also should have the ability to remain in place under
the traffic conditions of their use, preferably without the use of adhesives
or
fasteners.
Some forms of portable rumble strips fabricated solely of polymeric
materials may be suitable for use on roadways at the lower end of the vehicle
traffic speed range, such as in parking lots, on residential streets, or the
like.
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These lower-end rumble strips, however, do not have appropriate part density
and weight to make them suitable for use at the higher end of the vehicle
traffic
speed range. Specifically, a lower-end rumble strip made solely of polymeric
material typically will have a density below 0.05 pounds per cubic inch (1.38
g/cc), and thus will not produce sufficient pressure on the road surface for
acceptable movement stability after encountering impacts from higher speed
vehicles.
Rumble strips designed for service on roads and highways at the higher
end of the vehicle traffic speed range also may be made with polymeric
material,
113 however these higher-end rumble strips often incorporate rigid metal
ballast
inserts within the polymer material to attain a heavier part density for
enabling
satisfactory movement stability against the greater impact forces of higher
speed
vehicles, such as those exceeding 50 miles per hour (80 kph). The rigid metal
ballast inserts do not reinforce the physical durability of the base polymeric
material of the rumble strip, rather the metal ballast inserts simply add
weight to
improve stability of the rumble strip during use.
Summary
One problem with higher-end portable rumble strips that incorporate rigid
metal ballast inserts is that the metal inserts are prone damage, such as by
impact fracture, corrosion, or the like. The metal ballast inserts also
typically are
in the form of elongated rigid metal bars that can negatively affect the
overall
flexibility of the rumble strip design.
A unique portable rumble strip for a roadway warning device is described
herein that uses high-density filler material to achieve a desired overall
density
and roadway stability that enables the rumble strip to be suitable for use in
high-
speed traffic conditions without the use of conventional rigid metal ballast
inserts.
Generally, a portable rumble strip having an overall part density greater
than 0.06 pounds per cubic inch (Ib/in3), and more preferably about 0.08
lb/in3 or
greater, provides acceptable road stability at highway vehicle speeds, such as
those in the range of 50 to 80 mph, or greater. Accordingly, an exemplary
portable rumble strip has high-density filler(s) dispersed in a polymeric
matrix in
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an amount that achieves an overall part density greater than 0.06 lb/in3, such
as
in the range from 0.06 lb/in3 to 0.15 lb/in3.
According to an aspect, the portable rumble strip has an elongated
flexible body that incorporates a composite with a flexible elastomeric matrix
having the high-density filler material dispersed therein. The elongated
flexible
body including the flexible high-density composite may be a single unitary
piece.
Such a portable rumble strip may provide more complete flexibility in all
directions, unlike conventional portable rumble strips that incorporate rigid
housings or rigid metal bars into the rumble strip's geometric design. The
increased flexibility provided by the elongated flexible body may include a
flexible upper surface that absorbs impact from the vehicle, a flexible lower
surface that conforms to the roadway surface, and a flexible
middle/intermediate
portion that facilitates the flexibility of the upper and lower surfaces. Co-
vulcanization of distinct layers of the flexible body, if any, may improve
overall
flexibility and durability of the design.
According to an aspect, a portable rumble strip includes an elongated
flexible body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
and lower engagement surfaces, the elongated flexible body having a length
greater than width and the width greater than thickness, wherein the elongated
flexible body incorporates a composite having a flexible polymeric material
matrix and at least one filler dispersed in the matrix that enhances the
density of
the composite, wherein the at least one filler is included in an amount that
provides an overall density of the elongated flexible body in a range from
0.06
lb/in3 to 0.15 lb/in3.
In exemplary embodiments, the flexible polymeric material matrix of the
composite may be co-vulcanized with the one or more additional portions of the
flexible rumble strip body to form a unitary structure.
According to an aspect, the high-density filler material is dispersible and
mixable in the polymer matrix material to enable the overall flexibility of
the
rumble strip body, while also being resistant to corrosion in a typical
roadway
condition. To enhance the overall density of the part, the high-density filler
material has a density that is greater than the density of its surrounding
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polymeric matrix, and preferably has a specific gravity of at least 3.0 to
enable a
suitable volumetric loading in the polymeric matrix without significantly
affecting
the flexibility and performance of the rumble strip design.
According to an aspect, a portable rumble strip includes an elongated
flexible body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
and lower engagement surfaces, the elongated flexible body having a length
greater than width and the width greater than thickness, wherein the elongated
flexible body incorporates a composite having: a flexible elastomeric matrix,
and
at least one filler dispersed in the matrix, wherein: the at least one filler
has a
density greater than a density of the flexible elastomeric material matrix;
the at
least one filler has a specific gravity of 3.0 or greater; and the at least
one filler is
included in the composite in an amount that enhances the density of the
composite, such that an overall density of the elongated flexible body is in a
range from 0.06 lb/in3 to 0.15 lb/in3.
In exemplary embodiments, the composite and/or overall flexible body
may be devoid of pure iron, cast iron, plain carbon steel, or other non-
stainless
iron-based filler material that is susceptible to corrosion from road salts.
In exemplary embodiments, the at least one high-density filler is an oxide,
carbide, nitride, sulfide, sulfate, silicate, inorganic, or mineral comprising
at least
one alkaline earth, transition, or post transition metal element, and more
particularly such a material that is resistant to corrosion from road salts.
According to an aspect, the high-density filler material may be useful as a
processing aid for the polymeric matrix material. For example, some high-
density materials with a specific gravity of at least 3.0 may be used as an
antidegradant, accelerator, coupling agent, or the like; and overloading of
such a
high-density material can be useful to achieve the desired overall part
density for
improving stability of the rumble strip at higher vehicle speeds.
According to an aspect, a portable rumble strip includes an upper vehicle
engagement surface, a lower roadway engagement surface, and a leading edge
and trailing edge between the upper and lower engagement surfaces, wherein
the portable rumble strip includes a composite having a polymeric material
matrix and a filler dispersed in the matrix in an amount from 100 parts to
1100
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parts by weight per 100 parts by weight total polymer of the polymeric
material
matrix, wherein the density of the filler is greater than a density of the
polymeric
material matrix.
In exemplary embodiments, the high-density filler includes zinc oxide
(ZnO) in an amount between 500 parts to 1100 parts by weight per 100 parts by
weight total polymer of the polymeric material matrix of the composite, in
which
the ZnO also may be used as a processing aid for one or more polymers in the
polymeric material matrix.
According to an aspect, a portable rumble strip includes an elongated
body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
and lower engagement surfaces, the elongated body having a length greater
than width and the width greater than thickness, wherein the elongated body
includes at least one cavity, and at least one filler in the form of discrete
unbound
pieces of material is disposed within the cavity.
According to an aspect, a portable rumble strip includes an elongated
body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
and lower engagement surfaces, the elongated body having a length greater
than width and the width greater than thickness, wherein one or more frangible
articles are disposed in the elongated body.
According to a general aspect, a portable rumble strip for placement on a
roadway in a roadway warning system, includes filler material within a body of
the rumble strip, the filler material being of a type and in an amount that
increases the density of a rumble strip such that its mass can exert a
pressure
on the roadway to withstand impact from a vehicle, such as a passenger vehicle
or heavy truck, without movement of the rumble strip relative to the roadway.
The following description and the annexed drawings set forth certain
illustrative embodiments of the invention. These embodiments are indicative,
however, of but a few of the various ways in which the principles of the
invention
may be employed. Other objects, advantages and novel features according to
aspects of the invention will become apparent from the following detailed
description when considered in conjunction with the drawings.
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Brief Description of the Drawings
The annexed drawings, which are not necessarily to scale, show various
aspects of the invention.
Fig. 1 is a schematic perspective view showing multiple sets of portable
rumble strips of a roadway warning system according to an embodiment of the
present invention, in which the portable rumble strips extend across one
highway
lane in spaced relation to one another.
Fig. 2 is a perspective view of one exemplary form of portable rumble strip
according to an embodiment of the present invention.
Fig. 3 is a perspective view of the portable rumble strip in Fig. 2 rolled
into
a spiral.
Fig. 4 is an enlarged perspective view of an end portion of the rumble strip
in Fig. 2 showing an exemplary grip.
Fig. 5 is a lateral cross-sectional view of the rumble strip taken about the
line 5-5 in Fig. 4.
Fig. 6 is a longitudinal cross-sectional view of the rumble strip in Fig. 2.
Fig. 7 is a lateral cross-sectional view of another exemplary portable
rumble strip according to an embodiment, which is shown with exemplary high-
density filler being dispensed into an exemplary cavity.
Fig. 8 is a longitudinal cross-sectional view of the portable rumble strip in
Fig. 7.
Fig. 9 is a longitudinal cross-sectional view of another exemplary portable
rumble strip according to an embodiment having another exemplary high-density
filler.
Fig. 10 is a lateral cross-sectional view of the portable rumble strip in Fig.
9.
Detailed Description
The principles and aspects according to the present disclosure have
particular application to portable rumble strips for high-speed use, and thus
will
be described below chiefly in this context. It is understood, however, that
the
principles and aspects according to the present disclosure also may be
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applicable to other rumble strips for other applications, such as for low-
speed
applications.
