FIBERGLASS GUARD RAIL

Abstract

A guardrail system for use along a roadway. The guardrail system can include a longitudinal body that can be made from one or more plastics and have two or more longitudinal void spaces formed therein. At least one of the void spaces can be continuous from a first end of the body to a second end of the body. The system can also include a longitudinal member disposed within the continuous void space. The longitudinal member can be made from one or more metals to provide flexibility and strength to the guardrail.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/569,290, filed on Oct. 6, 2017, and to U.S. Provisional Patent Application No. 62/505,316, filed on May 12, 2017, which are both incorporated by reference herein.

BACKGROUND

Field

Embodiments described generally relate to guard rails. More particularly, such embodiments relate to highway guard rails.

Description of the Related Art

Guard rails are a safety barrier intended to shield a motorist who has left the roadway. Guard rails are typically made of galvanized beams that are designed to deflect or redirect a vehicle back to the roadway or slow the vehicle down to a complete stop.

SUMMARY

Guardrails and guardrail systems for use along a roadway are provided. In some examples, the guardrail system can include a longitudinal body that can be made from one or more plastics and have two or more longitudinal void spaces formed therein. At least one of the void spaces can be continuous from a first end of the body to a second end of the body. The system can also include a longitudinal member disposed within the continuous void space. The longitudinal member can be made from one or more metals to provide flexibility and strength to the guardrail.

In other examples, the guardrail system can include a first longitudinal body consisting essentially of one or more non-metallic materials. The first longitudinal body can have two or more longitudinal void spaces formed therein. The guardrail system can also include a second longitudinal body consisting essentially of one or more non-metallic materials. The second longitudinal body can have two or more longitudinal void spaces formed therein. The guardrail system can also include at least one substantially vertical post disposed between the first longitudinal body and the second longitudinal body. The guardrail system can also include a first longitudinal member disposed within any one of the longitudinal void spaces of the first longitudinal body and a second longitudinal member disposed within any one of the longitudinal void spaces of the second longitudinal body. The first and second longitudinal members can be flexible and made from one or more metals. The first and second longitudinal members can have a greater tensile strength than first and second longitudinal bodies. The guardrail system can also include a splicer disposed within the first and second longitudinal members that can be configured to connect to the at least one substantially vertical post, such that when a force is imparted on the longitudinal bodies, the longitudinal members transfer the load of the force through the splicer to the post.

In some examples, a guardrail for use along a roadway can include a longitudinal body made from fiber reinforced plastic. The longitudinal body can include at least two longitudinal void spaces formed within the body. The longitudinal void spaces can be non-concentric to each other and at least one longitudinal void space can have a cross section that is different from at least one other. The guard rail can also include a longitudinal member housed within any one of the longitudinal void spaces. The longitudinal member can be made from one or more metals to add flexibility and strength to the guardrail.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detailed description when read with the accompanying Figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 depicts a partial perspective view of an illustrative guardrail system, according to one or more embodiments described.

FIG. 2 depicts an illustrative cross-sectional view of a longitudinal body, according to one or more embodiments described.

FIG. 3 depicts an illustrative cross-sectional view of the guardrail system, according to one or more embodiments described.

FIG. 4 depicts a partial perspective view of the longitudinal body shown in FIG. 2, according to one or more embodiments described.

FIG. 5 depicts an illustrative schematic view of the longitudinal body secured to a post, according to one or more embodiments described.

FIG. 6 depicts another illustrative schematic view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 7 depicts another illustrative schematic view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 8 depicts a side perspective view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 9 depicts an elevation view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 10 depicts an elevation view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 11 depicts an elevation view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 12 depicts an elevation view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 13 depicts an elevation view of the longitudinal body secured to the post, according to one or more embodiments described.

FIG. 14 depicts a side view of the of the guardrail system, according to one or more embodiments described.

FIG. 15 depicts another side view of the guard rail system, according to one or more embodiments described.

FIG. 16 depicts a cross-sectional top view of the guardrail system, according to one or more embodiments described.

FIG. 17 depicts a partial perspective view of the guardrail system, according to one or more embodiments described.

FIG. 18 depicts a top view of the post, according to one or more embodiments described.

FIG. 19 depicts a bottom view of the post, according to one or more embodiments described.

FIG. 20 depicts a back view of the post, according to one or more embodiments described.

FIG. 21 depicts a side view of the post, according to one or more embodiments described.

FIG. 22 depicts a front view of the post, according to one or more embodiments described.

FIG. 23 depicts a perspective view of the post, according to one or more embodiments described.

FIG. 24 depicts a perspective view of a splicer, according to one or more embodiments described.

FIG. 25 depicts a side view of the splicer, according to one or more embodiments described.

FIG. 26 depicts an end view of the splicer, according to one or more embodiments described.

FIG. 27 depicts a perspective view of the splicer, according to one or more embodiments described.

FIG. 28 depicts a side view of the splicer, according to one or more embodiments described.

FIG. 29 depicts an end view of the splicer, according to one or more embodiments described.

FIG. 30 depicts a partial perspective view of another illustrative guardrail system, according to one or more embodiments described.

FIG. 31 depicts an illustrative end view of the guardrail system shown in FIG. 30 supported on a structural base, according to one or more embodiments described.

FIG. 32 depicts an illustrative perspective view of the post shown in FIGS. 30-31, according to one or more embodiments described.

FIG. 33 depicts an elevation end view of the post shown in FIGS. 30-32, according to one or more embodiments described.

FIG. 34 depicts an illustrative schematic view of a cable secured to the post shown in FIGS. 30-33, according to one or more embodiments described.

FIG. 35 depicts an illustrative schematic view of a beam using end plates to reinforce the cable shown in FIG. 34, according to one or more embodiments described.

FIG. 36 depicts an illustrative schematic view of the cable shown in FIG. 35 secured to the post, according to one or more embodiments described. The beam has been removed in this view to better illustrate the cable.

FIG. 37 depicts a side perspective view of the beam shown in FIG. 35 in connection with the post shown in FIGS. 31-34 and 36, according to one or more embodiments described.

FIG. 38 depicts an enlarged view of the cable shown in FIG. 37 secured to the post. The beam has been removed in this view to better illustrate the cable and retaining pins.

FIG. 39 depicts an enlarged interior view of the cable secured to the post as shown in FIGS. 34 and 36.

FIG. 40 depicts an elevation end view of the post depicted in FIGS. 30-32.

FIG. 41 depicts another side schematic view of the beam connected to the post shown in FIGS. 32 and 33, according to one or more embodiments described. This view shows the opposing side of the beam depicted in FIG. 37.

FIG. 42 depicts another side schematic view of the beam connected to the post shown in FIGS. 32 and 33, according to one or more embodiments described.

FIG. 43 depicts a schematic plan view of the guard rail system shown in FIGS. 30-42 in use along a roadway, according to one or more embodiments described.

FIG. 44 depicts a partial perspective view of another illustrative guardrail system, according to one or more embodiments described.

FIG. 45 depicts an illustrative end view of the guardrail system shown in FIG. 44 supported on a structural base, according to one or more embodiments described.

FIG. 46 depicts an illustrative perspective view of the post depicted in FIGS. 44 and 45, according to one or more embodiments described.

FIG. 47 depicts an elevation end view of the post shown in FIGS. 44-46, according to one or more embodiments described.

FIG. 48 depicts an illustrative schematic view of a cable secured to the post shown in FIGS. 44-47, according to one or more embodiments described.

FIG. 49 depicts another illustrative schematic view of a beam using end plates to reinforce the cable shown in FIG. 48, according to one or more embodiments described.

FIG. 50 depicts an illustrative schematic view of the cable shown in FIG. 48 secured to the post, according to one or more embodiments described. The beam has been removed in this view to better illustrate the cable.

FIG. 51 depicts a side perspective view of the beam shown in FIG. 49 in connection with the post, according to one or more embodiments described.

FIG. 52 depicts an enlarged view of the cable depicted in FIG. 48 secured to the post.

FIG. 53 depicts an enlarged interior view of the cable secured to the post as shown in FIG. 50.

FIG. 54 depicts an elevation end view of the post depicted in FIGS. 44-46.

FIG. 55 depicts another side schematic view of the beam, according to one or more embodiments described. This view shows the opposing side of the beam depicted in FIG. 51.

FIG. 56 depicts another side schematic view of the beam connected to the post, according to one or more embodiments described.

FIG. 57 depicts a schematic plan view of the guard rail system depicted in FIGS. 44-56 in use along a roadway, according to one or more embodiments described.

