Spiller, David V. (3615 Longridge Avenue, Sherman Oaks, CA, 91423, US)
| 1. | A parking stall bumper comprising: a substructure on a parking lot surface such that said substructure comprises a bottom surface on said parking lot surface and an exposed surface; and a fitted cap attached to said substructure, said cap entirely surrounding the exposed surface and being made from a material selected from the group consisting of metal, plastic, and rubber. |
| 2. | A parking stall bumper according to Claim 1, wherein the substructure comprises molded plastic. |
| 3. | A parking stall bumper according to Claim 1, wherein the substructure comprises molded rubber. |
| 4. | A parking stall bumper according to Claim 1, wherein the substructure comprises concrete. |
| 5. | A parking stall bumper according to Claim 4, with the proviso that the substructure is not reinforced with rebar. |
| 6. | A parking stall bumper according to Claim 4, wherein the substructure is unreinforced concrete. |
| 7. | A parking stall bumper according to Claim 1, wherein the fitted cap comprises written material thereon. |
| 8. | A parking stall bumper according to Claim 7, wherein the written material comprises advertising for a product or service. |
| 9. | A parking stall bumper according to Claim 7, wherein the fitted cap comprises metal with the written material silkscreened thereon. |
| 10. | A method of producing concrete parking stall bumpers comprising: feeding a predetermined amount of concrete into a mold in the form of a parking stall bumper, said mold being positioned on a vibrating table ; moving a tamper head into engagement with the concrete in the mold ; vibrating the mold and hence the concrete within the mold ; transferring the mold and vibrated concrete to a discharge position; discharging formed parking bumpers onto the ground or other surface; advancing the machine in preparation for a subsequent cycle of operations; and affixing a cap at least partially surrounding said concrete bumper. |
| 11. | The method of Claim 10, additionally comprising making one or more holes in the bumper. |
| 12. | The method of Claim 10, wherein the cap is formed or molded from a material selected from the group consisting of metal, plastic, and rubber. |
| 13. | The method of Claim 10, wherein the cap has printed material on it. |
| 14. | The method of Claim 13 wherein the printed material is advertising for a product or service. |
| 15. | A machine for the production of concrete parking bumpers comprising: a concrete feeder; a mold box in the shape of a parking bumper into which the concrete feeder feeds concrete, the mold box comprising a plurality of channels the same size as the desired bumpers, a tamper, the tamper adapted to move into engagement with the concrete in the mold box, the tamper comprising a plurality of tamper heads which are the same size of the desired bumpers, a vibrating table on which the mold box is situated so as to permit vibration of the mold box and hence the concrete within it, a hole puncher adapted to punch one or more holes in the concrete while the concrete is in the mold box; and a discharge mechanism adapted to remove the bumper from the mold box and discharge the bumper onto the ground or other surface. |
| 16. | A machine according to Claim 15, wherein the tamper heads have a shape selected from the group consisting of rounded, arched, triangular, trapezoidal, flat, or rectangular. |
| 17. | The machine of Claim 15, wherein the discharge mechanism comprises a ram adapted to push the mold box. |
| 18. | The machine of Claim 15, wherein the discharge mechanism comprises a vertically moveable frame. |
| 19. | A dry concrete mix adapted for formation of concrete parking bumpers, comprising a mixture per 0. 765 cubic meters of: 12252040 kg Sand 245408 kg #5 Rock 306510 kg 3/8 Rock; 385646 kg of a blend of Portland cement and flyash ; 37506300 ml accelerant. |
| 20. | The dry concrete mix of Claim 19, wherein the accelerant is Pozzolithol 122HE.. |
| 21. | The dry concrete mix of Claim 20, wherein, within 10% of the following amounts are used per 0.765 cubic meters: used: 1633 kg Sand; 326 kg #5 Rock; 408 kg 318 Rock; 512 kg of a blend of Portland cement and flyash ; and 5070 ml Pozzolithe 122 HE. |
| 22. | The mixture of Claim 19, wherein the mixture has less than 10% moisture content. |
Additionally, the invention relates to a parking stall bumper with superior durability which comprises a substructure and a protective cap.
Description of the Related Art Parking lots used in commercial or residential properties designate parking spaces with straight parallel lines painted on the ground surface several feet apart to accommodate the width and length of most motor vehicles.