Referring to Fig. 1, an exemplary portable roadway warning device 10, or
system, is shown deployed on a roadway 12, such as a highway, to provide a
perceptible noise and physical warning vibration to an operator of a vehicle
14
when the vehicle drives over the warning system 10. In the illustrated
embodiment, the roadway warning system 10 includes a plurality of spaced apart
portable rumble strips 16, each of which is deployed to span across at least a
portion of a roadway 12. As shown, each rumble strip 16 of the warning system
10 may be an independent portable unit, although the warning system 10 may
include rumble strips 16 operably coupled together, such as end-to-end, which
may depend on the length of the rumble strip 12 and/or the width of the
roadway
12, for example.
Fig. 2 shows an enlarged view of an exemplary portable rumble strip 16 of
the warning system 10 is shown. Generally, the portable rumble strip 16 has an
elongated body 18, including an upper or top vehicle engagement surface 20
and a lower or bottom roadway engagement surface 22. Connecting the upper
surface 20 and lower surface 22 are respective edges, or sides, including a
leading edge 24 for receiving initial impact from the vehicle, an opposite
trailing
edge 26, and lateral side edges 27, 28 that connect the leading and trailing
edges 24, 26. The distance between the upper surface 20 and the lower surface
22 generally defines an overall thickness, T, of the rumble strip 16, which
may
correspond to an overall thickness of the edges 24, 26, 27 and 28. The rumble
strip 16 may have a generally uniform thickness T, or the thickness may vary
in
the longitudinal and/or lateral directions. As shown, the elongated body 18
has a
length, L, between the lateral side edges 27, 28 that is greater than a width,
W,
between the leading and trailing edges 24, 26. In addition, the width W
between
the upper surface 20 and the lower surface 22 is greater than the thickness T
of
the rumble strip 16.
Although the dimensions of the rumble strip 16 may vary, the elongated
body 18 desirably may be of sufficient length L to reach across a single
highway
lane, which typically is 11 feet wide, and as such the elongated body 18 may
be
in a range from 8 feet to 11 feet in length. The rumble strip 16 may have its
width
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W in a range between 8 inches and 16 inches. In addition, the rumble strip 16
should be of sufficient thickness T to generate a noticeable audible and
physical
vibration to warn the vehicle operator, including truck drivers, when driving
over
the rumble strip 16, but the thickness T should not be so severe as to startle
the
drivers, and should not cause damage or adversely affect the stability of the
vehicles. To that end, the exemplary rumble strip 16 may have its thickness T
in
a range between 0.5 inch and 1 inch, and more preferably may be about 0.75
inches, for example.
To facilitate ease of portability and enable the rumble strip 16 to be picked
up and transported by hand, the elongated body 18 of the portable rumble strip
16 may include one or grips 30. As shown in the enlarged view of Fig. 3, for
example, the grips 30 may be in the form of hand grip slots. The grips 30 may
be adjacent to one or both lateral side edges 27, 28 of the rumble strip body
18,
as shown. Although not shown in the illustrated embodiment, one or both of the
lateral side edges 27, 28 of the elongated body may include a suitable
connector
for connecting the rumble strip 16 to another rumble strip of the portable
warning
system 10. This may be particularly desirable where the roadway is wide, or
the
overall length L of the rumble strip 16 is less than 8 feet.
In exemplary embodiments, the elongated body 18 of the rumble strip 16
has sufficient flexibility to permit the rumble strip 16 to be rolled up
lengthwise
from one lateral side edge 27 to the other lateral side edge 28 (end-to-end)
for
ease of transportation and storage when not in use, and just as easily
unrolled
during deployment of the rumble strip 16. Such rolling may include simply
folding or bending the rumble strip 16 essentially in half so that the lateral
side
edges 27 and 28 are brought closer together, or may include rolling the rumble
strip 16 in a spiral pattern, as shown in Fig. 3 for example. When rolled into
a
spiral roll, the rumble strip 16 may have an outer diameter between about 18
inches and 48 inches, for example.
To achieve such flexibility, the elongated flexible body 18 of the rumble
strip 16 is made with a base material of one or more suitably resilient or
flexible
materials. Such resilient or flexible materials may include one or more
suitable
types of polymer, such as suitable elastomeric materials, including by way of
non-limiting example: natural rubber, ethylene propylene diene monomer rubber
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(EPDM), styrene-butadiene rubber (SBR), butyl-rubber, nitrile-rubber, or other
thermoset or thermoplastic elastomers, such as polyurethane, including any
combinations of the foregoing.
Because the flexible material(s) of the type(s) described above generally
have a density of about 0.04 lb/in3 to about 0.05 lb/in3 the flexible
material(s) of
the rumble strip body 18 on their own do not provide sufficient pressure on
the
roadway surface to remain in place under heavy traffic at higher end highway
speeds. Accordingly, the exemplary portable rumble strip 16 described herein
uses high-density filler material within a flexible material matrix of the
rumble
strip body 18 to achieve a desired overall part density that enables the
rumble
strip 16 to be suitable for use in high-speed traffic conditions, while also
providing enhanced freedom of flexibility in multiple directions to aid in
performance and portability of the rumble strip design.
Referring to the lateral cross-sectional view of Fig. 5 and the longitudinal
cross-sectional view of Fig. 6, one exemplary form of the flexible rumble
strip
body 18 made with a high-density composite 32 having a flexible material
matrix
34 and at least one high-density filler material 36 dispersed in the matrix 34
is
shown. As described in further detail below, the amount and combined weight of
the high-density filler material 36 dispersed in the flexible material matrix
34
should be sufficient to cause the rumble strip 16 to stay in place under heavy
traffic at highway speeds, but should not make the rumble strip 16 so heavy
that
it cannot easily be rolled up or moved by one or two persons. For example, the
overall weight of the rumble strip body 18 approximately 11 feet in length by
about 1 foot wide by about 0.75 inch thick may be in a range from about 75
lbs.
to about 125 lbs., such as about 100 lbs. In addition, the high-density filler
material 36 preferably is dispersed within the flexible material matrix 34 in
a
manner that provides enhanced freedom of flexibility of the rumble strip body
18
in multiple directions to thereby aid in the performance, conformability to
the road
surface, portability, or storability of the rumble strip.
As shown in the lateral cross-sectional view of Fig. 5, the high-density
composite 32 having the flexible material matrix 34 and high-density filler 36
may
constitute essentially the entirety of an upper portion 38 of the flexible
rumble
strip body 18, including the upper vehicle engagement surface 20, an
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intermediate (e.g., middle or center) portion 40 between the upper surface 20
and lower surface 22, and a majority of the respective edges 24, 26, 27 and
28.
As shown in the longitudinal cross-sectional view of Fig. 6, the high-density
composite 32 forms a portion of the rumble strip body 18 in the longitudinal
direction, which may be along a majority of the rumble strip length, or
essentially
an entirety of the rumble strip length. In exemplary embodiments, one or more
additional portions or layers of flexible material may be provided in the
rumble
strip body 18, such as a lower or bottom portion 42 that includes the lower
surface 22. As described in further detail below, the lower portion or layer
42
may be formed with a different flexible material composition than that of the
upper portion 38 having the high-density filler 36 (also referred to as the
upper
composite layer 38 or high-density composite layer 38 in this embodiment).
As shown in the cross-sectional view, the upper vehicle engagement
surface 20, the lower roadway engagement surface 22, the trailing edge 26, and
the lateral side edges 27 and 28, each may be substantially flat surfaces,
with
the trailing edge 26 and side edges 27, 28 being perpendicular to the upper
and
lower surfaces 20, 22. The leading edge 24 of the rumble strip body 18 that
faces toward oncoming vehicle traffic may be tapered or beveled to reduce any
possible movement of the rumble strip caused by initial contact of the vehicle
tires with the rumble strip. The included angle of the tapered or beveled
leading
edge 24 may be in the range from about 10-degrees to about 15-degrees, for
example. The shape and dimensions of any of these surfaces 20, 22, 24, 26
and 28 may be modified as desired to achieve certain functionality of the
rumble
strip 16. For example, the upper vehicle engagement surface 20 may be
cambered or rounded in the width direction between the leading and trailing
edges 24, 26. Likewise, the trailing edge 26 could be tapered or beveled
similarly to the leading edge 24.
To provide a better grip between the lower surface 22 and the roadway, or
to reduce possible skidding of vehicle tires against the upper surface 20, one
or
both of the upper and lower surfaces 20, 22 of the rumble strip body 18 may
have texturing 44. The texturing 44 may be in any suitable form, such as in
the
form of an open diamond pattern (as best shown in Fig. 4) to provide a channel
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effect to permit the escape of water from both underneath and above the rumble
strip 16.
As noted above, the lower portion or layer 42 of the flexible rumble strip
body 18 may be formed with a different flexible material composition than that
of
the upper high-density composite layer 38 having the high-density filler 36.
The
flexible material composition of the lower layer 42 may be made of any
suitable
flexible material composition, which may or may not be a composite having
additional filler material contained within a flexible material matrix of the
lower
layer 42.