DETAILED DESCRIPTION

It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.

Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein.

The terms “up” and “down”; “upward” and “downward”; “upper” and “lower”; “upwardly” and “downwardly”; “above” and “below”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular spatial orientation since the apparatus and methods of using the same may be equally effective at various angles or orientations.

Further, the terms “guardrail” or “guardrails” and “barrier” or “barriers” may be used throughout this application to include any type of guardrail and/or barrier which may be formed at least in part using cables, guardrails and support posts incorporating teachings of the present invention. The term “road” or “roadway” may be used throughout this application to include any highway, roadway or path satisfactory for vehicle traffic. Guardrails and barriers incorporating teachings of the present invention may be installed in median strips or along shoulders of highways, roadways or any other path which is likely to encounter vehicular traffic.

FIG. 1 depicts a partial perspective view of an illustrative guardrail system 1100, according to one or more embodiments. The guardrail system 1100 can include a post 1200, and one or more longitudinal bodies or rails 1300, 1302. As also seen in FIGS. 21-23, the post 1200 can have one or more channels 1210, 1212. In some examples, the channels 1210, 1212 can be cutouts. In other examples, the channels 1210, 1212 can be molded, stamped, or otherwise formed in the post 1200. The channels 1210, 1212 can be C-shaped, U-shaped, V-shaped, or any other shape capable of receiving the longitudinal bodies 1300, 1302, respectively, within or at least partially within the channels 1210, 1212, respectively. The entire cross-section of the longitudinal bodies 1300, 1302 can nest or otherwise be located within the channels 1210, 1212 or a portion of the cross-section of the longitudinal bodies 1300, 1302 can overhang an edge of the channels 1210, 1212. In some examples, the channels 1210, 1212 can be entirely disposed within the post 1200. Channels 1210, 1212 entirely disposed with the post 1200 can be cylindrical, rectangular cuboid, triangular prism, square cuboid or any other shape capable of receiving the longitudinal bodies 1300, 1302 within or at least partially therein. In some examples, the number of channels 1210, 1212 can match the number of longitudinal bodies 1300, 1302. There can be 1, 2, 3, 4 or more channels and longitudinal bodies. The channels 1210, 1212 can have holes 1202, 1204, 1206 in a top of the channels and holes 1207, 1208, 1209 in a bottom of the channels. The post 1200 can be fabricated from any number of materials including, aluminum, steel, stainless steel, iron, and blends or alloys thereof, as well as other non-metallic materials including wood, carbon fiber, fiberglass or other engineered resins.

The post 1200 can be secured to a supportive base on the roadway (not pictured) in a multitude of ways. In one example, bolts 1230, 1231, 1232, 1233 or other mechanical fastener can be drilled, inserted, or otherwise disposed through holes 1240, 1241, 1242, 1243, respectively in the post 1200 and the supportive base. In another example, the post 1200 can be secured in the ground itself, without the need for the base, using concrete footings, tension anchors and cabling, or other means well-known to those skilled in the art.

FIG. 2 depicts an illustrative cross-sectional view of the longitudinal body 1300. FIG. 3 depicts a cross-sectional view of the guardrail system 1100. FIG. 4 depicts an illustrative view of the longitudinal body 1300. The longitudinal bodies 1300, 1302 can contain one or more longitudinal void spaces or longitudinal voids (two are shown 1310, 1320). The longitudinal voids 1310, 1320 can be cylindrical, rectangular cuboid, triangular prism, square cuboid or any other three-dimensional shape that runs along the entire length of the longitudinal bodies 1300, 1302. In some examples, the longitudinal voids 1310, 1320 can be co-linear and aligned in a cross-wise dimension of the longitudinal body 1300. In some examples, each longitudinal void can be encapsulated and separated from one another by the longitudinal body 1300. In some examples, the longitudinal void 1320 can be configured to collapse should the guardrail 1100 be impacted by a vehicle, a boulder, or other moving object.

In some examples, at least one longitudinal void space, e.g., longitudinal void space 1310, can have a cross section that is different from at least one other longitudinal void space, e.g., longitudinal void space 1320. For example, as shown in FIG. 2, the longitudinal void space 1310 has a circular cross-section, whereas the longitudinal void space 1320 has a rectangular cross section. In addition to or in lieu of having different cross-sectional shapes, the cross section of at least one longitudinal void space can have a different average cross-sectional length. For example, both longitudinal void spaces 1310, 1320 can have a generally circular cross section or a generally rectangular cross section, but an average cross-sectional length of the longitudinal void space 1310 can be greater than or less than the average cross-sectional length of the longitudinal void space 1320.

In some examples, the ends of the longitudinal voids 1310, 1320 can be accessible, i.e., open, at the ends of the longitudinal bodies 1300, 1302. In other examples, the ends of the longitudinal voids 1310, 1320 can be inaccessible, i.e., plugged, sealed, or otherwise closed off, at the ends of the longitudinal bodies 1300, 1302. Closing off the ends of the longitudinal voids 1310, 1320 can reduce or prevent water, snow, dirt, or other debris from entering into the longitudinal voids 1310, 1320. In some examples, the ends of the longitudinal bodies 1300, 1320 can be a solid wall with the longitudinal voids 1310, 1320 terminating at an inner surface of the solid end walls of the longitudinal bodies 1300, 1302.

In some examples, one or more of the longitudinal voids 1310, 1320 can contain a filler material. For example, the longitudinal voids 1310, 1320 can be at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95% or at least 99% filled with filler material. The filler material can be or include, but is not limited to a foam, an epoxy, fiberglass, a plastic, or any combination or mixture thereof. The foam can be quantum foam, polyurethane foam (foam rubber), XPS foam, polystyrene, expanded polystyrene (EPS), phenolic, or many other manufactured foam or any combination thereof. In other examples, the filler material can be or include, but is not limited to, one or more gels or other semi-solid/semi-liquid materials. In some examples, the filler material can be a viscoelastic material.

In some examples, one or more of the longitudinal voids 1310, 1320 can be empty of any solid material. For example, in some embodiments one or more of the longitudinal voids 1310, 1320 can be free from any filler material or other material with a volume of the longitudinal voids 1310, 1320 occupied by air or other gas or other mixture of gases.

The longitudinal bodies 1300, 1302 can be made from one or more fiber reinforced plastics, such as one or more fiberglass composites. Any suitable material, however, can be used to fabricate the longitudinal bodies 1300, 1302. For example, suitable materials can include, but are not limited to, any one or more metals (such as aluminum, steel, stainless steel, brass, nickel), wood, other composite materials (such as ceramics, wood/polymer blends, cloth/polymer blends, etc.), and plastics (such as polyethylene, polypropylene, polystyrene, polyurethane, polyethylethylketone (PEEK), polytetrafluoroethylene (PTFE), polyamide resins (such as nylon 6 (N6), nylon 66 (N66)), polyester resins (such as polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer), polynitrile resins (such as polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers, methacrylonitrile-styrene-butadiene copolymers, acrylonitrile-butadiene-styrene (ABS), polymethacrylate resins (such as polymethyl methacrylate and polyethylacrylate), cellulose resins (such as cellulose acetate and cellulose acetate butyrate), polyimide resins (such as aromatic polyimides), polycarbonates (PC), elastomers (such as ethylene-propylene rubber (EPR), ethylene propylene-diene monomer rubber (EPDM), styrenic block copolymers (SBC), polyisobutylene (PIB), butyl rubber, neoprene rubber, halobutyl rubber and the like), and mixtures, blends, or copolymers of any and all of the foregoing materials.

The longitudinal bodies 1300, 1302 can be non-corrosive. As such, the longitudinal bodies 1300, 1302 can be maintenance free from a corrosion standpoint. The longitudinal bodies 1300, 1302 can be non-electrically conductive and non-sparking when hit by steel or other ferrous materials. The longitudinal bodies 1300, 1302, if struck by lightning or shorted out from power lines won't conduct electricity. The longitudinal bodies 1300, 1302 can be non-combustible. The longitudinal bodies 1300, 1302 can be manufactured in any desired color, e.g., yellow, red, green, blue, orange, or white, or even camouflaged to blend in with the surrounding environment.