A driver entering a parking space directs the motor vehicle within the painted lines defining the parking space and moves forward until at least one of the front tires makes contact with a parking stall bumper that is secured to the ground, typically at one end of the parking space. Parking bumpers may be centered in parking spaces or may be positioned across two parking spaces. When the front tire contacts the parking stall bumper, the forward movement of the vehicle is substantially limited. Used in this way, parking bumpers enhance safety and prevent vehicles from accidentally moving forward and hitting another object or pedestrians, and also prevent one vehicle from accidentally contacting another vehicle in an opposite parking stall. Additionally, law requires that all parking spaces designated for the handicapped have a parking stall bumper.
Currently, the process of making parking stall bumpers is inefficient, requiring significant time and labor to produce a small number of bumpers. Typically, a steel mold is used and concrete is hand poured into the mold.
The concrete bumpers may also be reinforced with metal posts set in the concrete. This process allows for approximately 200 bumpers to be made per day by a small group of people. With the benefits of both safety and prevention of property damage, parking stall bumpers should be more widely used, but time and money required with the arduous process of producing the bumpers limits their availability and, use.
The present invention speeds the process of making parking stall bumpers from making hundreds a day to thousands. Using this new process, a small staff is able to produce up to 4000 bumpers per day, or a dozen every minute. This time saving method also provides a more durable product, over twice the strength of bumpers currently in use, which allows the new bumpers to endure severe environmental conditions and daily abuse from vehicles.
Additionally, a cap affixed to the bumper gives added strength, as well as precludes the use of metal bars as a structural element inside the bumpers.
Summary of the Invention The present invention provides for a method of mass producing parking stall bumpers using a machine which includes feeding a predetermined amount of concrete into a mold which is positioned on a vibrating table, moving a tamper head into engagement with the concrete mold, vibrating the mold and hence the concrete within the mold, optionally making one or more holes in the concrete, transferring the mold and concrete to a discharge position, discharging the formed concrete parking bumpers on to the ground or other supporting surface, and advancing the machine in preparation for a subsequent cycle of operations. A further embodiment comprises an additional method for affixing a cap to said bumper. Another embodiment provides for the cap to be made of a material selected from the group consisting of metal, plastic, and rubber. An additional embodiment provides for the cap to have printed material on it, optionally, wherein the material is advertising for a product or service.
A further embodiment of the invention provides for a machine for producing concrete parking stall bumpers, which comprises: a concrete feeder; a mold box into which the concrete feeder feeds concrete, the mold box comprising a plurality of channels the same size as the desired bumpers, a tamper, the tamper adapted to move into engagement with the concrete in the mold box, the tamper comprising a plurality of tamper heads which are the same size of the desired bumpers, a vibrating table on which the mold box is situated so as to permit vibration of the mold box and hence the concrete within it, optionally, a hole puncher adapted to punch one or more holes in the concrete while the concrete is in the mold box; and a discharge mechanism adapted to remove the bumper from the mold box and discharge the bumper onto the ground or other surface.
A further embodiment provides for the machine to have tamper heads which have a shape selected from the group consisting of rounded, arched, triangular, trapezoidal, flat, or rectangular. The machine may also comprise a discharge mechanism comprising a ram adapted to push the mold box, or alternatively a discharge mechanism comprising a vertically moveable frame.
One embodiment of the present invention provides for a parking stall bumper comprising a substructure and a fitted cap attached thereto, said cap being made from a material selected from the group consisting of metal, plastic, and rubber. Embodiments for the present invention include parking bumpers with a substructure comprising concrete, plastic, or rubber. A further embodiment provides for a bumper in which the concrete substructure is not reinforced with rebar. Alternatively, the bumper may comprise a concrete substructure which is otherwise unreinforced concrete. An additional embodiment allows for the substructure of the bumper to be made of injection molded plastic.
A further embodiment provides for the bumper to comprise a cap on which written material is printed and alternatively, where this written material comprises advertis9ing for a product or service. An additional embodiment provides for the written material to be silk-screened thereon.
One embodiment of the present invention provides for a dry concrete mix for use in making the parking stall bumpers comprising a unique mixture of sand, flyash, Portland cement, and admixtures.
