U.S. patent application number 10/253541 was filed with the patent office on 2003-05-15 for road marker base with improved adherence and light transmission.
This patent application is currently assigned to Hallen Products, Ltd.. Invention is credited to Siblik, Allen D..
Application Number | 20030091388 10/253541 |
Document ID | / |
Family ID | 34636771 |
Filed Date | 2003-05-15 |
United States Patent
Application |
20030091388 |
Kind Code |
A1 |
Siblik, Allen D. |
May 15, 2003 |
Road marker base with improved adherence and light transmission
Abstract
A method of forming a road marker and the resulting road marker
including a metallic base and a light transmitter, includes coating
the metallic base with an oxidation inhibiting layer; and mounting
the light transmitter on the base. The coating may be performed
before the mounting. The coating may be a plating.
Inventors: |
Siblik, Allen D.;
(Wadsworth, IL) |
Correspondence
Address: |
Barnes & Thornburg
Suite 900
750 17th Street, N.W.
Washington
DC
20006
US
|
Assignee: |
Hallen Products, Ltd.
|
Family ID: |
34636771 |
Appl. No.: |
10/253541 |
Filed: |
September 25, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60326982 |
Oct 5, 2001 |
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Current U.S.
Class: |
404/13 |
Current CPC
Class: |
E01F 9/553 20160201 |
Class at
Publication: |
404/13 |
International
Class: |
E01F 009/06 |
Claims
What is claimed:
1. A road marker comprising: a metallic base for mounting on a
road; a light transmitter mounted on the base to reflect vehicle
lights traveling on the road; and an oxidation inhibiting coating
on the base.
2. A road marker according to claim 1, wherein the base comprises a
cast heat treated metal.
3. A road marker according to claim 1, wherein the base is
iron.
4. A road marker according to claim 1, wherein the base is
steel.
5. A road marker according to claim 1, wherein the base is
aluminum.
6. A road marker according to claim 1, wherein the coating is
plated on the base.
7. A road marker according to claim 6, wherein the coating is
zinc.
8. A road marker according to claim 1, wherein the coating is
zinc.
9. A road marker according to claim 6, wherein the coating is also
between the light transmitter and the base.
10. A method of forming a road marker including a metallic base and
a light transmitter, comprising: coating the metallic base with an
oxidation inhibiting layer; and mounting the light transmitter on
the base.
11. The method according to claim 10 wherein the coating is
performed before the mounting.
12. The method according to claim 10 wherein the coating is
performed by platting.
Description
CROSS-REFERENCE
[0001] The present application claims the benefit of U.S.
Provisional Application Ser. No. 60/326,982 filed Oct. 5, 2001,
which is incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates generally to road markers and
more specifically to a base for a road marker with improved
retained light transmission and securement in a recess of the
road.
[0003] Pavement road markers generally include a base and a light
source or reflector on the base. The base is mounted in a recess in
the road and held thereto, for example, by epoxy. The bases usually
include a reflector support surface and a series of locators or
buttons extending from the lateral edge thereof. The bottom surface
of the locators engages the top surface of the roadway to position
the reflector support surface at a given distance below the top
surface of the roadway. The locators are an integral part of the
base which is generally a cast of iron material. Such a road marker
is illustrated in U.S. Pat. No. 5,454,664 to Siblik.
[0004] One of the problems experienced by all road markers is that
they are damaged and/or ejected from the recess in the road surface
by continual forces applied by snowplow blades or other snow
removal equipment. Typically, the adhesive epoxy will secure the
base to a recess in the road and forms a stronger bond with the
base than it does with the road. Thus, they move as a unit and the
bond between the epoxy and the road is broken. Once this bond is
broken, further impact from snowplows or other snow removal devices
will eject the road marker from the recess in the roadway.
[0005] It has also been noticed that there are times that the epoxy
does not form a good bond with the base and therefore provides a
gap which is increased when forces are applied from a plow or other
sources.