The longitudinal bodies 1300, 1302 can have an ultimate lengthwise tensile strength that is less than 90,000 psi, less than 80,000 psi, less than 70,000 psi, less than 60,000 psi, less than 50,000 psi, less than 40,000 psi, less than 35,000 psi, less than 30,000 psi, less than 25,000 psi, less than 20,000 psi, less than 15,000 psi, less than 10,000 psi. The longitudinal bodies 300, 302 can have an ultimate lengthwise tensile strength that is between 5,000 psi and 90,000 psi, between 5,000 psi an 80,000 psi, between 5,000 psi and 70,000 psi, between 5,000 psi and 60,000 psi, between 5,000 psi and 50,000 psi, between 5,000 psi and 40,000 psi, between 5,000 psi and 30,000 psi, between 5,000 psi and 20,000 psi, between 10,000 and 90,000 psi, between 10,000 psi an 80,000 psi, between 10,000 psi and 70,000 psi, between 10,000 psi and 60,000 psi, between 10,000 psi and 50,000 psi, between 10,000 psi and 40,000 psi, between 10,000 psi and 30,000 psi, between 10,000 psi and 20,000 psi.

The longitudinal bodies 1300, 1302 can have an ultimate crosswise tensile strength that is less than 90,000 psi, less than 80,000 psi, less than 70,000 psi, less than 60,000 psi, less than 50,000 psi, less than 40,000 psi, less than 35,000 psi, less than 30,000 psi, less than 25,000 psi, less than 20,000 psi, less than 15,000 psi, less than 10,000 psi, or less than 5,000 psi. The longitudinal bodies 1300, 1302 can have an ultimate crosswise tensile strength that is between 5,000 psi and 90,000 psi, between 5,000 psi an 80,000 psi, between 5,000 psi and 70,000 psi, between 5,000 psi and 60,000 psi, between 5,000 psi and 50,000 psi, between 5,000 psi and 40,000 psi, between 5,000 psi and 30,000 psi, between 5,000 psi and 20,000 psi, between 10,000 and 90,000 psi, between 10,000 psi an 80,000 psi, between 10,000 psi and 70,000 psi, between 10,000 psi and 60,000 psi, between 10,000 psi and 50,000 psi, between 10,000 psi and 40,000 psi, between 10,000 psi and 30,000 psi, between 10,000 psi and 20,000 psi.

The longitudinal bodies 1300, 1302 can have a lengthwise flexural strength that is less than 90,000 psi, less than 80,000 psi, less than 70,000 psi, less than 60,000 psi, less than 50,000 psi, less than 40,000 psi, less than 35,000 psi, less than 30,000 psi, less than 25,000 psi, less than 20,000 psi, less than 15,000 psi, less than 10,000 psi. The longitudinal bodies 1300, 1302 can have a lengthwise flexural strength that is between 5,000 psi and 90,000 psi, between 5,000 psi an 80,000 psi, between 5,000 psi and 70,000 psi, between 5,000 psi and 60,000 psi, between 5,000 psi and 50,000 psi, between 5,000 psi and 40,000 psi, between 5,000 psi and 30,000 psi, between 5,000 psi and 20,000 psi, between 10,000 and 90,000 psi, between 10,000 psi an 80,000 psi, between 10,000 psi and 70,000 psi, between 10,000 psi and 60,000 psi, between 10,000 psi and 50,000 psi, between 10,000 psi and 40,000 psi, between 10,000 psi and 30,000 psi, between 10,000 psi and 20,000 psi.

The longitudinal bodies 1300, 1302 can have a crosswise flexural strength that is less than 90,000 psi, less than 80,000 psi, less than 70,000 psi, less than 60,000 psi, less than 50,000 psi, less than 40,000 psi, less than 35,000 psi, less than 30,000 psi, less than 25,000 psi, less than 20,000 psi, less than 15,000 psi, less than 10,000 psi, or less than 5,000 psi. The longitudinal bodies 1300, 1302 can have a crosswise flexural strength that is between 5,000 psi and 90,000 psi, between 5,000 psi an 80,000 psi, between 5,000 psi and 70,000 psi, between 5,000 psi and 60,000 psi, between 5,000 psi and 50,000 psi, between 5,000 psi and 40,000 psi, between 5,000 psi and 30,000 psi, between 5,000 psi and 20,000 psi, between 10,000 and 90,000 psi, between 10,000 psi an 80,000 psi, between 10,000 psi and 70,000 psi, between 10,000 psi and 60,000 psi, between 10,000 psi and 50,000 psi, between 10,000 psi and 40,000 psi, between 10,000 psi and 30,000 psi, or between 10,000 psi and 20,000 psi.

The longitudinal bodies 1300, 1302 can have a lengthwise yield strength that is less than 90,000 psi, less than 80,000 psi, less than 70,000 psi, less than 60,000 psi, less than 50,000 psi, less than 40,000 psi, less than 35,000 psi, less than 30,000 psi, less than 25,000 psi, less than 20,000 psi, less than 15,000 psi, less than 10,000 psi. The longitudinal bodies 1300, 1302 can have a lengthwise yield strength that is between 5,000 psi and 90,000 psi, between 5,000 psi an 80,000 psi, between 5,000 psi and 70,000 psi, between 5,000 psi and 60,000 psi, between 5,000 psi and 50,000 psi, between 5,000 psi and 40,000 psi, between 5,000 psi and 30,000 psi, between 5,000 psi and 20,000 psi, between 10,000 and 90,000 psi, between 10,000 psi an 80,000 psi, between 10,000 psi and 70,000 psi, between 10,000 psi and 60,000 psi, between 10,000 psi and 50,000 psi, between 10,000 psi and 40,000 psi, between 10,000 psi and 30,000 psi, between 10,000 psi and 20,000 psi.

The longitudinal bodies 1300, 1302 can have a crosswise yield strength that is less than 90,000 psi, less than 80,000 psi, less than 70,000 psi, less than 60,000 psi, less than 50,000 psi, less than 40,000 psi, less than 35,000 psi, less than 30,000 psi, less than 25,000 psi, less than 20,000 psi, less than 15,000 psi, less than 10,000 psi, or less than 5,000 psi. The longitudinal bodies 1300, 1302 can have an crosswise yield strength that is between 5,000 psi and 90,000 psi, between 5,000 psi an 80,000 psi, between 5,000 psi and 70,000 psi, between 5,000 psi and 60,000 psi, between 5,000 psi and 50,000 psi, between 5,000 psi and 40,000 psi, between 5,000 psi and 30,000 psi, between 5,000 psi and 20,000 psi, between 10,000 and 90,000 psi, between 10,000 psi an 80,000 psi, between 10,000 psi and 70,000 psi, between 10,000 psi and 60,000 psi, between 10,000 psi and 50,000 psi, between 10,000 psi and 40,000 psi, between 10,000 psi and 30,000 psi, between 10,000 psi and 20,000 psi.

Several ASTM standards are available to provide guidance on performing tensile tests and the correct test is easily ascertainable by one skilled in art depending on the material being tested. Three of the most common standards are ASTM E8 for metallic materials, ASTM D3039 for polymer matrix composite materials and ASTM D638 for unreinforced and reinforced plastics. Although there can be many variations on the standard tensile test, a tensile test most often involves loading a test specimen in a universal testing machine and applying an increasing uniaxial load to the specimen until failure occurs. The sample can be supported in the test frame any number of ways: hydraulic grips, mechanically fastened clevis grips or threaded grips. The method of gripping most often depends on the material being tested, its geometry and the capabilities of the test frame.

The guardrail system 1100 can also include one or more longitudinal members (two are shown 1400, 1402). The longitudinal members 1400, 1402 can be disposed within any of the longitudinal void spaces 1310, 1312, 1320, 1322. In addition to being referred to as a longitudinal member, the longitudinal members 1400, 1402 can also be referred to as a metallic structural member, a flexible longitudinal member, or a rod. In some examples, the longitudinal member, e.g., longitudinal member 1400, can be disposed within a longitudinal void space, e.g., longitudinal void space 1300, in an unsecured configuration. In other examples, the longitudinal member, e.g., longitudinal member 1400, can be disposed within a longitudinal void space, e.g., longitudinal void space 1300, in a secured configuration. For example, an exterior surface of the longitudinal member, e.g., longitudinal member 1400, adhered to an inner surface of the longitudinal void space, e.g., longitudinal void space 1300. In some examples, the exterior surface of the longitudinal member, e.g., longitudinal member 1400, can be adhered to the inner surface of the longitudinal void space, e.g., longitudinal void space 1300, during a pultrusion process that can be used to manufacture the guardrail system 1100. In some examples, the exterior surface of the longitudinal member, e.g., longitudinal member 1400, can be adhered to the inner surface of the longitudinal void space, e.g., longitudinal void space 1300, with one or more adhesives.