Brief Description of the Drawings Figure 1 shows the mold on the vibrating table with the tamper head carriage up and the feed tray under the mix-holding hopper. The ram acting between the main and secondary frames, which acts as a vibration damper between the two frames is also shown.
Figure 2 shows the mold on the vibrating table, with the feed tray moved to a position over the mold on the table and with the tamper head carriage up.
Figure 3 shows the feed tray returned to under the mix-holding hopper, with the mold on the vibrating table and the tamper head carriage lowered.
Figure 4 shows the secondary frame moved horizontally relative to the main frame. The tamper head and mold move with the vibrated concrete product in the mold.
Figure 5 shows the tamper head and mold moved vertically downwards to the ground.
Figure 6 shows the tamper head and mold raised vertically to deposit the concrete product on the ground.
Figure 7 shows the secondary frame returned to over the vibrating table with the tamper head raised vertically to repeat the cycle.
Figure 8 shows the location of the mold clamps on opposite sides of the vibrating table. The clamps are fixed to the main frame and rotate about a pivot by the action of a hydraulic ram. The clamps hold the mold on the table during vibration of the table and are fitted with air bags which act as dampers to reduce or eliminate the transfer of vibration from the secondary frame to the main frame.
Figure 9 shows the secondary frame assembly with slide shafts on which the mold carriage and the tamper head carriage move vertically up and down.
Figure 10 shows the main frame assembly onto which the secondary frame is mounted.
Figure 11 is a perspective view showing the top, front, and side of a rounded parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 12 is a side elevation view of a rounded parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 13 is a front elevation view of a rounded parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 14 is a top plan view of a rounded parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 15 is a bottom plan view of a rounded parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 16 is a perspective view showing the top, front, and side of a trapezoidal parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 17 is a side elevation view of a trapezoidal parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 18 is a front elevation view of a trapezoidal parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 19 is a top plan view of a trapezoidal parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 20 is a bottom plan view of a trapezoidal parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 21 is a perspective view showing the top, front, and side of a triangular parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 22 is a side elevation view of a triangular parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 23 is a front elevation view of a triangular parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 24 is a top plan view of a triangular parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 25 is a bottom plan view of a triangular parking bumper with a cap and holes into which an article for affixing the cap to the bumper and the bumper to the ground can be inserted.
Figure 26 is a perspective view showing the top, front, and side of a rounded parking bumper with a cap in which no holes were formed in order to attach the cap.
Figure 27 is a side elevation view of a rounded parking bumper with a cap in which no holes were formed in order to attach the cap.
Figure 28 is a front elevation view of a rounded parking bumper with a cap in which no holes were formed in order to attach the cap.
Figure 29 is a top plan view of a rounded parking bumper with a cap in which no holes were formed in order to attach the cap.
Figure 30 is a bottom plan view of a rounded parking bumper with a cap in which no holes were formed in order to attach the cap.
Figures 31A-31C, illustrate how a bumper and cap may be attached to each other and to the ground using a rod and theft-detenwing screws.
Detailed Description of the Preferred Embodiment Currently, only 100-200 parking bumpers can be produced per day by a small staff using a method of hand- pouring concrete into molds. This method is both labor-intensive and messy. In contrast, the present invention is able to produce over 4000 per day with a similarly sized staff. The process of making the blocks at such a fast rate is achieved using a specially modified machine from Finlay Block-Making Equipment Ltd. The F44 GA Universal Block Machine uses a mold box, which receives a concrete mixture that is vibrated and compacted into the shape of a parking bumper. Additionally, holes may be formed into the bumpers. The machine drives along a specially- designed smooth concrete slab to support the 18,000 pound machine, dropping the parking bumpers and then using laser-guided vision to detect the location of the next drop site for another set of bumpers.
The Finley block machine receives the concrete from a forklift which carries the mix from a mixer. The concrete flows into a mold box comprising a plurality of channels which are the same size as the desired bumpers.
A vibrating table under the mold box is used to evenly distribute the mix into the channels. A tamper head with a plurality of tampers of the same length and width of the desired bumpers is lowered onto the molded concrete to produce a shaped top on each individual bumper. The shape of the tamper may be arched to produce bumpers with a rounded top, or it may be angled in a variety of ways to produce a triangular, trapezoidal, or rectangular bumper.