To further increase the grip between the lower surface 22 of the rumble
strip and the roadway, the lower layer 42 of the rumble strip body may be made
with a softer polymer material than the flexible matrix material 34 of the
upper
layer 38. For example, the lower layer 42 of the rumble strip body 18 may have
a Shore A hardness in a range from about 40 to about 60, such as about 45; and
the upper high-density composite layer 38 may have a Shore A hardness in a
range from about 65 to about 80, such as about 75. This may enable the lower
layer 42 to better conform to an uneven roadway surface to enhance contact
area, while enabling the upper layer 38 to better withstand highspeed vehicle
impact. It is understood, however, that these relative hardnesses between
layers
38, 42 (or any other layers) may be the same, or may be varied as desired.
Because the upper portion 38 and/or intermediate portion 40 of the
rumble strip body 18 may contain the high-density filler 36 while the bottom
portion 42 does not, the thickness or volume of the high-density composite 32
(i.e., upper composite layer 38 in the illustrated embodiment) may be several
times greater than the thickness or volume of the lower portion 42. For
example,
where the overall thickness T of the rumble strip body 18 is approximately
0.75
inches, the thickness Ti of the upper portion 38 may be approximately 5/8 inch
and the thickness 12 of the lower portion 42 may be approximately 1/8 inch,
for
example. This can enable the lower portion 42 to provide functional
conformance and damping, for example, without providing too much material
that is absent the high-density filler 36, which could otherwise affect the
overall
(average) part density and thus roadway stability.
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In exemplary embodiments, the upper high-density composite layer 38 is
integrally formed with the flexible material of the lower layer 42 (or other
layers, if
any), such as via co-vulcanizing of the layers, thereby forming a unitary
flexible
body 18 of the rumble strip. In such a co-vulcanizing process, the respective
flexible materials (e.g., elastomeric polymers) of both the upper layer 38 and
lower layer 42 are heated and cured such that the polymeric chains of both
layers 38, 42 are crosslinked together to form a unitary structure. The co-
vulcanizing process may occur during co-molding of the respective layers under
heat and pressure. In the illustrated embodiment, for example, due to
crosslinking of the flexible material(s) between layers 38 and 42, including
the
flexible material(s) of the composite 32, the overall rumble strip body 18 is
considered to be a single unitary body.
Although the layers 38 and 42 (and/or other layers, if any) may be
integrally formed into a unitary structure as noted above, alternative
processing
techniques for forming the flexible body 18 also may be employed. For example,
alternatively or additionally to co-vulcanizing and/or co-molding, the heated
viscous material of one or both layers 38, 42 (or other layers, if any) may
impregnate the other layer. Alternatively or additionally, at least one of the
layer
portions 38 or 42 could be preformed and precured as a discrete article, and
the
other layer portion(s) 38 or 42 could be formed on the preformed article in
which
the heated viscous material of the second formed article impregnates the
preformed article. Alternatively, the upper and lower portions 38, 42 (or
other
portions, if any) could be molded as discrete articles and bonded together
with a
suitable adhesive, such as an adhesive that provides porous wicking and/or
crosslinking (after heating/curing) with one or both of the upper and lower
portions 38, 42. Although these alternative processing techniques may be
employed, it may be preferred that multiple layers of the flexible body 18
(e.g.,
upper and lower layers 38, 42 including composite 32), if any, are formed as
integral and unitary with each other such as by co-vulcanization/crosslinking.
This can improve the durability of the rumble strip design by reducing and
eliminating interfaces between layers, and also can improve the overall
flexibility
of the rumble strip design. It is furthermore understood that although the
upper
and lower portions 38, 42 are shown as distinct layers of different material,
the
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entirety of the rumble strip body 18 could be fabricated with the flexible
high-
density composite 32 having the high-density filler 36 contained within.
As indicated above, the high-density composite 32 of the rumble strip
body includes a flexible material matrix 34 and at least one high-density
filler
material 36 dispersed in the matrix 34. The high-density composite 32 also may
include other materials to aid in the performance of the rumble strip or to
aid in
the fabrication of the rumble strip, as may desired. For example, the high-
density composite 32 may include minor constituent materials used to aid in
the
processing of the polymeric (e.g., elastomeric) material, such as processing
aids,
113 curatives, or other constituent materials. These various ingredients of
the
exemplary composite composition (also referred to as a "compound") will be
described in further detail below.
Flexible Material Matrix
The flexible material matrix 34 of the high-density composite 32 may
include any suitable polymeric material or combination of polymeric materials
that provides a desired flexibility of the rumble strip body 18, and also
which
enables a desired distribution of the high-density filler material 36 within
the
flexible material matrix 34. By way of non-limiting example, the flexible
material
of the matrix 34 may include suitable elastomers, including natural rubber,
ethylene propylene diene monomer rubber (EPDM), styrene-butadiene rubber
(S BR), butyl-rubber, nitrile-rubber, or other thermoset or thermoplastic
elastomers, such as polyurethane, or the like, including any combinations of
the
foregoing. In exemplary embodiments, one or more or all of the polymeric
matrix
materials are cured (vulcanized) to form a crosslinked polymeric matrix. The
density of only the flexible polymer material portion(s) of the rumble strip
body 18
(without accounting for the high-density filler 36 or other materials)
generally is in
the range from 0.035 lb/in3 to 0.050 lb/in3.
Processing Aids, Curatives, and Other Constituent Materials
The high-density composite 32 (e.g., upper composite layer 38) and other
polymeric portions of the rumble strip body (e.g., lower layer 42), if any,
may
include other constituent materials, or remnant traces thereof, including
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processing aids, curatives, or other minor constituent materials used to aid
in the
processing of the polymeric (e.g., elastomeric) material. For example, without
limitation, during compounding of the high-density composite 32, the polymeric
compound of the flexible matrix material 34 may include, in addition to
elastomer(s), the following additional ingredients (with exemplary amounts in
parts by weight per hundred polymer (e.g., elastomer) where "hundred polymer"
(e.g., "hundred elastonner") as used herein means 100 parts by weight total
polymer(s) (e.g., total elastomer(s)): processing oils/aids (from about 0 to
about
75 phr), antidegradants (from about 0 to about 10 phr), curatives (from about
0 to
10 phr), accelerators (from about 0 to about 10 phr), coupling agents (from
about
0 to about 30 phr), colorants, and the like. These ingredients or other
suitable
ingredients may be added as noted, increased, decreased, or omitted, as may
be desired to achieve the desired propert(ies) of the flexible material matrix
34.
High-Density Filler Material
It has been found that the portable rumble strip body 18 having an overall
body density greater than 0.06 lb/in3, and more preferably about 0.08 lbs/in3
or
greater, provides acceptable road stability at highway vehicle speeds. As
noted
above, the density of only the flexible polymer material portion(s) of the
rumble
strip body 18 (without accounting for the high-density filler 36 or other
materials)
generally is in the range from 0.035 lb/in3 to 0.050 lb/in3, which falls which
below
the desired overall rumble strip body density.
Accordingly, the exemplary rumble strip 16 provides the high-density filler
material 36 dispersed in the flexible material matrix 34 of the rumble strip
body in
an amount that achieves an overall part density greater than 0.06 lb/in3, and
more preferably at least about 0.08 lb/in3 or greater, such as an overall part
density in the range from 0.06 lb/in3 to 0.15 lb/in3. This increased density
of the
rumble strip body 18 restricts movement of the portable rumble strip by
vehicle
impact, or raising up from the roadway caused by the trailing draft of passing
vehicles. In exemplary embodiments, this increased overall part density is
achieved without the use of rigid metal ballast inserts such as solid metal
bars
molded into the flexible body 18 or attached to the body. As used herein, the
term "overall part density" or "overall body density" refers to an overall
density of
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the entire elongated flexible body 18 of the rumble strip 16; whereas the
phrase
"composite material density" or "layer density" refers to an overall or
aggregate
density of that particular layer or composite portion of the body 18.
The high-density filler material 36 (also referred to as high-density filler
36) may be any suitable material (or combination of materials) in any suitable
form (or combination of forms) that is mechanically mixable, dispersible, and
fixable within the flexible material matrix 34 prior to permanently forming
the
high-density composite 32 of the rumble strip body 18. This is in contrast
with
conventional rigid metal ballast inserts, like metal bars or other large
pieces of
metal such as those greater than 10 mm in length (e.g., metal slugs, or the
like),
which cannot practically be mixed and dispersed within the flexible material
matrix 34, but instead are inserted and then molded in place. The distribution
of
the high-density filler 36 in the flexible material matrix 34 may be achieved
by
any suitable technique, such as via conventional elastomeric mixing techniques
(e.g. internal mixers, mills or extruders) and conventional molding techniques
(e.g., compression molding and vulcanizing, transfer and injection molding, or
the like).