The longitudinal members 1400, 1402 can have a crosswise ultimate tensile strength that is at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 100% greater than the crosswise ultimate tensile strength of the longitudinal bodies 1300, 1302. The longitudinal members 1400, 1402 can have a lengthwise ultimate tensile strength that is at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 100% greater than the lengthwise ultimate tensile strength of the longitudinal bodies 1300, 1302. The longitudinal members 1400, 1402 can have a crosswise yield strength that is at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 100% greater than the crosswise yield strength of the longitudinal bodies 1300, 1302. The longitudinal members 1400, 1402 can have a lengthwise yield strength that is at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 100% greater than the lengthwise yield strength of the longitudinal bodies 1300, 1302.

The longitudinal members 1400, 1402 can have an ultimate lengthwise tensile strength that is greater than 10,000 psi, greater than 20,000 psi, greater than 25,000 psi, greater than 30,000 psi, greater than 35,000 psi, greater than 40,000 psi, greater than 45,000 psi, greater than 50,000 psi, greater than 55,000 psi, greater than 65,000 psi, greater than 75,000 psi, or greater than 80,000 psi. The longitudinal members 1400, 1402 can have an ultimate lengthwise tensile strength that is between 10,000 psi and 90,000 psi, between 15,000 psi an 80,000 psi, between 20,000 psi and 70,000 psi, between 25,000 psi and 60,000 psi, between 25,000 psi and 70,000 psi, between 25,000 psi and 80,000 psi, between 30,000 psi and 50,000 psi, or between 30,000 psi and 60,000 psi.

The longitudinal members 1400, 1402 can have an ultimate crosswise tensile strength that is greater than 10,000 psi, greater than 20,000 psi, greater than 25,000 psi, greater than 30,000 psi, greater than 35,000 psi, greater than 40,000 psi, greater than 45,000 psi, greater than 50,000 psi, greater than 55,000 psi, greater than 65,000 psi, greater than 75,000 psi, or greater than 80,000 psi. The longitudinal members 1400, 1402 can have an ultimate crosswise tensile strength that is between 10,000 psi and 90,000 psi, between 15,000 psi an 80,000 psi, between 20,000 psi and 70,000 psi, between 25,000 psi and 60,000 psi, between 25,000 psi and 70,000 psi, between 25,000 psi and 80,000 psi, between 30,000 psi and 50,000 psi, or between 30,000 psi and 60,000 psi.

The longitudinal members 1400, 1402 can have a lengthwise flexural strength that is greater than 10,000 psi, greater than 20,000 psi, greater than 25,000 psi, greater than 30,000 psi, greater than 35,000 psi, greater than 40,000 psi, greater than 45,000 psi, greater than 50,000 psi, greater than 55,000 psi, greater than 65,000 psi, greater than 75,000 psi, or greater than 80,000 psi. The longitudinal members 1400, 1402 can have a lengthwise flexural strength that is between 10,000 psi and 90,000 psi, between 15,000 psi an 80,000 psi, between 20,000 psi and 70,000 psi, between 25,000 psi and 60,000 psi, between 25,000 psi and 70,000 psi, between 25,000 psi and 80,000 psi, between 30,000 psi and 50,000 psi, or between 30,000 psi and 60,000 psi.

The longitudinal members 1400, 1402 can have a crosswise flexural strength that is greater than 10,000 psi, greater than 20,000 psi, greater than 25,000 psi, greater than 30,000 psi, greater than 35,000 psi, greater than 40,000 psi, greater than 45,000 psi, greater than 50,000 psi, greater than 55,000 psi, greater than 65,000 psi, greater than 75,000 psi, or greater than 80,000 psi. The longitudinal members 1400, 1402 can have a crosswise flexural strength that is between 10,000 psi and 90,000 psi, between 15,000 psi an 80,000 psi, between 20,000 psi and 70,000 psi, between 25,000 psi and 60,000 psi, between 25,000 psi and 70,000 psi, between 25,000 psi and 80,000 psi, between 30,000 psi and 50,000 psi, or between 30,000 psi and 60,000 psi.

The longitudinal members 1400, 1402 can have a lengthwise yield strength that is greater than 10,000 psi, greater than 20,000 psi, greater than 25,000 psi, greater than 30,000 psi, greater than 35,000 psi, greater than 40,000 psi, greater than 45,000 psi, greater than 50,000 psi, greater than 55,000 psi, greater than 65,000 psi, greater than 75,000 psi, or greater than 80,000 psi. The longitudinal members 1400, 1402 can have a lengthwise yield strength that is between 10,000 psi and 90,000 psi, between 15,000 psi an 80,000 psi, between 20,000 psi and 70,000 psi, between 25,000 psi and 60,000 psi, between 25,000 psi and 70,000 psi, between 25,000 psi and 80,000 psi, between 30,000 psi and 50,000 psi, or between 30,000 psi and 60,000 psi.

The longitudinal members 1400, 1402 can have a crosswise yield strength that is greater than 10,000 psi, greater than 20,000 psi, greater than 25,000 psi, greater than 30,000 psi, greater than 35,000 psi, greater than 40,000 psi, greater than 45,000 psi, greater than 50,000 psi, greater than 55,000 psi, greater than 65,000 psi, greater than 75,000 psi, or greater than 80,000 psi. The longitudinal members 1400, 1402 can have a crosswise yield strength that is between 10,000 psi and 90,000 psi, between 15,000 psi an 80,000 psi, between 20,000 psi and 70,000 psi, between 25,000 psi and 60,000 psi, between 25,000 psi and 70,000 psi, between 25,000 psi and 80,000 psi, between 30,000 psi and 50,000 psi, or between 30,000 psi and 60,000 psi.

The longitudinal members 1400, 1402 can be made from one or more metals, non-metallic materials, or any combination thereof. Illustrative metals can be or include, but are not limited to, iron, aluminum, copper, steel, stainless steel, titanium, galvanized steel, or any alloy or combination thereof. In some examples, the longitudinal members 1400, 1402 can be made from a 316 species of stainless steel. Any suitable material, however, can be used to fabricate the longitudinal members 1400, 1402. For example, suitable materials can include, but are not limited to, fiber reinforced plastics, any one or more metals (such as aluminum, steel, stainless steel, brass, nickel), wood, other composite materials (such as ceramics, wood/polymer blends, cloth/polymer blends, etc.), and plastics (such as polyethylene, polypropylene, polystyrene, polyurethane, polyethylethylketone (PEEK), polytetrafluoroethylene (PTFE), polyamide resins (such as nylon 6 (N6), nylon 66 (N66)), polyester resins (such as polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer) polynitrile resins (such as polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers, methacrylonitrile-styrene-butadiene copolymers; and acrylonitrile-butadiene-styrene (ABS)), polymethacrylate resins (such as polymethyl methacrylate and polyethylacrylate), cellulose resins (such as cellulose acetate and cellulose acetate butyrate); polyimide resins (such as aromatic polyimides), polycarbonates (PC), elastomers (such as ethylene-propylene rubber (EPR), ethylene propylene-diene monomer rubber (EPDM), styrenic block copolymers (SBC), polyisobutylene (PIB), butyl rubber, neoprene rubber, halobutyl rubber and the like)), and mixtures, blends, or copolymers of any and all of the foregoing materials. In some examples, the longitudinal members can be made from one or more generally high strength materials such as composite fibers, KEVLAR®, or the like. In some examples, the longitudinal members 1400, 1402 can be solid. In some examples, the longitudinal members 1400, 1402 can be hollow.

The longitudinal members 1400, 1402 can provide flexibility and/or strength to the guardrail 1100. For example, the longitudinal members 1400, 1402 can be made from one or more metals and can provide flexibility and strength to the guardrail 1100. In some examples, the longitudinal members 1400, 1402 can have a greater tensile strength than the longitudinal bodies 1300, 1302. In other examples, the longitudinal members 1400, 1402 can be made from one or more metals, have a greater tensile strength than the longitudinal bodies 1300, 1302, and provide flexibility and strength to the guardrail 1100. In some examples, guardrail system 1100, if impacted by a vehicle, boulder, or other moving object, can spread the impact energy amongst several adjacent posts, thus reducing or eliminating local failure due to concentrated energy loads. The guardrail system 1100 can meet the energy absorption requirements of the Federal MASH TL4 crash test.