Alternatively, each tamper may also comprise a plurality of holes on the tamper head. These holes are spaced such that another apparatus can be passed through the tamper and be used to punch holes in the bumpers by inserting rods through the holes in the tamper and then into the concrete. An apparatus comprising a horizontal frame of parallel metal bars and a plurality of vertically protruding rods may be lowered over the top of the tamper head, and the rods pass through the holes in the tamper head to punch holes into the concrete bumpers. The bumpers are then discharged from the machine onto a surface, such as the ground or an engineered surface, without causing breakage or other damage to the bumpers. The block machine then drives forward to a point which is determined by the size of the parking bumpers plus a suitable gap, where the process repeats itself. The process of making a set of bumpers, preferably six at a time, takes only 30 seconds, making the process extremely efficient. In addition, this mechanized system requires significantly less manual labor than traditional means of forming concrete parking bumpers, as will be appreciated by those in the art.
The Finlay machine requires the use of a zero-slump concrete mix, which is an extremely dry mix (i. e. a residual moisture of less than 10%, more preferably less than 5%, still more preferably less than 2%, and in certain embodiments less than 1% moisture). The dry mixture yields a quick turn around time on precast products. A variety of components may be used to achieve this zero-slump mix, and a preferred embodiment is described below.
For this preferred embodiment a custom Portland cement blend using a product called flyash was designed to accommodate the sensitivity of the machine's requirements. Portland cement is commonly known in the art. Flyash is a product of the combustion of coal in power generating plants. It enhances strength, impermeability, and durability of concrete. The mix may also comprise chemical admixtures, such as retardants and accelerants, used to cure and get various results in the quality and durability of the final product. The preferred mix design used comprises the following : sand, various sizes and types of rock for strength and durability, a Portland cemenVflyash blend, and Pozzolith@ 122-HE (Master Builders, Inc.).
Pozzoliths 122-HE is a ready-to-use, liquid admixture used to make a more uniform and predictable quality concrete while accelerating setting time. This admixture increases early and ultimate strengths, both compressive and flexural, as well as high durability to damage from freezing and thawing. Reduced water content required for workability and accelerated setting time characteristics also make it an ideal product for use in the present invention. However, other acceferants may be better suited for applications of the present invention in which temperature, humidity, or other factors affect the mixing and curing conditions of the concrete, as would be understood by one of skill in the art.
The specific quantities of each component used to produce 0.765 cubic meters (1 cubic yard) of concrete mix in the preferred embodiment are as follows : (2700-4500 Ibs.) 1225-2040 kg Sand, preferably washed concrete sand; (540-900 Ibs.) 245-408 kg #5 Rock, which is rock measuring 5/16 inches or less ; (675-1125 Ibs.) 306-510 kg #3/8 Rock, which is rock measuring 3/8 inches or less ; (850-1425 Ibs.) 385-646 kg of a custom blend of Portland cement and flyash (Most preferably a 70: 30 ratio blend of Portland cement to flyash, respectively, would be used.); and (125-210 fl. oz.) 3750-6300 ml Pozzoliths 122-HE (Master Builders, Inc.), or other accelerant. Accelerants are admixtures that reduce the amount of time required for a concrete product to set.
In a particularly preferred formulation, the following amounts are used per 0.765 cubic meters : (3600 Ibs.) 1633 kg Sand; (720 Ibs.) 326 kg #5 Rock; (900 Ibs.) 408 kg 3/8 Rock; (1130 Ibs.) 512 kg of a custom blend of Portland cement and flyash ; and (169 fl. oz.) 5070 ml Pozzolith 122-HE or other accelerant.
The amounts of each of the ingredients in the particularly preferred formulation can be increased or decreased by up to 10%, more preferably by up to 5%. The particularly preferred mix design yielded a PSI (pounds per square inch) rating of up to 5000 pounds, more than double the strength of materials used in parking bumpers today. The components of the mix are highly dependent on the environmental conditions (humidity, temperature, etc.) of the location where mixing and curing of the concrete takes place, as can be appreciated by one in the art.
The mix can be altered and various admixtures can be used depending on the conditions of a particular mixing and curing site, as will be understood by one of skill in the art.
The basic parts and functions of the Finley machine are described in the published United Kingdom patent application No. GB2336801, and a detailed description of the structure and function of the Finley machine is described here in detail.