As indicated above, the high-density filler material 36 is dispersed within
the flexible material matrix 34 in a manner that provides enhanced freedom of
flexibility of the rumble strip body 18. This enhanced freedom of flexibility
may
include flexibility in multiple directions of the rumble strip body 18, such
as in two
or more of the x-(lateral), y-(longitudinal) and z-(vertical) directions
(illustrated in
Fig. 2). For example, the enhanced flexibility of the rumble strip body 18 may
include flexibility and resiliency of the upper vehicle engagement surface 20
that
absorbs impact from the vehicle. The flexible body 18 should possess
acceptable physical durability to withstand the continuous impacting forces
from
heavy vehicle traffic, including that of semi-trucks for example. In addition,
the
lower roadway engagement surface 22 may have sufficient flexibility such that
it
can conform to an uneven roadway surface or crown. The increased contact
area provided by such a lower flexible surface 22 enhances the resistance to
sliding or movement during impact from moving vehicles. Furthermore, an
intermediate portion 40, or middle, of the flexible body 18 also has
sufficient
flexibility to enable the flexible movement of the upper and lower surfaces
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of the body. The flexible intermediate portion 40 also may provide a greater
degree of flexibility to enable rolling of the portable rumble strip 16 (as
shown in
Fig. 3, for example) to aid in the portable deployment, removal, or storage
thereof.
In exemplary embodiments, the high-density filler material 36 is uniformly
dispersed throughout the flexible material matrix 34 such that the overall
composite 32 has uniform properties, including that of hardness, flexibility,
strength, and the like. This is in contrast with conventional rigid metal
ballast
inserts (such as solid metal bars) that are not dispersed within the matrix,
but
113 rather are typically inserted or molded in place at localized regions
of the body,
which thereby results in less flexibility of the body. Generally, the larger
the size
of the high-density filler material 36, the more difficult it is to mix and
uniformly
disperse, and thus the less uniform are the properties of the overall
composite,
which may affect overall flexibility.
The high-density filler 36 may be in any suitable form, such as powder,
particulate, fragments, grains, pellets, balls, short fibers, or the like,
which may
be in any suitable size or shape, such as round, blocky, elongated, acicular,
or
the like. A typical size of the individual pieces of high-density filler
material 36
may be in a range from about 0.1 micrometers (microns) to about 1 micron, for
example; however, the size could be in a range from below about 0.1 microns to
about 500 microns. Generally, if the size of the high-density filler 36 is too
large
and heavy, it can affect processability and uniform distribution of the high-
density
filler 36 in the flexible material matrix 34. In exemplary embodiments, the
size of
the high-density filler material 36 has a mean size (D50) in a range from
about
0.1 microns to about 1,000 microns, and more particularly in a range from
about
0.1 microns to about 500 microns, and even more particularly in a range from
about 0.1 micron to about 100 microns, for example.
As noted above, the high-density filler material 36 is provided to increase
the overall part density of the rumble strip body 18, and thus the high-
density
filler material 36 has a density that is greater than that of its surrounding
flexible
material matrix 34. Also noted above, in exemplary embodiments the high-
density filler 36 is loaded in an amount that achieves an overall density of
the
rumble strip body 18 in the range from about 0.06 lb/in3to about 0.15 lb/in3,
or
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more preferably at least about 0.08 lb/in3. The amount of high-density filler
material 36 (in both weight and volume percent) in the composite 32 will vary
based on the density (specific gravity) of the high-density filler material 36
(or
combination of high-density materials). For example, Table 1 shows four
exemplary compositions in accordance with specific embodiments which show
an amount by weight of high-density filler material 36, and other ingredients,
in
parts per hundred (phr) by weight total elastonner(s) of the flexible material
matrix
34.
TABLE 1
Parts (phr)
Ingredient Ex. 1 Ex. 2
Ex. 3 Ex. 4
Elastomer(s) 100 100 100 100
High-Density Filler
Lead Oxide (Pb0) 250
Iron Oxide (Fe304) 900
Zinc Oxide (ZnO) 800
Barium Sulfate
1000
(BaSO4)
Plasticizer Oil 10 10 10 10
Vulcanization/Processing Aids 10 10 10 10
Total Parts 370 1020 920 1120
Density, Pounds per Cubic Inch 0.09 0.13 0.12
0.12
Although only four different types of high-density filler 36 are shown in
Examples 1-4 of Table 1, the exemplary composition of the high-density
composite 32 is not limited these specific types. Generally, exemplary types
of
the high-density filler material 36 may include, but is not limited to,
oxides,
carbides, nitrides, sulfides, sulfates, silicates, inorganics, minerals, metal
alloys
or pure metals comprising alkaline earth, transition, or post transition metal
elements. Examples of such metal elements forming the oxides, carbides,
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sulfates, etc., of the high-density filler include, but are not limited to,
calcium,
barium, magnesium, iron, zinc, and lead, among others. Some types of these
materials will be better suited based on environmental conditions (e.g.,
corrosion-resistance), processability with the polymeric or elastomeric matrix
34,
or cost, among other considerations, as discussed in further detail below.
Generally, the amount and density of the high-density filler material 36 is
sufficient to achieve the desired overall part density of the rumble strip
body 18,
while also enabling suitable volumetric loading of the high-density filler 36
in the
flexible material matrix 34 without significantly affecting the flexibility
and
performance of the rumble strip design. As is evident from the Examples in
Table 1, the amount by weight of high-density filler material 36 in the
composite
will vary based on the density (specific gravity) of the high-density filler
material
(or combination of materials) because this will affect the volumetric ratio of
high-
density filler to flexible matrix material 34. Because the elastomer(s) of the
flexible material matrix 34 have a density of about 0.04 lb/in3 to about 0.05
lb/in3,
and because the desired overall density of the rumble strip body 18 is
preferably
about 0.08 lb/in3 or greater to achieve the desired weight and road stability
for
highway vehicle speeds, it has been found that using fillers with a specific
gravity
below 3.0 makes it difficult to attain the other desired properties (e.g.,
flexibility,
strength, etc.) of the flexible body 18. This is because a filler material
with a
specific gravity below about 3.0 may require too much to be added to attain a
targeted material density of at least 0.08 lb/in3, and as the filler loading
increases, the desired properties of the composite (compression set, permanent
set, elongation, flexibility, etc.) decrease. Thus, a specific gravity of the
high-
density filler 36 (or average specific gravity of the combination of materials
in the
filler 36) may be at least about 3.0 or greater, such as in a range from 3.0
to
20.0, for example.
By way of comparative example, if the 250 parts of lead oxide (Pb0) in
Example 1 were replaced with talc (magnesium silicate), then this would
require
1500 parts to achieve the same 0.09 lb/in3 density, and this amount of talc
would
not result in a suitable compound. This is because talc has a specific gravity
of
2.6 and lead oxide (litharge) has a specific gravity of 9.5. Generally, based
on a
specific gravity of the high-density filler being at least about 3.0, an
exemplary
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amount of the high-density filler 36 (or combination of high-density fillers)
in the
composite composition may be in a range from about 100 phr to about 1100 phr
(parts by weight per 100 parts by weight of total polymer(s) (e.g., total
elastomer(s)) of the flexible polymer matrix 34), such as about any of 100,
200,
300, 400, 500, 600, 700, 800, 900, 1000 or 1100 phr, which may be based on
the specific gravity of the high-density filler(s) 36.
Because the high-density composite 32 of the rumble strip body 18 may
constitute only a portion of the overall rumble strip body 18, the high-
density
composite portion (i.e., upper composite layer 38 in the illustrated
embodiment)
may require a density greater than 0.08 lb/in3 to compensate for the relative
lower density of the other part(s) of the body (e.g., lower portion 42 in the
illustrated embodiment). Accordingly, based on the volume of the high-density
composite 32 in the rumble strip body 18 relative to other portions, the high-
density composite portion may have a density in a range from 0.08 lb/in3 to
0.15
lb/in3, and more preferably in a range from 0.09 lb/in3 to 0.15 lb/in3, such
as
about any of 0.09, 0.10, 0.11, 0.12, 0.13, or 0.14 lb/in3, or greater. As
noted
above, when averaged together, the density of the high-density composite
portion(s) and the other portion(s) of the body (e.g., lower portion 42), if
any,
should have an overall part density greater than 0.06 lb/in3, and more
preferably
about 0.08 lb/in3 or greater. Based on the overall (averaged) part density,
the
weight of the rumble strip body having dimensions of 11 ft. x 1.0 ft. x 0.75
in.
may be in a range from 75 to 150 lbs., for example.
In exemplary embodiments, it may be advantageous to use high-density
filler material(s) 36 that are resistant to corrosion in a typical roadway
condition
where road salts such as sodium chloride may be present. This is because,
although the high-density filler 36 (e.g., particles) generally will be
encapsulated
and protected by the flexible material matrix 34, fissures may develop in the
matrix 34 over time which can expose the high-density filler 36 to the
corrosive
elements. Many alkaline earth, transition, or post transition metal oxides,
carbides, nitrides, sulfates, and the like, will exhibit corrosion-resistance
in a
typical roadway condition, and should improve over the corrosion
susceptibility of
pure iron, cast iron, plain carbon steel, or other non-stainless iron-based
materials.
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As discussed above, it is preferable that the specific gravity of the high-
density filler material 36 is greater than about 3.0, which may somewhat limit
the
available candidates of materials that also offer corrosion-resistance. The
high-
density fillers of Pb0, ZnO, Fe304, and BaSO4 depicted in Table 1 are some
non-limiting examples of oxide and sulfate materials that are corrosion-
resistant.