The guardrail system 1100 can be non-corrosive. As such, the guardrail system 1100 can be maintenance free from a corrosion standpoint. The guardrail system 1100 can be non-electrically conductive and non-sparking when hit by steel or other ferrous materials. In some examples, the guardrail system 1100, if struck by lightning or shorted out from power lines won't conduct electricity. The guardrail system 100 can be non-combustible. The guardrail system 1100 can be manufactured in any desired color, e.g., yellow, red, green, blue, orange, or white, or even camouflaged to blend in with the surrounding environment.

FIGS. 5-17 illustrate some of the mechanisms for securing adjacent longitudinal bodies 1300, 1302, 1304, 1306 containing longitudinal members 1400, 1402, 1404, 1406 disposed within the longitudinal voids of the longitudinal bodies 1300, 1302, 1304, 1306 to the post 1200, according to one or more embodiments provided herein. FIGS. 5-17 illustrate some of the mechanisms for securing splicers or splice tubes or splice sleeves 1500, 1502 to the post 1200. In some examples, the longitudinal bodies 1300, 1302, 1404, 1306 can be secured to the post 1200 at the post channels 1210, 1212 using one or more fasteners 1220, 1222. The fasteners 1220, 1222 can be sized and shaped to fit within holes formed through the top and bottom of the channels 1210, 1212, and corresponding holes formed through the top and bottom of the longitudinal bodies 1300, 1302. The cross-sectional shape of the fasteners and holes described within the application are preferably round, but can be any non-round shape such as elliptical, oval, triangular, square, or other polygonal shape so as to prevent relative rotation. The elliptical holes can make it easier to align the components.

It should be appreciated, however, that securing the longitudinal bodies 1300, 1302, 1304, 1306 to the post 1200, the longitudinal members 1400, 1402, 1404, 1406, or the splicers 1500, 1502 can be achieved using other fasteners and techniques, such as a rivet, nut and bolt, or the like. Additionally, the longitudinal members 1400, 1402, 1404, 1406 that can be disposed within the longitudinal voids 1310, 1320 can be attached to the longitudinal bodies 1300, 1302, 1304, 1306 and post 1200 using fasteners 1220, 1222 by aligning the holes in the longitudinal members 1400, 1402, 1404, 1406 with the holes 1202, 1204, 1206, 1207, 1208, 1209 formed through the channels 1210, 1220 and the holes in the longitudinal bodies 1300, 1302, 1304, 1306.

FIGS. 5-17 also illustrate mechanisms for adjoining two adjacent rail sections 1300, 1302, 1304, 1306. Two adjacent rail sections 1602, 1604, the first rail section 1602 including the longitudinal bodies 1300 and 1302, the second rail section 1604 including the longitudinal bodies 1304, 1306 can be secured at a post 1200. At least one of the rail sections 1602, 1604 can be secured to the post 1200 as discussed and described above. The second rail section 1604 can also be secured to the post 1200 using a second fastener (not shown) through a second set of holes 1206 in the same post channel. The second rail section 1604 can either be adjacent to the first rail section 1602, contacting the first rail section 1602, or be tapered such that it can be partially disposed within disposed within the longitudinal bodies 1302, 1304 of the first rail section 1602. In the case where the second rail section 1604 is partially disposed within the first rail section 1602, both rail sections can be attached to the post 1200 using the same fastener.

FIGS. 5-17 also illustrate mechanisms for adjoining a first rod section 1606 that can include the longitudinal members 1400, 1402 with an adjacent second rod section 1608 that can include the longitudinal members 1404, 1406. The two adjacent rod sections 1606 and 1608 can be secured using splicers 1500, 1502. The splicers 1500, 1502 are further illustrated in FIGS. 24-29. The number of splicers 1500, 1502 can match the number of longitudinal voids 1310, 1320. There can be 1, 2, 3, 4 or more splicers 1500, 1502 and 1, 2, 3, 4 or more longitudinal voids 1310, 1320. The splicers 1500, 1502 can slide over both adjacent rod sections 1606, 1608. For example, splicer 1500 can slide over adjacent longitudinal members 1400 and 1404 of the first and second rod sections 1606, 1608, respectively, and splicer 1502 can slide over adjacent longitudinal members 1402 and 1406 of the first and second rod sections 1606, 1608, respectively.

Additionally, when the longitudinal members 1400, 1402, 1404, 1406 of the first and second rod sections 1606, 1608 are hollow, the splicers 1500, 1502 can be disposed within one or both adjacent longitudinal members 1400, 1402, 1404, 1406. The splicers 1500, 1502 can have holes 1504, 1506 that can be aligned with the holes 1202, 1204, 1206 in the post 1200 and the holes in one or both rail sections 1606, 1608 to secure the splicer 1500, 1502 to the post 1200 using the fasteners as outlined above. The splicers 1500, 1502 can additionally contain adhesive on the side of the splicer 1500, 1502 that comes into contact with the longitudinal members 1400, 1402, 1404, 1406 to better secure the splicer 1500, 1502 to the longitudinal members 1400, 1402, 1404, 1406 in the first and second rod sections 1606, 1608.

Additionally, the splicer 1500, 1502 can be secured to just the rod sections 1606, 1608 or to the rail sections 1602, 1604 and the rod sections 1606, 1608 as outlined above without being fastened to the post 1200. The splicer 1500, 1502 can be cylindrical, rectangular cuboid, triangular prism, square cuboid or any other shape capable of fitting into longitudinal voids 1310, 1320. The splicers 1500, 1502 can be tapered, at the ends or anywhere along the length of the splicer. The splicer 1500, 1502 can be can be made from any of the materials described herein. If there are more than one splicer 1500, 1502, the splicers 1500, 1502 can be made out of more than one material. For example, a first splicer 1500 can be stainless steel and a second splicer 1502 can be fiber reinforced plastic. The rod sections 1606, 1608 themselves can additionally be secured at post 1200. At least one of the longitudinal members 1400, 1402, 1404, 1406 in the first and second rod sections 1606, 1608 can have one or more holes to secure the rod sections 1606, 1608 to the post 1200 and rail sections 1602, 1604 as illustrated above using fasteners.

In some examples, the splicers 1500, 1502 can be made of a 316 species of stainless steel, which can reduce or avoid any corrosion issues that generally arise over time when using conventional steel splices. In some examples, the splicers 1500, 1502 can be made of a fiber reinforced plastic, which can reduce or avoid any corrosion issue that generally arise over time when using conventional steel splices. In some examples, the splicers 1500, 1502 can be a cylindrical tube made of a 316 species of stainless steel. In other examples, the splicers 1500, 1502 can be a rectangular or square cuboid made of a fiber reinforced plastic.

The longitudinal members 1400, 1402, 1404, 1406 of the first and second rod sections 1606, 1608 can additionally be secured to the splicer 1500, 1502 by passing the fasteners 1220, 1222 through holes 1202, 1204, 1206, 1207, 1208, 1209 in the post 1200, holes in the longitudinal bodies 1300, 1302, 1304, 1306, holes in the longitudinal members 1400, 1402, 1404, 1406, and holes 1504, 1506 in the splicers 1500, 1502. The second rod section 1608 can also be secured to the post 1200 using a second fastener (not shown) through a second set of holes 1206, 1209 in the same post channel 1210 and holes in the second rail section 1304, 1306 and corresponding holes in the second rod section 1608. The second rod section 1608 can either be adjacent to the first rod section 1606, contacting the first rod section 1606, or tapered such that it can be partially disposed within a hollow portion of the first rod section 1606. In the case where the second rod section 1608 is partially disposed within the first rod section 1606, both rod sections 1606, 1608 can be attached to the post 1200 using the same fastener 1220.

A plurality of posts 1200 can be located about a length of the roadway and a plurality of longitudinal bodies 1300 and longitudinal members 1400 can be disposed therebetween to form a continuous or substantially continuous guard rail or barrier for the road. In the instance of a vehicle coming in contact with the guardrail system 1100, the longitudinal bodies 1300 and longitudinal members 1400 performs similar to a net, catching or deflecting the vehicle. It has been discovered that an excessive force from a vehicle can break and/or separate the longitudinal bodies 1300 from the posts 1200, but the longitudinal members 1400 help absorb the load of the vehicle thereby providing an improved system for redirecting the vehicle back to the roadway or slowing the vehicle down to a complete stop.

It has also been discovered that the channels 1210, 1212 can absorb at least a portion of any upward and downward load to on an inner surface thereof, thereby removing or substantially reducing a demand on the fasteners used to secure the longitudinal bodies 1300 and the longitudinal members 1400 to resist the load. As such, the fasteners can be designed to only transfer loads in an axial direction from a post to an adjacent post.