[0006] Also, with the present design bases, water collects on the
base around the reflector creating what is known in the industry as
"ponding." Once the evaporation process begins, any residue
collects on all surfaces of the casting as well as the reflector.
The residue that dries along the portions of the reflector reduces
visibility or reflectivity and the functional performance of the
unit. The natural "tire wiping" action from the vehicles does
remove the upper portion of the residue, but cannot remove the
lower portion of the residue from the reflective lens. This residue
could represent up to 50% of the reflector surface.
[0007] The vast majority of snow plowable raised pavement markers
are made of iron heat treated to withstand the impact and abrasion
of the plows running over their surfaces. The heat treat process
performed does not protect the surfaces of the casting from
rusting. Reflectors are mounted in recessed areas to protect them
from damage but still allowing visibility once installed.
Immediately after installation, the complete outer surface of the
casting begins to rust (oxidize).
[0008] Any rust between the casting and epoxy used to install the
marker in the roadway will not allow the correct or necessary bond
between the casting and the epoxy. Even after installation, any
impact that would cause a "seal break" will allow the rust process
to begin and further contaminate the security of the bond.
[0009] The moisture collects in the casting up to the actual road
level. This moisture accelerates the rust process and once the
evaporation process begins, the residue from the rust collects on
all surfaces of the casting as well as the reflector. This is
another source of the reduced reflectivity.
[0010] The present invention recognizes that one of the sources of
both of these problems is rust or oxidation. A road marker of the
present invention includes a metallic base for mounting on a road
and a light transmitter mounted on the base to transmit light or
reflect vehicle lights traveling on the road. An oxidation
inhibiting coating is provided on the base. The base may be a cast
heat treated metal for example iron or steel or may be aluminum for
example.
[0011] The coating may be plated on the base. The coating may be
zinc. The coating may also be between the reflector and the
base.
[0012] A method of forming a road marker including a metallic base
and a light transmitter, includes coating the metallic base with an
oxidation inhibiting layer; and mounting the light transmitter on
the base. The coating is performed before the mounting. The coating
may be a plating.
[0013] These and other aspects of the present invention will become
apparent from the following detailed description of the invention,
when considered in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a top plan view of a base of a bidirectional road
marker.
[0015] FIG. 2 is a full cross sectional view taken substantially
along line II-II of FIG. 1 with a reflector shown in phantom.
[0016] FIG. 3 is a side elevational view of the base of FIG. 1 in
its installed position in a roadway.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The present invention reduces the source of both of the
problems by reducing the rusting of the base. All casting (for
example Iron or Steel) or any other material (for example aluminum)
that can oxidize or rust will be coated with a commercially
available "plating" or metal treatment. As an example, a 0.00015"
thick Clear Zinc plating is applied. Other rust proof coatings may
be used. Plating is preferred in that it will last longer. This
process will enhance the performance of the entire assembly and
reduce the problems. For non-snow plowable bases, any method of
coating can be used since they are only subject to wear from the
vehicle's tires.
[0018] Plating the raw casting, after heat treatment but before
assembly (with the reflector), will prevent the rust problem during
and after installation. Even a "seal break" condition will not
allow the rust process to begin. In addition, the plating under the
reflector pad will reduce the likelihood of premature separation
between the "butyl" pad which secures the reflector to the base and
the base coating.
[0019] Further, the plating on the top surfaces where the natural
"ponding" of water takes place will significantly slow the inherent
rust process and will only rust as the wear from tires or plow
blades causes the plating to be removed or as long as the plating
lasts. This, in turn, will have a beneficial effect on the
performance of the reflector or light transmitter. The normal
residue will not accumulate as fast or as much due to the areas not
contacted by tires or plow blades will last as long as the plating
can withstand the elements. With the reduced residue, the reflector
lens will perform "like new" which will translate into a
brighter/longer condition.