The general corrosion resistance of such oxide, carbide, nitride, sulfate,
etc.
materials are in contrast with some pure metals or metal alloys, such as pure
iron, cast iron, or plain carbon steel, for example, which generally form rust
in the
form of hematite (Fe2O3) which is an unstable oxide that spalls off and
provides
113 no corrosion-resistant effect. Thus, in exemplary embodiments, the
rumble strip
body is devoid of pure iron, cast iron, plain carbon steel, or other non-
stainless
iron-based materials; and also may be devoid of other pure metals/metal alloys
that form an unstable oxide (e.g., those with a Pilling-Bedworth ratio of less
than
about 1 and greater than about 2).
In addition, some metal oxides, nitrides, carbides, sulfates, inorganics,
minerals, etc. (such as some listed in Table 1), may be less expensive, less
reactive, less toxic, more processible with the elastomer, etc., than their
base
metal itself. Therefore, the oxide, nitride, sulfate, etc. form of the high-
density
filler material 36 may be more desirable from this perspective as well,
provided
such material is suitable for increasing the density of the composite 32
without
detrimental effects to the flexible material matrix 34.
In addition to one or more of the foregoing attributes of providing high
density (e.g., specific gravity greater than 3.0), general processability,
corrosion-
resistance, cost, availability, etc., it may be beneficial to use a high-
density filler
material 36 that also can be used as a processing aid to the polymer matrix
material 34 (e.g., elastomeric). In exemplary embodiments, zinc oxide (ZnO) is
a
particularly attractive material because it may be used as an accelerator in
polymeric (e.g., elastomeric) compositions. In this manner, the ZnO material
may be added in a sufficient quantity as an accelerator to the polymer matrix
material (e.g., elastomeric) composition, and then can be overloaded to an
amount that achieves the desired composite layer 32 density and/or overall
part
density of the rumble strip body 18. Zinc oxide is a readily-available,
inexpensive, non-toxic, and corrosion-resistant material. Zinc oxide also has
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specific gravity of about 4.4, meaning that an appropriate amount may be added
to the composite composition without affecting the desired properties of
flexibility, strength, etc. of the rumble strip body 18. In exemplary
embodiments,
the ZnO is provided in the high-density composite 32 in an amount from about
500 phr to about 1100 phr (parts by weight per 100 parts by weight of total
polymer(s) (e.g., total elastomer(s)) of the flexible polymer matrix 34), and
more
particularly from about 600 phr to about 800 phr. In exemplary embodiments,
the ZnO is added in powder form with a particle size having a range from about
0.1 micron to about 0.5 microns, more particularly 0.1-0.2 microns, to enable
113 suitable performance of the rumble strip design.
While an exemplary form or forms of the portable roadway warning
system 10 (and more particularly the exemplary portable rumble strip 16) have
been described above, it should be apparent to those having ordinary skill in
the
art that alternative configurations also could be employed. For example,
although the rumble strip body 18 is shown and described with the high-density
composite 32 forming at least the upper portion 38, including the vehicle
engagement surface 20 and at least a portion of the side surfaces 24, 26, 27
and
28, the high-density composition 32 could instead form one or more
intermediate
layers or portions (e.g., within intermediate portion 40) between the lower
layer
42 and corresponding upper layer (each of which lower and upper layer might
not contain high-density filler material as described above, or each of which
may
have a density less than 0.060 lb/in3). As indicated above, the different
layers
(e.g., lower, intermediate and upper layer) could each include different base
materials, different fillers, and be of different sizes or locations to
provide
different functionality as may be desired. Although, as noted above, it is
preferred that the high-density composite 32, regardless of its location, is
of
sufficient density and size (based on its density) to provide the desired
weight
and road stability of the rumble strip body 18, while still preferably
enabling the
overall flexibility of the rumble strip design.
Turning now to Figs. 7 and 8, another exemplary embodiment of a rumble
strip 116 for a roadway warning system is shown in lateral cross-section (Fig.
7)
and longitudinal cross-section (Fig. 8). The rumble strip 116 is similar to
the
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above-described rumble strip 16, and consequently the same reference
numerals but indexed by 100 are used to denote structures corresponding to
similar structures in the rumble strips 16, 116. In addition, the foregoing
description of the rumble strip 16 is equally applicable to the rumble strip
116,
except as noted below. Moreover, aspects of the rumble strips 16, 116 may be
substituted for one another or used in conjunction with one another where
applicable.
As shown, the rumble strip 116 includes an elongated body 118 having an
upper vehicle engagement surface 120, a lower roadway engagement surface
122, and a leading edge 124 and trailing edge 126 between the upper and lower
engagement surfaces 120, 122. Similarly to the rumble strip 16, in exemplary
embodiments the elongated body 118 of the rumble strip 116 has a length
greater than its width, and its width greater than its thickness. Also in
exemplary
embodiments, the rumble strip body 118 may be a flexible body 118 to provide
enhanced freedom of flexibility in multiple directions to aid in performance
and
portability of the rumble strip design, among other considerations. To achieve
such flexibility, one or more portions of the rumble strip body 118 may be
made
with one or more suitably resilient or flexible materials, including
processing aids
and other constituents, such as those materials described above.
At least one difference between the exemplary rumble strip 116 and the
above-described rumble strip 16 is that the high-density filler material 136
of
rumble strip 116 is in the form of discrete unbound pieces of material
disposed
within a cavity 137 of the body 118, instead of being discrete pieces
dispersed
and embedded in a polymer matrix as is the case with exemplary embodiments
of the rumble strip 16. Such a design with the discrete unbound pieces of high-
density filler material 136 may enable a greater variety in the type of
material that
can be included in the rumble strip body 118 because dispersing the material
within a matrix is not a concern. Moreover, because the discrete unbound
pieces of the filler material 136 may be movable against each other and/or
displaceable relative to each other within the cavity 137, this may enable the
rumble strip body 118 to maintain at least some flexibility by permitting
deformations (flexion, compression, etc.) within the overall bulk of discrete
unbound pieces in the cavity 137. In addition, because the overall bulk of
high-
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density filler material 136 is in the form of individual and preferably small
pieces,
each individual piece preferably would not have sufficient mass to create an
impactful projectile if ejected from the rumble strip 116 in the event of
catastrophic failure. Rather, the discrete unbound pieces of high-density
filler
136 would be dispersed from the cavity 137 as a cloud, for example.
The discrete unbound pieces of high-density filler material 136 may
include one or more types of material in any suitable form or forms. In
exemplary embodiments, the discrete unbound pieces provide a bulk flowable
material that partially or entirely fills the cavity 137 of the body 118. The
flowable
material may be poured into the cavity 137 and may remain relatively loose to
enhance deformability of the body 118, or may be tamped or compacted as it
fills
the cavity 137, or thereafter, to increase packing density. The flowable
material
may be a free-flowing material with a high-degree of flowability, or the
flowable
particulate may have a lower-degree of flowability with some cohesion between
particles. Generally, a bulk flowable material enables at least some
displacement of its constituent solid pieces relative to each other. The
degree of
flowability will be influenced by a variety of factors, such as friction
between
particles, Van der Waals or static forces, storage environment, moisture, etc.
A
suitable test method, such as with the use of a powder rheometer, may be used
to determine the flowability. Generally, the higher degree of flowability of
the
material will enhance pourability into the cavity 137 and also may enhance
flexibility of the rumble strip body 118 due to the easier movement of the
particles against each other.
In exemplary embodiments, the discrete unbound pieces of high-density
filler 136 include one or more types of particles which may be in powder form.
The particles may have any suitable shape and size (or size distribution) as
may
be desired for the physical properties of the bulk material. The particles may
be
generally spherical or have a low aspect ratio, or may be irregular or have a
high
aspect ratio. Irregular particles generally will have greater resistance to
flow but
may provide improved compaction (green strength) if desired. The particle size
for such powders may be in a range from about 0.1 microns to about 500
microns, for example. Finer particles generally have greater surface area and
may have a higher resistance to flow. Larger pieces greater than 500 microns
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also could be used, such as pieces as large as about 1 millimeter (mm), or
possibly greater. The greater the mass of each individual piece, however, the
greater the impact force of the piece if ejected from the cavity 137 of the
rumble
strip body 118 (i.e., in the event of catastrophic failure). Therefore, pieces
smaller than 1 mm, and more particularly a flowable powder having a mean size
(050) from about 100 microns to about 1,000 microns (1 mm) may be preferred.
The discrete unbound pieces of high-density filler 136 also may include short-
fibers, if desired, or may include aggregate particles composed of many small
pieces adhered together. Such an aggregate particle still constitutes a
discrete
unbound piece that can be intermixed with and movable relative to other
discrete
unbound pieces of the high-density filler 136 in the cavity 137.
The composition of the discrete unbound pieces of high-density filler 136
may include a single type of material or may include a mixture of different
types
of material. Generally, exemplary types of material used in the high-density
filler
136 may be the same as the high-density filler 36 described above, including
but
not limited to, one or more of oxides, carbides, nitrides, sulfides, sulfates,
silicates, inorganics, minerals, metal alloys or pure metals comprising
alkaline
earth, transition, or post transition metal elements. In the rumble strip 116,
however, because the high-density filler 136 is not dispersed within a matrix,
there may be less concern over material interactions with the matrix material.