FIG. 30 depicts a partial perspective view of an illustrative fiberglass guardrail system 2100, and FIG. 31 depicts an illustrative end view of the guardrail system 2100 supported on a structural base 2400, according to one or more embodiments described. The guardrail system 2100 can include a post 2200, and a longitudinal body or beam 2300. The post 2200 can be vertically oriented, or at least substantially vertical, and can include two or more legs 2220, 2222 extending from an inner body or support 2250. A generally horizontal plate or spacer 2252 can used between the legs 2220, 2222 to provide additional support to the post 2200. The post 2200 can be fabricated from any number of materials including, aluminum, steel, stainless steel, iron, and blends or alloys thereof, as well as other non-metallic materials including carbon fiber, fiberglass or other engineered plastics and resins. Preferably, the guardrail system 2100 is substantially constructed from electrically non-conductive materials, such as fiberglass.

The structural base 2400 can be constructed of wood, cement, metal, or any other material capable of providing a secured foundation for the guardrail system 2100. The structural base 2400 can be a wall, curb, slab, beam, post, foundation, or the like. The legs 2220, 2222 of the post 2200 can be adapted or modified to fit on or about the outer surfaces 2410, 2411 of the structural base 2400. The structural base 2400 can be any foundation, curbing, or railing that is known in the art, or yet to be discovered. For example, the structural base 2400 can be a conventional concrete curb.

Referring to FIGS. 30 and 31, the legs 2220, 2222 can be substantially parallel to one another, forming a gap or opening therebetween. A lower portion of the legs 2220, 2222 can be adapted to secure the post 2200 to the base 2400. For example, each leg 2220, 2222 can an inner surface 2221, 2223, respectively, that straddles and contacts the upper portion of the base 2400. The post 2200 can include one or more openings or apertures (i.e. mounting slots) 2224, 2225, as shown in FIGS. 30 and 32, to help secure the post to the base 2400. A bolt or other mechanical fastener can be drilled or otherwise disposed through the supportive base 2400 and through the mounting slots 2224, 2225. An adhesive can also be applied to the inner surfaces 2221, 2223 of the legs 2220, 2222 to adhere the post 2200 to the upper surfaces 2410, 2411 of the base 2400. The adhesive can also be applied to the underside of the plate 2252. Any suitable adhesive can be used, such as an epoxy based resin, for example. In another embodiment, the post legs 2220, 2222 can be secured into the ground itself, without the need for the base 2400. For example, concrete footings, tension anchors and cabling, or other means apparent to those skilled in the art can be used.

FIG. 32 depicts an illustrative perspective view of the post 2200, according to one or more embodiments described, and FIG. 33 depicts an elevation end view of the post 2200, according to one or more embodiments described. Referring to FIGS. 32 and 33, the top of the post 2200 can be curved, slanted or flat. The post 2200 can include a first mounting bracket 2240 located between the legs 2220, 2222. The mounting bracket 240 can be u-shaped having a base 2245 that can contact and support the weight of the beam 2300. The mounting bracket 2240 can be a tube having a cross-sectional shape that is square or rectangular, whereby one side and/or facet of the tub is removed to form a trough or u-shaped basket that corresponds in shape to one end of the beam 2300. As will be explained in more detail below, the post 2200 can further include one or more holes or openings (six are shown 2233, 2234, 2241, 2242, 2243, 2244) for securing the beam 2300 to the post 2200.

FIG. 34 depicts an illustrative schematic view of a second or backside of the post 2200 depicted in FIG. 32. As shown in FIG. 34, the post includes a second or backside mounting bracket 2230 that is also u-shaped having a base 2235 located between the legs 2220, 2222. The second mounting bracket 2230 can share the inner body 2250 as the first or front side mounting bracket 2240. Although described as two separate pieces, the bases 2235, 2245 could be a single generally horizontal plate welded or otherwise attached between the legs 2220, 2222.

FIG. 34 further depicts an illustrative schematic view of the wire 2320 secured to the post 2200, according to one or more embodiments described. The guardrail system 2100 can further include a wire or cable 2320 that can be at least partially disposed within the beam 2300 and mechanically linked to the post 2200. FIG. 34 depicts an illustrative schematic view of the wire 2320 secured to the post 2200, according to one or more embodiments described. This view shows the wire 2320 without the beam 2300. As illustrated, the wire 2320 can be a continuous loop or band made of one more pieces of wire, cable or other elongated support structure. For ease and simplicity of description, the guardrail system 2100 will be further described below with reference to a single wire 2320. It is contemplated and should be understood, however, that any number of wires 2320 can be used, depending on the desired strength and design capacity of the guardrail. For example, the number of wires 2320 can range from a low of 1, 2, or 3 to a high of 10, 15, or 20. If multiple wires 2320 are desired, the gauge of each wire 2320 used can be the same or it can vary.

FIG. 35 depicts a side perspective view of a first side of the beam 2300, according to one or more embodiments described. The beam 2300 is a generally straight, longitudinal structure having two opposing sides 2311, 2312. The side 2311 is visible in FIG. 30. The opposing side 2312 can include one or more longitudinal grooves 2315 formed therein, as shown in FIG. 35. The longitudinal grooves 2315 reduce the weight of the beam 2300, while increasing the plank's structural strength, much like an I-beam.

The beam 2300 can be made from one or more fiber reinforced plastics, such as one or more fiberglass composites. Any suitable material, however, can be used to fabricate the beam 2300. For example, suitable materials can include, but are not limited to, any one or more metals (such as aluminum, steel, stainless steel, brass, nickel), wood, other composite materials (such as ceramics, wood/polymer blends, cloth/polymer blends, etc.), and plastics (such as polyethylene, polypropylene, polystyrene, polyurethane, polyethylethylketone (PEEK), polytetrafluoroethylene (PTFE), polyamide resins (such as nylon 6 (N6), nylon 66 (N66)), polyester resins (such as polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer) polynitrile resins (such as polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers, methacrylonitrile-styrene-butadiene copolymers; and acrylonitrile-butadiene-styrene (ABS)), polymethacrylate resins (such as polymethyl methacrylate and polyethylacrylate), cellulose resins (such as cellulose acetate and cellulose acetate butyrate); polyimide resins (such as aromatic polyimides), polycarbonates (PC), elastomers (such as ethylene-propylene rubber (EPR), ethylene propylene-diene monomer rubber (EPDM), styrenic block copolymers (SBC), polyisobutylene (PIB), butyl rubber, neoprene rubber, halobutyl rubber and the like)), and mixtures, blends, or copolymers of any and all of the foregoing materials.

Still referring to FIG. 35, each wire 2320 can be disposed within the one or more grooves 2315. Said another way, the grooves 2315 can provide a channel or conduit for the wire 2320. One or more plates 2350, 2351 can be located on one or both ends of the beam 2300, as shown in FIGS. 36 and 37. For example, a first plate 2350 can be located at a first end of the beam 2300 and a second plate 2351 can be located at a second end of the beam 2300 used to reinforce the wire 2320.

Referring again to FIG. 30 in conjunction with FIGS. 36-37, the wire 2320 can fit through an upper wire hole 2354 of one end plate 2350, 2351 returning back within the beam 300 through a lower wire hole 2355 of the same end plate 2350, 2351 forming a return loop 2322, 2324 located outside of the beam 2300, as shown in FIG. 35. The end plates 2350, 2351 can be secured to the distal ends of the beam 2300 before or after assembly of the wire 2320 using an adhesive to adhere the end plates 2350, 2351 to the ends of the beam 2300. Alternatively, the tension of the wire 2320 can hold the end plates 2350, 2351 firmly in place so no adhesive is necessary.

As mentioned above, any number of wires 2320 can be used, and each wire 2320 forms a continuous loop. Each wire 2320 can be formed from one or more sections of wire/cable that are connected together or otherwise secured to one another to form the continuous loop. Any suitable fastener or mechanism can be used, such as for example, a turnbuckle, clamp, or the like. Each wire 2320 can be constructed of any number of materials including iron, aluminum, copper, stainless steel, any alloys thereof. Each wire 2320 can also be made from one or more high strength, non-metallic materials such as composite fibers, KEVLAR®, or the like. If more than one wire 2320 is desired, each wire 2320 can be made from any one or more foregoing materials. In other words, the materials used to make each wire 2320 can be the same or can be different.