[0020] A base 16 for a road marker capable of carrying one or more
light sources or reflectors is illustrated in the FIGS. 1-3. Base
16 is but an example of a snow plowable road marker and other road
marks which would rust or oxidize could be used with the present
invention. These could include non-snow plowable road markers.
Whereas FIGS. 1-3 is a base designed for a bidirectional road
marker, a base designed for a unidirectional road marker may also
be used. The base includes a reflector support surface 18
surrounded by a moat 17. A pair of sloping vision ramps 20 extends
there from in the direction of travel T. The vision ramps 20
terminate in a downwardly expending surface 22, edge 23 and an
undercut surface 24.
[0021] The total surface of the base is coated with an oxidation
inhibiting coating C. Because the thickness of the coating or the
plating is so thin compared to the other dimensions of the marker
it is not shown in FIGS. 1-3, but is represented by the legend C.
As shown in FIG. 2, the coating C is also between the base 16 and
the reflector 70.
[0022] Laterally flanking the reflector support surface 18 and the
vision ramps 20 are side rail portions 26 of the base 16 having
matching generally accurate upward surfaces 28 which are radiused
downwardly at the opposite ends along the direction of travel and
cresting adjacent the reflector support surface 18. The surfaces 28
of the rail 26 are flanked along their upward sides by angular
downward and sloping side surfaces 30 which terminate at an edge
32.
[0023] The base 16 includes a plurality of protrusions 34 extending
horizontally there from in opposite directions and transverse to
the direction of travel T. The protrusions have a bottom surface 36
for engaging the top surface of a road adjacent a recess in the
road. The bottom surface also defines the height of the reflector
support surface 18 relative to the road top surface. FIG. 3
specifically shows a recess R having the base 16 therein with the
bottom surface 36 of the protrusions 34 resting on the road surface
S. The base 16 is held in the recess R by adhesives A.
[0024] The protrusions 34 are used only during the period of
installation wherein the protrusions 34 set the height of the
reflector support surface 18 relative to the road support surface
S. Once the adhesive A has hardened, they serve little other
purpose and generally have a negative affect during plowing. The
ends of sloping surfaces 28 of the rails 26 and the edge 23 of the
vision ramps 20 all terminate below the bottom or locating surface
36 of the protrusions 34 and consequently the road surface S. When
properly installed, the adhesive A also covers these edges. Thus,
the edges of the top surface do not offer easy targets for snowplow
plates or other movable objects which would create undesirable
forces breaking the seal between the base 16, the adhesive A and
the recess R. Also, the ends of the rails 26 and the vision ramps
20 are below the road surfaces and are encased in the adhesive A
and offer further resistance to movement along the direction of
travel T.
[0025] To further increase the resistance of the base 16 to
movement within the recess R, the bottom surface 52. The bottom
surface 52 includes various vertical protuberances. The first are
ribs 54 and the second are side webs 56.
[0026] Both vertical protuberances 54 and 56 offer resistance to
movement of the base 16 in the recess R as well as to disperse the
liquid adhesive up over the side surfaces 37 such that the edge 32
is completely encased by the adhesive. When properly designed, they
eliminate the need for caulking after the adhesive is set because
the adhesive did not appropriately spread past the edge 32 and onto
surface 30.
[0027] Preferably, a reflector 70 with a center post of metal 68 is
used, as illustrated in phantom in FIG. 2 on the support surface 18
extending up there from and transverse to direction of travel T.
The wall 68 at least has the height of the reflector. This provides
the protection as described in U.S. Pat. No. 4,454,664. A pad or
strip of butyl mastic are applied to the bottom portions of the
back wall of the bottom of the reflector 70. Such a mastic is
indicated as 72 in phantom.
[0028] A method of forming a road marker including a metallic base
16 and a reflector 70, includes coating the metallic base 16 with
an oxidation inhibiting layer C; and mounting the reflector 70 on
the base 16. The coating C is performed before the mounting. The
coating may be a plating.