In
addition, depending on the encapsulation of the overall bulk of high-density
filler
136 within the cavity 137, there also may be less concern over environmental
corrosion caused by road salts, for example. Accordingly, materials such as
pure iron, cast iron, plain carbon steel, or other non-stainless iron-based
materials may be utilized in the rumble strip 116 with reduced adverse effect.
Thus, by way of example and not limitation, an inexpensive flowable iron
powder
could be dispensed as the high-density filler material 136 into the cavity
137, or
other pocket, in the rumble strip body 118.
To facilitate the flowability of the high-density filler 136, the composition
of
the high-density filler 136 may include materials other than high-density
materials. For example, suitable lubricants, such as graphite, stearates
(e.g.,
magnesium stearate), stearic acid, oils, or the like could be used in the
composition. The lubricants may be chosen as desired based on their
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performance and compatibility with the high-density materials in the filler
136.
Alternatively or additionally, other suitable materials may be added to the
composition of the high-density filler to aid in compaction or packing
density, if
desired.
Similarly to the above-described rumble strip 16, the amount and type of
material(s) in the composition of the high-density filler 136 should be chosen
to
provide an overall density of the rumble strip body 118 that results in
sufficient
pressure on the roadway surface for acceptable resistance to movement, such
as for use in high-speed traffic conditions. Accordingly, in exemplary
embodiments the high-density filler 136 is loaded into the cavity 137 in an
amount that achieves an overall density of the rumble strip body 118 in the
range
from about 0.06 lb/ins to about 0.15 lb/in3, or more preferably at least about
0.08
lb/ins. The amount of high-density filler 136 (in both weight and volume
percent)
in the cavity 137 will vary based on the density (specific gravity) of the
high-
density filler material 136 (or combination of materials in the high-density
filler
136). Similarly to the rumble strip 16, the body 118 of the rumble strip 116
may
be made with polymer(s) (e.g., elastomer(s)) having a density of about 0.04
lb/ins
to about 0.05 lb/in3; and because the desired overall density of the rumble
strip
body 118 preferably may be about 0.08 lb/ins or greater to achieve the desired
weight and road stability for highway vehicle speeds, using a high-density
filler
material 136 (e.g., individually or as a mixture) with a specific gravity
below 3.0
may make it difficult to attain the desired overall density of the body 118.
Thus,
a specific gravity of the high-density filler 136 (e.g., the specific gravity
of the
material or mixture of materials) may be at least about 3.0 or greater, such
as in
a range from 3.0 to 20.0, for example. Because some void space may be
contained in the cavity 137 such as between individual pieces and/or in a head
space of the cavity 137, the calculation of void space may need to be
accounted
for in determining the desired specific gravity of the high-density filler
136.
The cavity 137 in the rumble strip body 118 may be formed in any suitable
manner with any suitable configuration as may be desired for the application.
In
the illustrated embodiment, the cavity 137 is a hollow chamber formed by
internal surfaces 141 of the body 118. For example, the rumble strip body 118
may be molded as a hollow article, and a fill port 150 may be provided at any
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suitable location to allow the discrete unbound pieces of high-density filler
material 136 to be dispensed into the cavity 137 via the fill port 150. A
suitable
closure 152, such as a plug, is provided to close and seal the cavity 137
after a
desired amount of the high-density filler 136 is dispensed into the cavity
137.
The amount of high-density filler 136 may at least partially fill the cavity
137, or
may entirely fill the cavity 137 with suitable void space to permit
flowability of the
filler 136 in the cavity thereby enhancing flexibility of the body 118.
The cavity 137 may be located at any suitable position in the body 118 to
account for weight distribution, flexibility, etc. In the illustrated
embodiment
shown in Fig. 7, for example, the cavity 137 is essentially centrally located
in the
lateral direction of the body 118 and extends laterally along a majority of
the
width of the body 118. As shown in Fig. 8, the cavity 137 may extend in the
longitudinal direction along at least a portion of the length of the rumble
strip
body 118. To facilitate fillability, multiple cavities 137 may be provided in
the
body 118, such as a plurality of longitudinally spaced apart cavities 137 each
having a fill port 150 and at least partially filled with high-density filler
136, which
may be the same type of filler, or different types as desired.
In an alternative embodiment (not shown), the discrete unbound pieces of
high-density filler 136 may be dispensed into a bag or bladder that is then co-
molded with the rumble strip body 118 to form the cavity 137 filled with the
high-
density filler 136. Any suitable bag or bladder capable of withstanding the
processing conditions of molding the body 118 may be used. The bag or
bladder filled with high-density filler 136 may be introduced at any step
during
the molding process and may be positioned at any suitable location. Multiple
bags or bladders filled with high-density filler 136 may be used and
positioned in
the body 118. In exemplary embodiments, the bag or bladder may be made with
a compatible polymer (e.g., elastomer) that provides flexibility and which may
enable co-vulcanization with the surrounding portions of the rumble strip body
118.
Similarly to the rumble strip 16, the body 118 of rumble strip 116 may be
made of the same material (e.g., flexible polymeric, such as one or more
elastomers), or may be made of different materials. For example, similarly to
rumble strip 16, the lower portion 142 of the rumble strip body 118 may be
made
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with a softer polymer material the upper portion 139. This may enable the
lower
portion 142 to better conform to an uneven roadway surface to enhance contact
area, while enabling the upper portion 139 to better withstand highspeed
vehicle
impact. It is understood, however, that these relative hardnesses between
portions 139, 142 (or any other portions or layers) may be the same, or may be
varied as desired. In exemplary embodiments, the upper portion 139 is
integrally
molded with the lower portion 142 (or one or more other layers, if any), such
as
via co-vulcanizing. The co-vulcanizing process may occur during co-molding of
the respective layers under heat and pressure. Alternatively or additionally,
the
heated viscous material of one or both layers 138, 142 (or other layers, if
any)
may impregnate the other layer. Alternatively or additionally, at least one of
the
layer portions 138 or 142 could be preformed and precured as a discrete
article,
and the other layer portion(s) 138 or 142 could be formed on the preformed
article in which the heated viscous material of the second formed article
impregnates the preformed article. Alternatively, the upper and lower portions
138, 142 (or other portions, if any) could be molded as discrete articles and
bonded together with a suitable adhesive, such as an adhesive that provides
porous wicking and/or crosslinking (after heating/curing) with one or both of
the
upper and lower portions 138, 142. Alternatively, the upper and lower portions
138, 132 may form respective portions of an openable and closeable rumble
strip body in the form of a container or case containing the discrete unbound
pieces of high-density filler 136.
Turning now to Figs. 9 and 10, another exemplary embodiment of a
rumble strip 216 for a roadway warning system is shown in lateral cross-
section
(Fig. 10) and longitudinal cross-section (Fig. 9). The rumble strip 216 is
similar
to the above-described rumble strips 16, 116 and consequently the same
reference numerals but in the 200-series are used to denote structures
corresponding to similar structures in the rumble strips 16, 116, 216. In
addition,
the foregoing description of the rumble strips 16, 116 are equally applicable
to
the rumble strip 216, except as noted below. Moreover, aspects of the rumble
strips 16, 116, 216 may be substituted for one another or used in conjunction
with one another where applicable.
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As shown, the rumble strip 216 includes an elongated body 218 having an
upper vehicle engagement surface 220, a lower roadway engagement surface
222, and a leading edge 224 and trailing edge 226 between the upper and lower
engagement surfaces 220, 222. Similarly to the rumble strip 16, in exemplary
embodiments the elongated body 218 of the rumble strip 216 has a length
greater than its width, and its width greater than its thickness. Also in
exemplary
embodiments, the rumble strip body 218 may be a flexible body 218. To achieve
flexibility, one or more portions of the rumble strip body 218 may be made
with
one or more suitably resilient or flexible materials, including processing
aids and
other constituents, such as those materials described above.
At least one difference with the exemplary rumble strip 216 is that the
high-density filler material 236 is in the form of one or more frangible
articles 236
disposed within the rumble strip body 218. In exemplary embodiments, the
frangible article(s) 236 are brittle and easily breakable (e.g., can be broken
by
hand, such as with about 25 pounds of force). As shown in the illustrated
embodiment, the one or more frangible articles 236 may be fixed within the
rumble strip body 218, such as being encased by the one or more materials
forming the rumble strip body 218. Such a design with the frangible article(s)
236 may enable a greater variety in the type of material that can be included
in
the rumble strip body 218 because dispersing the material within a matrix is
not
a concern. In addition, because the frangible article(s) 236 are brittle and
easily
breakable, if a piece of frangible article 236 were ejected from the rumble
strip
body 218 in event of catastrophic failure, the piece of frangible article
would
break and/or disintegrate on impact.
The frangible article(s) 236 may include one or more types of material in
any suitable form or forms. The material or mixture of materials forming the
frangible article 236 may be the same as those described above in connection
with the high-density filler 36 and the high-density filler 136. The material
or
mixture of materials constituting the frangible article 236 may be formed into
any
suitable structure as desired. For example, the material(s) constituting the
frangible article 236 may be pressed into a green state to form the final
frangible
article 236. Alternatively or additionally, a binder, such as a heat-sensitive
binder, may be utilized to facilitate particle-to-particle bonding to form the
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frangible article 236. The binder may be a weak binder or may be provided in
minute amounts to facilitate fragility. The frangible article 236 may have a
relatively high-porosity to facilitate fragility. The final shape of the
frangible
article 236 may be a bar, rod, slug, puck, brick, or any other suitable shape,
which may be placed at any suitable location in the rumble strip body 218.