As mentioned, the posts 2200 and beams 2300 can be fabricated from one or more non-conductive materials. Non-conductive materials can reduce the passage of an electrical current between the posts 2200 and beams 2300, such as in the event of a lightning strike or a downed power line. More preferably, one or more fiberglass materials or other fiber reinforced plastics or resins are used because of the high strength properties. As the guardrail system 2100 is intended to be used along a roadway, in the elements, and subject to contact with electrical hazards, including lightening, downed power lines, and the like, such non-conductive materials can be used in the fabrication of the beams 2300 and/or posts 2200 to prevent the transfer of an electric current throughout the system 2100. It should also be appreciated that the design of the beams 2300 provide an insulation or barrier coating for the wire 2320 disposed therein. As such, the overall system 2100 significantly reduces the risk of electrocution if a motorist or other person were to be near the guardrail system 2100 if/when hit by lightning or a down power line.

FIGS. 38-42 illustrate the mechanisms for securing the beam 2300 with the wire 2320 to the post 2200, according to one or more embodiments provided herein. For example, the beam 2300 can be secured to the mounting brackets 2230, 2240 at both ends of the beam 2300 using one or more retaining pins 2370, 2372. The retaining pins can be sized and shaped to fit within the holes 2233, 2234, 2243, 2244 formed through the mounting brackets 2230, 2240, and corresponding holes formed through the beam 2300. The cross sectional shape of the pins 2370, 2372 and holes 2233, 2234, 2243, 2244 are preferably round, but can be any non-round shape such as elliptical, oval, triangular, square, or other polygonal shape so as to prevent relative rotation. Once inserted through the mounting brackets 2230, 2240 and the beam 2300, the exposed ends of the retaining pins 2370, 2371, 2372, 2373 can be secured in place by, for example, a cotter pin or other securing mechanism. It should be appreciated, however, that securing the beam 2300 to the mounting brackets 2230, 2240 can be achieved using other fasteners and techniques, such as a rivet, nut and bolt, or the like.

In other embodiments, the retaining pins 2370, 2371, 2372, 2373 can be inserted outside the end plates 2350, 2351, within the wire loop 2322, 2324. Said another way, the retaining pins 2370, 2371, 2372, 2373 can be inserted inside the wire loops 2322, 2324, between the wire loop 2322, 2324 and the end plate 2350, 2351.

Considering the centrally located body 2250 within the post 2200, the length of the body 2250 can vary, depending on the design criteria of the support post 2200. For example, as illustrated in FIGS. 30-34, the body 2250 can extend from the base 2235, 2245 of the mounting brackets 2230, 2240 to the top end of the post 2200 or proximate the top end of the post 2200. In other embodiments, as further illustrated in FIGS. 39 and 40, the body 2250 of the support post 2200 can extend from a top end, at least proximal the top end, of the post 2200 to the generally horizontal plate 2252.

FIG. 43 depicts a schematic plan view of the guard rail system 2100 located along a roadway, according to one or more embodiments described. As depicted, a plurality of posts 2200 are located about a length of the roadway and a plurality of beams 2300 are disposed therebetween to form a continuous guard rail or barrier for the road. In the instance of a vehicle coming in contact with the guardrail system 2100, the wire 2320 performs similar to a net, catching or deflecting the vehicle. It has been discovered that an excessive force from a vehicle can break and/or separate the beam 2300 from the posts 2200, while the wire 2320 transfers the load of the vehicle through the retaining pins 2370, 2371, 2372, 2373 to the posts 2200, thereby providing an improved system for redirecting the vehicle back to the roadway or slowing the vehicle down to a complete stop.

As should be appreciated by those skilled in the art, the guardrail system described herein makes use of fiberglass as part of the load bearing posts; simplifies installation, repair and retrofit; is electrically non-conductive; and can utilize any type of connector or connection including adhesives to form a compete guardrail system m

FIG. 44 depicts a partial perspective view of an illustrative fiberglass guardrail system 3100, according to one or more embodiments. The guardrail system 3100 can include a post 3200, and a longitudinal body or beam 3300. The post 3200 can be an arched shaped member having two or more legs 3220, 3222 extending therefrom. The post 3200 can be fabricated from any number of materials including, aluminum, steel, stainless steel, iron, and blends or alloys thereof, as well as other non-metallic materials including carbon fiber, fiberglass or other engineered resins.

The legs 3220, 3222 can be substantially parallel to one another, forming a gap or opening therebetween. As will be explained in more detail below, the legs 3220, 3222 can be adapted to secure the post 3200 to a ridged or structurally supportive base, commonly located parallel to a roadway, as shown in FIG. 45.

FIG. 45 depicts an illustrative end view of the guardrail system 3100 supported on a structural base 3400, according to one or more embodiments described. The structural base 3400 can be constructed of wood, cement, metal, or any other material capable of providing a secured foundation for the guardrail system 3100. The structural base 3400 can be a wall, curb, slab, beam, post, foundation, or the like. The structural base 3400 can have an upper portion with outer surfaces 3410, 3411 that are adapted to fit within the legs 3220, 3222 of the post 3200.

Each leg 3220, 3222 has an inner surface 3221, 3223, respectively, that straddles and contacts the upper portion of the base 3400. The post 3200 can be secured to the base 3400 in a multitude of ways. For example, the post 3200 can include one or more openings or apertures (i.e. mounting slots) 3224, 3225, as shown in FIG. 46, to help secure the post to the base 3400. A bolt or other mechanical fastener can be drilled or otherwise disposed through the supportive base 3400 and through the mounting slots 3224, 3225. An adhesive can also be applied to the inner surfaces 3221, 3223 of the legs 3220, 3222 to adhere the post 3200 to the upper surfaces 3410, 3411 of the base 3400. In another embodiment, the post 3200 may secure the post legs 3220, 3222 in the ground itself, without the need for the base 3400, using concrete footings, tension anchors and cabling, or other means apparent to those skilled in the art.

FIG. 46 depicts an illustrative perspective view of the post 3200, according to one or more embodiments described, and FIG. 47 depicts an elevation end view of the post 3200, according to one or more embodiments described. Referring to FIGS. 46 and 47, the post 3200 can further include an inner body or support 3250 and one or more mounting brackets 3230, 3240 extending therefrom. The one or more mounting brackets 3230, 3240 can extend from the body 3250 and can be generally parallel to the legs 3220, 3222. Each mounting brackets 3230, 3240 can be u-shaped having a base 3235, 3245 that can contact and support the weight of the beam 3300. The mounting brackets 3230, 3240 can be, but are not limited to, a tube, having a cross-sectional shape that is square or rectangular, lacking the top edge and/or facet, that corresponds in shape to the distal ends of the beam 3300. As will be explained in more detail below, the post 3200 can further include one or more holes or openings (four are shown 3241, 3242, 3243, 3244) for securing the beam 3300 to the mounting brackets 3230, 3240.

The guardrail system 3100 can further include a wire or cable 3320 that can at least partially disposed within the beam 3300 and mechanically linked to the support post 3200. FIG. 48 depicts an illustrative schematic view of the cable 3320 secured to the post 3200, according to one or more embodiments described. This view shows the cable 3320 without the beam 3300. As illustrated, the wire 3320 can be a continuous loop or band made of one more pieces of wire, cable or other elongated support structure.

FIG. 49 depicts a side perspective view of a first side of the beam 3300, according to one or more embodiments described. The beam 3300 is a generally straight, longitudinal structure having two opposing sides 3311, 3312. The side 3311 is visible in FIG. 44. The opposing side 3312 can include one or more longitudinal grooves 3315 formed therein, as shown in FIG. 49. The longitudinal grooves 3315 reduce the weight of the beam 3300, while increasing the plank's structural strength, much like an I-beam.

The beam 3300 can be made from one or more fiber reinforced plastics, such as one or more fiberglass composites. Any suitable material, however, can be used to fabricate the beam 3300. For example, suitable materials can include, but are not limited to, any one or more metals (such as aluminum, steel, stainless steel, brass, nickel), wood, other composite materials (such as ceramics, wood/polymer blends, cloth/polymer blends, etc.), and plastics (such as polyethylene, polypropylene, polystyrene, polyurethane, polyethylethylketone (PEEK), polytetrafluoroethylene (PTFE), polyamide resins (such as nylon 6 (N6), nylon 66 (N66)), polyester resins (such as polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene isophthalate (PEI), PET/PEI copolymer) polynitrile resins (such as polyacrylonitrile (PAN), polymethacrylonitrile, acrylonitrile-styrene copolymers (AS), methacrylonitrile-styrene copolymers, methacrylonitrile-styrene-butadiene copolymers; and acrylonitrile-butadiene-styrene (ABS)), polymethacrylate resins (such as polymethyl methacrylate and polyethylacrylate), cellulose resins (such as cellulose acetate and cellulose acetate butyrate); polyimide resins (such as aromatic polyimides), polycarbonates (PC), elastomers (such as ethylene-propylene rubber (EPR), ethylene propylene-diene monomer rubber (EPDM), styrenic block copolymers (SBC), polyisobutylene (PIB), butyl rubber, neoprene rubber, halobutyl rubber and the like)), and mixtures, blends, or copolymers of any and all of the foregoing materials.