The machine shown in the drawings is for use in the production of parking stall bumpers and includes a main frame 10 (see Figure 10) and a secondary frame 11 (see Figure 9) mounted on and movable relative to the main frame 10. The main frame 10 is of generally rectangular form in plan view, having wheels 12 adjacent its four comers. A drive system (not show) is provided for driving the wheels 12 so as to advance the machine at the end of a cycle of operations and when, for any other reason, it is desired to move the machine. The majority of the operations of the machine are computer-controlled with a console (not shown) located in the operator's cabin (also not shown) so that the operator can, if required, override the computer and/or otherwise control operation of the machine.
The different stages in the cycle of operations of the machine are illustrated in Figures 1 to 7 of the drawings.
A holding hopper 13 for the concrete mix is mounted on the main frame 10 and has a discharge gate (not shown) which is opened when it is desired to discharge a controlled amount of the concrete mix from the hopper 13 to a feed tray 14 which is suspended beneath a carrier 15 mounted via load cells 16 on the main frame 10. The load cells 16 are arranged to generate output signals responsive to the mass of the feed tray 14 and its contents, such signals being transmitted to the machine computer which can be programmed to respond to the presence of a predetermined (adjustable) mass of concrete mix in the feed tray 14 to send a signal to the controls for the discharge gate of the hopper 13 to effect closing of the hopper discharge gate when the required mass of concrete mix has been discharged into the feed tray 14. The condition shown in Figure 1 is thus one in which, preparatory to the commencement of a cycle of operations, the feed tray 14 has been filled with the required mass of concrete mix.
The feed tray 14 is movable from the position shown in Figure 1 into the position shown in Figure 2 under the action of a hydraulic cylinder/ram (x) which acts on an arm (y) pivotally mounted on a torsion cross member 17, the arm (y) being connected to the feed tray 14 by means of a link 18.
When the feed tray 14 has been moved into the position shown in Figure 2, i. e. above the opening of the mold 19, the contents thereof fall into the mold 19. The mold 19 is contained within a mold carrier which, in turn is mounted within a frame carrier 20 attached to the secondary frame 11, the frame carrier 20 being provided with wheels 21 which are arranged to run on a frame runway 22 on the main frame 10.
The mold 19 is in the form of a mold box which, as shown in Figure 8, is arranged to rest on, and be vibrated by, a vibrating table 23. The mold box 19 is provided at either side with projecting lugs 24 which are engaged by pivotally mounted clamping members 25 to hold the mold box 19 securely in engagement with the vibrating table 23. The clamping members 25 are operated by hydraulic rams 26 and air bags 27 are fitted to the clamping members 25 and act as dampers during vibration of the mold box 19.
The vibrating table 23 is caused to vibrate by means of four servomotors 28 which are arranged to drive four shafts on which eccentric masses are mounted. The phase relationships between the motors 28 and the eccentric masses are under the control of the machine computer system which is so programmed that the operator can select the vibration conditions appropriate to a particular block configuration. The arrangement is such that the vibrating table 23 can rapidly be brought from a condition in which it is vibrating with a maximum amplitude to zero amplitude, while the shafts on which the eccentric masses are mounted continue to rotate. While, however, the concrete mix is being transferred into the mold box 19, the vibrating table 23 is caused to vibrate with small amplitude vibrations during the filling of the mold box 19 so as to ensure effective filling of all parts of the mold. It will be appreciated that the clamping members 25 will be in their operative positions before vibration of the table 23 is commenced.
A vibration isolation ram 29 is positioned above the vibrating table 23 and acts between the secondary frame 11 and the primary frame 10 to prevent the transmission of vibrations from the secondary frame 11, on which the vibrating table 23 is mounted, to the primary frame 10, on which the computer and other controls are mounted.
Once filling of the mold 19 has been completed, the hydraulic cylinder/ram (x) is operated once more to move the arm (y), the link 18 and the feed tray 14 from the positions shown in Figure 2 back to the positions shown in Figure 1, i. e. the condition shown in Figure 3 in which vibration of the table 23 at the maximum required amplitude is effected with the tamper carriage down, i. e. the tamper head is in engagement with the concrete in the mold, and the mold box 19 is clamped to the table 23. Upward and downward movement of the tamper carriage is effected by means of a tamper ram 30 which is connected to a tamper carrier 31 guided in its upward and downward movement by guide shafts 32 which form part of the secondary frame 11. The secondary frame 11 includes further guide shafts 33 which guide the frame carrier 20 during its upward and downward movements.