Similarly to the above-described rumble strips 16 and 116, the amount
and type of material(s) in the composition of the frangible article 236 should
be
chosen to provide an overall density of the rumble strip body 218 that results
in
sufficient pressure on the roadway surface for acceptable resistance to
movement, such as for use in high-speed traffic conditions. Accordingly, in
exemplary embodiments the frangible article 236 is disposed in the rumble
strip
body 218 in an amount that achieves an overall density of the rumble strip
body
118 in the range from about 0.06 lb/in3 to about 0.15 lb/in3, or more
preferably at
least about 0.08 lb/in3. Also similarly to the rumble strips 16 and 116, the
body
218 of the rumble strip 216 may be made with polymer(s) (e.g., elastomer(s))
having a density of about 0.04 lb/in3 to about 0.05 lb/in3, and to achieve a
suitable overall density of the rumble strip body 218, the specific gravity of
the
frangible article 236 as a whole (e.g., the average specific gravity of the
material
or mixture of materials forming the frangible article 236) may be at least
about
3.0 or greater, such as in a range from 3.0 to 20.0, for example. Because the
frangible article 236 may have porosity, the calculation of porosity may need
to
be accounted for in determining the desired specific gravity or density of the
overall frangible article 236.
Also similarly to the rumble strips 16 and 116, the body 218 of rumble
strip 216 may be made of the same material (e.g., flexible polymeric, such as
one or more elastomers), or may be made of different materials. For example,
the lower portion 242 of the rumble strip body 218 may be made with a softer
polymer material than the upper portion 239, or vice versa. In addition, the
upper portion 239 may be integrally molded with the lower portion 242 (or one
or
more other layers, if any), such as via co-vulcanizing. The co-vulcanizing
process may occur during co-molding of the respective layers under heat and
pressure. Alternatively or additionally, the heated viscous material of one or
both
layers 238, 242 (or other layers, if any) may impregnate the other layer.
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Alternatively or additionally, at least one of the layer portions 238 or 242
could be
preformed and precured as a discrete article, and the other layer portion(s)
238
or 242 could be formed on the preformed article in which the heated viscous
material of the second formed article impregnates the preformed article.
Alternatively, the upper and lower portions 238, 242 (or other portions, if
any)
could be molded as discrete articles and bonded together with a suitable
adhesive. Alternatively, the upper and lower portions 238, 232 may form
respective portions of an openable and closeable rumble strip body in the form
of
a case containing the frangible article(s) 236.
An exemplary roadway warning device has been described herein,
including a portable rumble strip that includes high-density filler material
to
achieve a desired overall density and roadway stability of the rumble strip
such
as for use in high-speed traffic conditions without the use of conventional
rigid
metal ballast inserts. In some exemplary embodiments, the filler is dispersed
and embedded within a flexible polymer composite matrix of the rumble strip
body. In some exemplary embodiments, the filler is in the form of discrete
unbound pieces of material disposed within a cavity of the rumble strip body.
In
some exemplary embodiments, the filler is in the form of a frangible article
disposed within the rumble strip body.
According to an aspect, a portable rumble strip includes an elongated
flexible body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
and lower engagement surfaces, the elongated flexible body having a length
greater than width and the width greater than thickness, wherein the elongated
flexible body incorporates a composite having a flexible polymeric material
matrix and at least one filler dispersed in the matrix that enhances the
density of
the composite, wherein the at least one filler is included in an amount that
provides an overall density of the elongated flexible body in a range from
0.06
lb/in3 to 0.15 lb/in3.
According to an aspect, a portable rumble strip includes an elongated
flexible body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
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and lower engagement surfaces, the elongated flexible body having a length
greater than width and the width greater than thickness, wherein the elongated
flexible body incorporates a composite having: a flexible elastomeric matrix,
at
least one filler dispersed in the matrix, wherein: the at least one filler has
a
density greater than a density of the flexible elastomeric material matrix;
the at
least one filler has a specific gravity of 3.0 or greater; and the at least
one filler is
included in the composite in an amount that enhances the density of the
composite, such that an overall density of the elongated flexible body is in a
range from 0.06 lb/in3 to 0.15 lb/in3.
According to an aspect, a portable rumble strip includes an upper vehicle
engagement surface, a lower roadway engagement surface, and a leading edge
and trailing edge between the upper and lower engagement surfaces, wherein
the portable rumble strip includes a composite having a polymeric material
matrix and a filler dispersed in the matrix in an amount from 100 parts to
1100
parts by weight per 100 parts by weight total polymer of the polymeric
material
matrix, wherein the density of the filler is greater than a density of the
polymeric
material matrix.
Embodiment(s) may include one or more features of the foregoing
aspect(s), separately or in any suitable combination, which may be combined
with one or more of the following additional features, which may be included
separately or in any suitable combination.
In some embodiments, the flexible polymeric material matrix of the
composite is co-vulcanized with the one or more additional portions of the
body
to form a unitary structure.
In some embodiments, the at least one filler is dispersed uniformly
throughout the matrix of the composite such that the elongated flexible body
is
free to flex in multiple different directions at any location along the length
of the
body that corresponds with the composite.
In some embodiments, the at least one filler has a density greater than a
density of the flexible polymeric material matrix.
In some embodiments, the at least one filler has a specific gravity of 3.0
or greater.
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In some embodiments, the at least one filler is included in an amount from
100 parts to 1100 parts by weight per 100 parts by weight total polymer of the
flexible polymeric material matrix of the composite.
In some embodiments, the flexible polymeric material matrix has a density
of less than 0.060 lb/in3.
In some embodiments, the flexible polymeric material matrix includes a
thermoset or thermoplastic elastomer.
In some embodiments, the at least one filler has greater corrosion
resistance to sodium chloride than plain carbon steel.
In some embodiments, the at least one filler is in powder form, and an
average particle size of the powder is in a range from 0.1 microns to 500
microns.
In some embodiments, the at least one filler is an oxide, carbide, nitride,
sulfide, sulfate, silicate, inorganic, or mineral comprising at least one
alkaline
earth, transition, or post transition metal element.
In some embodiments, the at least one filler includes one or more of lead
oxide (Pb0), iron oxide (Fe304), zinc oxide (Zn0), or barium sulfate (BaSO4).
In some embodiments, the at least one filler that enhances the density of
the composite is ZnO in an amount from 500 parts to 1100 parts by weight per
100 parts by weight total polymer of the flexible polymeric material matrix of
the
composite.
In some embodiments, the composite, the at least one filler, and/or the
flexible polymeric material matrix includes one or more additional materials.
In some embodiments, the composite forms at least one flexible layer that
cooperates with one or more additional flexible layers comprising polymeric
material such that the elongated flexible body of the rumble strip is free to
flex in
multiple directions, bend in a direction of the length to bring longitudinal
ends of
the body toward each other, or roll into a spiral in a direction of the
length.
In some embodiments, the density of the composite layer is greater than a
density of the one or more additional flexible layers, and an overall average
density of all layers of the elongated flexible body in a range from 0.06
lb/in3 to
0.15 lb/in3.
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In some embodiments, the composite forms an upper layer including at
least the upper vehicle engagement surface, and wherein the one or more
additional flexible layers includes a lower layer including at least the lower
roadway engagement surface.
In some embodiments, the lower layer is co-vulcanized and unitary with
the upper layer to form a single unitary elongated flexible body that is
portable as
a single unit.
In some embodiments, the upper layer formed by the composite is harder
than the lower layer.
In some embodiments, an entirety of the elongated flexible body bounded
by its outer surfaces is formed by the composite having the flexible polymeric
material matrix and the at least one filler dispersed in the matrix that
enhances
the density of the composite.
In some embodiments, the composite and/or the elongated flexible body
is devoid pure iron, cast iron, plain carbon steel, or other non-stainless
iron-
based materials.
In some embodiments, the rumble strip is devoid of rigid metal inserts,
such as those having a minimum size of greater than 10 mm.
In some embodiments, the rumble strip is devoid of a housing that
contains the elongated flexible body and/or the composite, and more
particularly
a housing that is more rigid than that of the composite.
In some embodiments, the overall density of the elongated flexible body in
a range of: from 0.07 lb/in3 to 0.15 lb/in3, from 0.08 lb/in3 to 0.15 lb/in3,
from 0.09
lb/in3 to 0.15 lb/in3, from 0.10 lb/in3 to 0.15 lb/in3, from 0.11 lb/in3 to
0.15 lb/in3,
from 0.12 lb/in3 to 0.15 lb/in3, from 0.13 lb/in3 to 0.15 lb/in3, from 0.08
lb/in3 to
0.14 lb/in3, from 0.09 lb/in3 to 0.14 lb/in3, or any range or subrange below
the
stated values.