[0029] As previously discussed, the water will collect on the face
of the reflector 70, fill in the moat 17 and totally up the ramps
20. By providing the coating C on the casting, it does not reduce
the amount of moisture being retained, but it significantly reduces
the rust or oxidation residue which, when evaporated, coats the
reflector surface 70. Also, the coating increases the adherence of
the reflector 70 to support 18 of the base 16 and the base 16 to
the adhesive A.
[0030] To illustrate the effectiveness of the present
anti-oxidation coating, test results of prior art, non-coated road
markers were compared against a test of coated road markers. Table
1 illustrates the results. The first three models in the column on
the left are available from Hallen Products, Ltd. of Gurnee, Ill.
Fifty markers each were installed on asphalt and concrete sections
of Interstate Route 270 in Ohio. The resulting percentage of
retained brightness is shown. The percentage of retained brightness
was obtained by measuring the reflectivity of the markers at two
periods in time and comparing the relative dirtiness. The ratio of
the two dirtiness readings provide the percentage of retained
brightness. The average is given at the bottom of the table. As
indicated in the table, all of the readings were taken for 178
days, with the first reading being Sep. 15, 2000, and the second
reading being on Mar. 16, 2001. Thus, a full winter period elapsed
between the two dates in which the readings were taken.
[0031] The right side of the table shows two other models available
from Hallen Products. They are aligned with their corresponding
model from the previous experiment. Even though they have somewhat
different product numbers, they use the same base and, thus, would
have the same pooling and road wear. In each of the columns for
asphalt and concrete, there are two readings provided. The averages
on the left are for 20 markers, and the averages on the right are
for 40 markers. The selection of the 20 markers represent the
markers that are measured with the same instrument. The averages
for the 40 markers are for all of the readings, even though they
may have been taken by two different instruments. The averages are
also shown for the coated markers. These were installed in
Maryland. The concrete was on Interstate I-97, and the asphalt was
on Maryland Route 100. The times of the various readings are
indicated in notes B, C, D and E. With respect to note E, there was
no meter reading available on one of the 40 markers and, therefore,
the average represents 39 markers.
1 TABLE 1 % Retained Brightness % Retained Brightness (A) Asphalt
Concrete Model Asphalt (50) Concrete (50) (20/40) (20/40) Model
H960 20 30 H1010HP 15 25.9 6643M1W 12.5 22.9 62.8 (B)/56.2 (B) 51.3
(D)/48.5 (D) 1W664 Morthstar 41 9.6 24.0 90.4 (C)/82.4 (C) 53.7
(D)/50.8 (E) H960HP AVERAGE: 14.3 25.7 76.6/69.3 52.5/40.6 Notes:
(A) Sep. 15, 2000 to Mar. 12, 2001 (178 days) (B) Oct. 17, 2001 to
Apr. 15, 2002 (189 days) (C) Nov. 13, 2001 to Apr. 15, 2002 (153
days) (D) Oct. 24, 2001 to Apr. 15, 2002 (182 days) (E) Oct. 24,
2001 to Apr. 15, 2002 (182 days); 39 markers
[0032] A review of the table will indicate that the coated road
markers in concrete showed twice the retained reflectivity from
that of the non-coated equivalent marker. This is true for the
individual markers, as well as for the averages. Also, for the
asphalt, the coated marker shows almost a 5 to 10 times
improvement. Although the comparison may not be exact, in that they
are different roads and the amount of moisture and traffic may be
different for each of the time periods taken, the results still
show a substantial increase in retained reflectivity, even if one
took into account a substantial variation in traffic and weather
conditions.
[0033] As used herein, a light transmitter is an element which
reflects external light or may be a light source itself. The
ability of the light source to transmit the light would also be
subject to reduction due to dirt on its outer surface. Thus, the
present invention would increase its transmission of light.
[0034] Although the present invention has been described and
illustrated in detail, it is to be clearly understood that this is
done by way of illustration and example only and is not to be taken
by way of limitation. The spirit and scope of the present invention
are to be limited only by the terms of the appended claims.
* * * * *