Once the vibrating table 23 has been caused to vibrate for the length of time which is needed to obtain the required product strength, the secondary frame 11 is moved bodily horizontally to produce the condition shown in Figure 4, in which the mold box 19 is displaced from the vibrating table 23. Such movement of the secondary frame 11 relative to the main frame 10 is effected by means of a hydraulic ram 34 which acts on an arm 35 pivotally mounted on a torsion cross member 36 forming part of the main frame 10. The pivot arm 35 is connected by a link 37 to the secondary frame 11.
After the components of the machine have been moved into the position shown in Figure 4, the tamper carrier and the mold carrier are lowered relative to the frame runway 22 to deposit the formed concrete product on the ground, the concrete product still being within the mold 19. Such movement is obtained by effecting guided downward movement of the secondary frame 11 relative to the main frame 10. The condition shown in Figure 5 is thus obtained. The mold carrier is connected by a link arm 38 to a pivotally mounted arm 39 which is rotated relative to the secondary frame 11 by means of a hydraulic ram 40.
After the concrete product has been deposited on the ground, the tamper carrier and the mold carrier are raised, being moved to the position shown in Figure 6, which corresponds to that of Figure 4, by effecting guided upward movement of the secondary frame 11 relative to the main frame 10. The mold box 19 will thus be disengaged from the formed parking bumper which will remain on the ground.
The secondary frame 11 will then be moved horizontally by appropriate operation of the hydraulic ram 34 which is connected to the arm 35 which acts via link 37 on the secondary frame 11. The components of the machine will thus be moved to the condition shown in Figure 7 (which corresponds to the position shown in Figure 1) in readiness for a further cycle of operations since, by this time, the feed tray 14 will have been filled with the predetermined amount of mix from the hopper 13.
Once the formed product has been deposited on the ground, the machine can be caused to advance by a distance corresponding to the size of the array of parking bumpers which has been formed plus a suitable gap.
The weight of the Finlay machine requires a special concrete slab for support. A slab was engineered to withstand the excessive weight and 10,000 pounds of compression and vibration that the machine produces. Five- foot deep excavation and recompaction took place, resulting in a solid subsurface of over 95% compaction. This sub-floor was then covered with 50 tons of #5 rebar and 1795 yards of 4000 psi concrete.
A concrete cement machine, preferably a LO-PRO batch plant, stores hundreds of tons of rock, sand, gravel, and cement powder. It then accurately weighs and disperses the different products onto a conveyor belt leading into a RAPID High Speed Pan Mixer (RAPID International USA, Inc.) or other mixer which is specifically designed to mix the zero slump concrete that is required in this process. A feed truck receives the mixture and delivers it to the modified F44 Block Machine. The block machine then proceeds to form the concrete bumpers.
Following the production of the bumpers, the bumpers are covered with fitted plastic tarps to cure for a period of time dependent on the environmental conditions of the location where the concrete is being cured. Slow drying of the concrete yields a stronger bumper, as will be appreciated by those in the art, Following a couple days of curing the tarps are removed, and clamping devices are used to pick up the bumpers. The clamping device is attached to a forklift, and the forklift is used to organize the bumpers into pallets.
Figures 11-30 show a variety of shapes of parking bumpers made according to the present invention.
As can be seen in these figures, the mold can be adapted to provide a wide variety of bumpers of varying shapes. Figures 31A-C illustrates one preferred manner for attaching the cap to the substrucutre. As can be seen in Figures 31A and 31B, a rod 105 with threading 110 can, advantageously, be used to easily attach the cap 115 to the bumper 120, while at the same time attaching the bumpers to a parking lot surface. The mold can be adapted to provide the bumper 120 with a threaded section 125 recessed into which the threading 110 fits. The rods 105 can be fitted with theft-locking recessed keys and a bottom nut 135. A theft chrome cap nut, shown in Figure 31 C can fit over the exposed top of the rod. In certain situations where theft is not a problem, ordinary screws and/or nuts can also be used. Also, the rods. 105 can be used to attach the cap 115 to the bumper 120 without attaching the bumper to the parking lot surface. Of course, a wide variety of other attachment mechanisms can be used to attach the capt to the bumper and/or the bumper to the parking lot surface. Advantageously, in certain embodiments, the cap can even simply be fited to the bumper without the need for any external attachment mechanism.