In some embodiments, the elongated flexible body has sufficient strength
and flexibility to withstand direct impact from a vehicle weighing at least
3,000
pounds at 50 mph or greater, and more particularly at least about 80,000 lbs.
at
speeds greater than 80 mph, without failure.
In some embodiments, the elongated flexible body has sufficient strength
and flexibility to withstand direct impact from a vehicle weighing at least
3,000
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pounds at 50 mph or greater, and more particularly at least about 80,000 lbs.
at
speeds greater than 80 mph, without significant movement relative to pavement
upon which the rumble strip rests, such as less than 1 inch of movement per
impact.
In some embodiments, the composite is devoid of pure iron, cast iron,
plain carbon steel, or other non-stainless iron-based filler material, and
more
particularly wherein the elongated flexible body is devoid of such filler
materials.
In some embodiments, the at least one filler is an oxide, carbide, nitride,
sulfide, sulfate, silicate, inorganic, or mineral comprising at least one
alkaline
1() earth, transition, or post transition metal element.
According to an aspect, a portable rumble strip includes an elongated
body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
and lower engagement surfaces, the elongated body having a length greater
than width and the width greater than thickness, wherein the elongated body
includes at least one cavity, and at least one filler in the form of discrete
unbound
pieces of material is disposed within the cavity.
Embodiment(s) may include one or more features of the foregoing aspect,
separately or in any suitable combination, which may be combined with one or
more of the following additional features, which may be included separately or
in
any suitable combination.
In some embodiments, the elongated body is a flexible polymeric body or
contains flexible portions of the elongated body.
In some embodiments, the at least one filler enhances the density of the
composite, and wherein the at least one filler is included in an amount that
provides an overall density of the elongated body in a range from 0.06 lb/in3
to
0.15 lb/in3.
In some embodiments, the discrete unbound pieces provide a bulk
flowable material in the cavity.
In some embodiments, the discrete unbound pieces provide a free-flowing
powder.
In some embodiments, the discrete unbound pieces have a mean size
(D50) less than about 1 mm.
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In some embodiments, the discrete unbound pieces is a flowable powder
having a mean size (D50) from about 100 microns to about 1,000 microns (1
mm).
In some embodiments, the discrete unbound pieces include oxides,
carbides, nitrides, sulfides, sulfates, silicates, inorganics, minerals, metal
alloys
or pure metals comprising alkaline earth, transition, or post transition metal
elements.
In some embodiments, the cavity is a hollow chamber formed by internal
surfaces of the elongated body.
In some embodiments, elongated body includes a fill port in fluid
communication with cavity, and optionally a closure to close and seal the
cavity.
In some embodiments, the discrete unbound pieces of filler are contained
in a bag or bladder that co-molded with the elongated body to form the cavity.
In some embodiments, the bag or bladder is made with a polymer that
provides flexibility and is co-vulcanized with surrounding portions of the
elongated body.
In some embodiments, the elongated body includes multiple cavities
containing the at least one filler, the multiple cavities being spaced apart
from
each other in the elongated body.
In some embodiments, one or more layers or portions of the elongated
body have different properties, the one or more layers or portions being co-
vulcanized together to form a unitary portion or entirety of the body.
According to an aspect, a portable rumble strip includes an elongated
body having an upper vehicle engagement surface, a lower roadway
engagement surface, and a leading edge and trailing edge between the upper
and lower engagement surfaces, the elongated body having a length greater
than width and the width greater than thickness, wherein one or more frangible
articles are disposed in the elongated body.
Embodiment(s) may include one or more features of the foregoing aspect,
separately or in any suitable combination, which may be combined with one or
more of the following additional features, which may be included separately or
in
any suitable combination.
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In some embodiments, the elongated body is a flexible polymeric body or
contains flexible portions of the elongated body.
In some embodiments, the one or more frangible articles enhance the
density of the composite, and wherein the one or more frangible articles are
included in an amount that provides an overall density of the elongated body
in a
range from 0.06 lb/in3 to 0.15 lb/in3.
In some embodiments, the one or more frangible articles are fixed within
the elongated body.
In some embodiments, the one or more frangible articles include a bar,
rod, slug, puck, brick, or any other suitable shape.
In some embodiments, the one or more frangible articles include oxides,
carbides, nitrides, sulfides, sulfates, silicates, inorganics, minerals, metal
alloys
or pure metals comprising alkaline earth, transition, or post transition metal
elements.
In some embodiments, one or more layers or portions of the elongated
body have different properties, the one or more layers or portions being co-
vulcanized together to form a unitary portion or entirety of the body.
According to an aspect, a portable rumble strip for placement on a
roadway in a roadway warning system includes filler material within a body of
the
rumble strip, the filler material being of a type and in an amount that
increases
the density of a rumble strip such that its mass can exert a pressure on the
roadway to withstand impact from a vehicle, such as a passenger vehicle or
heavy truck, without movement of the rumble strip relative to the roadway.
Embodiment(s) may include the foregoing aspect in combination with one
or more features of the foregoing aspect(s) or embodiment(s) separately or in
any suitable combination.
As used herein, the term "flexible" is used in its conventional meaning to
those having ordinary skill in the art, especially to those with ordinary
skill in the
art of polymeric and elastomeric compounding. Flexibility testing may be
achieved by a test method designed to test the resistance to crack growth of a
solid polymer, such as an elastomer (e.g., rubber), after repeated flexing. A
suitable test method is ASTM D813 (Crack Growth), which is usually measured
in the mm growth of a crack, with a lower growth number indicating a better
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resistance to cracking and increased flexibility. Another suitable test method
is
ASTM D1052 (Cut Growth Flexing), which gives an estimate of the ability of
rubber vulcanizates to resist crack growth of a pierced specimen when
subjected
to bend flexing. Yet another suitable test is ASTM D2632 which covers the
determination of impact resilience of solid rubber from measurement of the
vertical rebound of a dropped mass. Still another suitable test may be ASTM
1053 (Stiffness/Flexibility).
As used herein, an "operable connection," or a connection by which
entities are "operably connected," is one in which the entities are connected
in
such a way that the entities may perform as intended. An operable connection
may be a direct connection or an indirect connection in which an intermediate
entity or entities cooperate or otherwise are part of the connection or are in
between the operably connected entities. An operable connection or coupling
may include the entities being integral and unitary with each other.
It is to be understood that terms such as "top," "bottom," "upper," "lower,"
"left," "right," "front," "rear," "forward," "rearward," and the like as used
herein may
refer to an arbitrary frame of reference, rather than to the ordinary
gravitational
frame of reference.
It is to be understood that all ranges and ratio limits disclosed in the
specification and claims may be combined in any manner. It is to be understood
that unless specifically stated otherwise, references to "a," "an," and/or
"the" may
include one or more than one, and that reference to an item in the singular
may
also include the item in the plural.
The term "about" as used herein refers to any value which lies within the
range defined by a variation of up to 10% of the stated value, for example,
10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.01%, or
0.0% of the stated value, as well as values intervening such stated values.
The phrase "and/or" should be understood to mean "either or both' of the
elements so conjoined, i.e., elements that are conjunctively present in some
cases and disjunctively present in other cases. Other elements may optionally
be present other than the elements specifically identified by the "and/or"
clause,
whether related or unrelated to those elements specifically identified unless
clearly indicated to the contrary. Thus, as a non-limiting example, a
reference to
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"A and/or B," when used in conjunction with open-ended language such as
"comprising" can refer, in one embodiment, to A without B (optionally
including
elements other than B); in another embodiment, to B without A (optionally
including elements other than A); in yet another embodiment, to both A and B
(optionally including other elements); etc.
The word "or" should be understood to have the same meaning as
"and/or" as defined above. For example, when separating items in a list, "or"
or
"and/or" shall be interpreted as being inclusive, i.e., the inclusion of at
least one,
but also including more than one, of a number or list of elements, and,
optionally,
additional unlisted items. Only terms clearly indicated to the contrary, such
as
"only one of" or "exactly one of," may refer to the inclusion of exactly one
element of a number or list of elements. In general, the term "or" as used
herein
shall only be interpreted as indicating exclusive alternatives (i.e. "one or
the
other but not both") when preceded by terms of exclusivity, such as "one of,"
"only one of," or "exactly one of."
The transitional words or phrases, such as "comprising," "including,"
"carrying," "having," "containing," "involving," "holding," "incorporating,"
"made
of/with," "formed of/with," "fabricated of/with," and the like, are to be
understood
to be open-ended, i.e., to mean including but not limited to.
Although the invention has been shown and described with respect to a
certain embodiment or embodiments, it is obvious that equivalent alterations
and
modifications will occur to others skilled in the art upon the reading and
understanding of this specification and the annexed drawings. In particular
regard to the various functions performed by the above described elements
(components, assemblies, devices, compositions, etc.), the terms (including a
reference to a "means") used to describe such elements are intended to
correspond, unless otherwise indicated, to any element which performs the
specified function of the described element (i.e., that is functionally
equivalent),
even though not structurally equivalent to the disclosed structure which
performs
the function in the herein illustrated exemplary embodiment or embodiments of
the invention. In addition, while a particular feature of the invention may
have
been described above with respect to only one or more of several illustrated
embodiments, such feature may be combined with one or more other features of
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the other embodiments, as may be desired and advantageous for any given or
particular application.
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