Still referring to FIG. 49, the wire 3320 can disposed within the one or more grooves 3315. Said another way, the grooves 3315 can provide a channel or conduit for the wire 3320. One or more plates 3350 can be located on one or both ends of the beam 3300, as shown in FIGS. 50 and 51. For example, a first plate 3350 can be located at a first end of the beam 3300 and a second plate 3351 can be located at a second end of the beam 3300 used to reinforce the wire 3320.

Referring again to FIG. 44 in conjunction with FIGS. 50-51, the wire 3320 can fit through an upper wire hole 3354 of one end plate 3350, 3351 returning back within the beam 3300 through a lower wire hole 3355 of the same end plate 3350, 3351 forming a return loop 3322, 3324 located outside of the beam 3300, as shown in FIG. 49. The end plates 3350, 3351 can be secured to the distal ends of the beam 3300 before or after assembly of the wire 3320 using an adhesive to adhere the end plates 3350, 3351 to the ends of the beam 3300. Alternatively, the tension of the wire 3320 can hold the end plates 3350, 3351 firmly in place so no adhesive is necessary.

As mentioned above, the wire 3320 forms a continuous loop and can be formed from one or more sections of wire/cable that are connected together or otherwise secured to one another to form the continuous loop. Any suitable fastener or mechanism can be used, such as for example, a turnbuckle, clamp, or the like. The wire 3320 can be constructed of any number of materials including iron, aluminum, copper, stainless steel, any alloys thereof. The wire 3320 can also be made from one or more high strength, non-metallic materials such as composite fibers, KEVLAR®, or the like.

FIGS. 52-56 illustrate the mechanisms for securing the beam 3300 with cable 3320 to the post 3200, according to one or more embodiments provided herein. For example, the beam 3300 can be secured to the mounting brackets 3230, 3240 at both ends of the beam 3300 using one or more retaining pins 3370, 3372. The retaining pins can be sized and shaped to fit within the holes 3233, 3234, 3243, 3244 formed through the mounting brackets 3230, 3240, and corresponding holes formed through the beam 3300. The cross sectional shape of the pins 3370, 3372 and holes 3233, 3234, 3243, 3244 are preferably round, but can be any non-round shape such as elliptical, oval, triangular, square, or other polygonal shape so as to prevent relative rotation. Once inserted through the mounting brackets 3230, 3240 and the beam 3300, the exposed ends of the retaining pins 3370, 3371, 3372, 3373 can be secured in place by, for example, a cotter pin or other securing mechanism. It should be appreciated, however, that securing the beam 3300 to the mounting brackets 3230, 3240 can be achieved using other fasteners and techniques, such as a rivet, nut and bolt, or the like.

Alternatively, the retaining pins 3370, 3371, 3372, 3373 can be inserted outside the end plates 3350, 3351, within the wire loop 3322, 3324. Said another way, the retaining pins 3370, 3371, 3372, 3373 can be inserted inside the wire loops 3322, 3324, between the wire loop 3322, 3324 and the end plate 3350, 3351.

FIG. 57 depicts a schematic plan view of the guard rail system 3100 located along a roadway, according to one or more embodiments described. As depicted, a plurality of posts 3200 are located about a length of the roadway and a plurality of beams 3300 are disposed therebetween to form a continuous guard rail or barrier for the road. In the instance of a vehicle coming in contact with the guardrail system 3100, the wire 3320 performs similar to a net, catching or deflecting the vehicle. It has been discovered that an excessive force from a vehicle can break and/or separate the beam 3300 from the posts 3200, while the wire 3320 transfers the load of the vehicle through the retaining pins 3370, 3371, 3372, 3373 to the posts 3200, thereby providing an improved system for redirecting the vehicle back to the roadway or slowing the vehicle down to a complete stop.

Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges including the combination of any two values, e.g., the combination of any lower value with any upper value, the combination of any two lower values, and/or the combination of any two upper values are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.

Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

1. A guardrail for use along a roadway, comprising:

a longitudinal body made from one or more plastics and having two or more longitudinal void spaces formed therein, wherein at least one of the void spaces is continuous from a first end of the body to a second end of the body; and

a longitudinal member disposed within the continuous void space, the longitudinal member made from one or more metals to provide flexibility and strength to the guardrail.

2. The system of claim 1, wherein at least one of the longitudinal void spaces is cylindrical in shape.

3. The system of claim 2, wherein the longitudinal member is disposed within the longitudinal void space that is cylindrical in shape.

4. The system of claim 3, wherein the longitudinal member is a stainless-steel rod or a hollow stainless-steel tube.

5. The system of claim 4, wherein the longitudinal body comprises fiber reinforced plastic.

6. The system of claim 1, wherein at least one of the longitudinal void spaces is rectangular cuboid in shape.

7. The system of claim 6, wherein the longitudinal void space that is rectangular cuboid in shape is at least half filled with a filler material.

8. The system of claim 7, wherein the filler material comprises expandable polystyrene.

9. The system of claim 1, wherein:

at least one of the longitudinal void spaces is cylindrical in shape,

the longitudinal member is disposed within the longitudinal void space that is cylindrical in shape,

the longitudinal member is a stainless-steel rod or a hollow stainless-steel tube, at least one of the longitudinal void spaces is rectangular cuboid in shape,

the longitudinal void space that is rectangular cuboid in shape is at least half filled with a filler material, and

the longitudinal body comprises fiber reinforced plastic.

10. A guardrail system for use along a roadway, comprising:

a first longitudinal body consisting essentially of one or more non-metallic materials, the first longitudinal body having two or more longitudinal void spaces formed therein;

a second longitudinal body consisting essentially of one or more non-metallic materials, the second longitudinal body having two or more longitudinal void spaces formed therein;

at least one substantially vertical post disposed between the first longitudinal body and the second longitudinal body;

a first longitudinal member disposed within any one of the longitudinal void spaces of the first longitudinal body;

a second longitudinal member disposed within any one of the longitudinal void spaces of the second longitudinal body, wherein the first and second longitudinal members are flexible and made from one or more metals, the first and second longitudinal members having a greater tensile strength than first and second longitudinal bodies; and

a splicer disposed within the first and second longitudinal members and configured to connect to the at least one substantially vertical post, such that when a force is imparted on the longitudinal bodies, the longitudinal members transfer the load of the force through the splicer to the post.

11. The system of claim 9, wherein:

the at least one substantially vertical post is connected to both the first longitudinal body and the second longitudinal body, and

the first longitudinal member and the second longitudinal member both have an ultimate tensile strength that is at least 20% greater than the ultimate tensile strength of the first and second longitudinal bodies.

12. A guardrail for use along a roadway, comprising:

a longitudinal body made from fiber reinforced plastic;

at least two longitudinal void spaces formed within the body, wherein the longitudinal void spaces are non-concentric to each other and at least one longitudinal void space has a cross section that is different from at least one other; and

a longitudinal member housed within any one of the longitudinal void spaces, the longitudinal member made from one or more metals to add flexibility and strength to the guardrail.

13. The guardrail of claim 12, wherein the longitudinal member is a hollow stainless-steel tube or a solid stainless-steel rod.

14. The guardrail of claim 12, wherein at least one of the longitudinal void spaces is rectangular cuboid in shape and at least one of the longitudinal void spaces is cylindrical in shape.

15. The guardrail of claim 14, wherein the longitudinal void space that is rectangular cuboid in shape is at least half filled with a filler material.

16. The guardrail of claim 15, wherein the filler material comprises expandable polystyrene.

17. The guardrail of claim 12, wherein the longitudinal body has a first end and a second end, and wherein the longitudinal void spaces are continuous within the body and extend from the first end to the second end.

18. The guardrail of claim 12, wherein any one of the longitudinal void spaces is empty of any solid material or at least partially filled with one or more filler materials.

19. The guardrail of claim 12, wherein the longitudinal void spaces are co-linear and aligned in a cross-wise dimension of the longitudinal body.

20. The guardrail of claim 12, wherein each longitudinal void space is encapsulated and separated from one another by the body.