An alternative to using concrete as the material in the substructure is the use of molded plastic. Plastic can be formed into the desired shape and size of a bumper by injection molding and other means known to those of skill in the art. The plastic used should be durable and able to withstand a variety of environmental conditions, as well as wear caused by vehicles colliding with the bumper. The bumper may be a solid piece of plastic or hollow, as long as the structure is sufficiently stable to withstand use and the environment. Use of a cap over the bumper would add additional strength to a hollow bumper, and it would protect the outer surface of the bumper, as well. The bumper may have one or more holes which can be used to attach the cap to the substructure.
An additional alternative to the use of concrete in the substructure is to use rubber. Rubber can be shaped by a variety of means, including, but not being limited to, liquid injection molding and rubber to metal molding. Any means of shaping the rubber to form a parking stall bumper substructure may be used, as long as the final product is durable and strong enough to endure varying environmental conditions and collisions with vehicles hitting the bumper. Addition of a cap would increase the durability of a rubber bumper, as well.
A cap attached to each bumper provides added durability, impermeability, and strength to the overall structure of the bumper, as well as a more attractive parking stall bumper in comparison to those seen today. A cap may have any number of forms, including but not limited to rounded or arched, triangular, trapezoidal, rectangular, or any otherwise appropriate form which allows the cap to be fitted and attached to the bumper. Preferably, a 26- gauge galvanized metal is used and fed through a punch press to produce a cap that fits the shape and dimensions of the bumpers. Alternatively, the cap may be made from plastic, rubber, or any other material which confers durability to the bumper and protects the structural integrity of the concrete substructure, and it may be shaped or molded by any means know to those in the art. The material of which the cap is made may comprise written or printed material on its surface, as well. Optionally, this written or printed material may have a variety of purposes including, but not being limited to, advertising or decorative purposes. The written or printed material may be applied to the cap by painting, silk screening, or any other form of affixing artwork, advertising, graphics, or images to the cap.
Additionally, the cap may have one or more holes, preferably two holes at either end of the cap, through which a bolt or other form of coupling may be passed in order to affix the cap to the bumper, Ideally, the concrete bumpers will be anchored to the ground with a metal bolt which passes through a hole in the cap and then the hole in the concrete, however other methods for anchoring the bumpers to the ground and affixing the caps to the bumpers may be used. Also, in embodiments of the invention in which some form of bolt is used to attach the cap to the bumper, tamper-proof screws may be used to affix the cap to the bumper in order to prevent theft of the caps. Alternatively, the cap could be affixed to the bumper by a variety of other means, including but not restricted to adhesive, clamps, or straps. Additionally the cap may be made without holes, in which case the previously mentioned methods of attaching the cap to the bumper would be appropriate.
A variety of hole configurations can be formed into the bumpers depending on the desired method of attaching the caps to the bumper and the method of anchoring the bumper to the ground. The holes can be made using a mechanized process like that described above, in which an apparatus produces the holes while the bumpers are still in the molds, or the holes can be made in the bumpers after they have been discharged from the machine. Holes can be made in plastic or rubber during or following the molding process, by any means known to those in the art. Separate sets of holes for use in bolting the bumpers to the ground and attaching caps to the bumpers can be used. Alternatively, one or more holes can be made into which a bolt or other article can be inserted to both anchor the bumper to the ground and affix the cap to the bumper. Another option is to make a bumper without holes, which would yield a bumper that is held to the ground by gravity, straps wrapped around the bumper to hold it in place or some other configuration that doesn't require holes for anchoring the bumper to the ground. In this situation the cap could be affixed to the bumper by a variety of methods, including some form of adhesive, clamps, and/or straps. Alternatively the material forming the cap could be wrapped completely around the concrete substructure in a continuous or semi-continuous manner, allowing the cap to be held in place by the weight of the bumper itself.
While the present invention has been described in some detail for purposes of clarity and understanding, one skilled in the art will appreciate that various changes in form and detail can be made without departing from the true scope of the invention.
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