CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This Application claims the benefit of U.S. Provisional Application 61/326,402 filed on April 21, 2010, U.S. Provisional Application 61/365,091 filed on July 16, 2010, and U.S. Provisional Application 61/386,120 filed on September 24, 2010, the disclosures of which are incorporated by reference herein in their entirety.

FIELD OF THE INVENTION

[0002] The present invention relates to a road marker having a solid body adapted to withstand tensile forces of a vehicle tire and lens protection in the form of vertical exterior ribs which extend beyond the exposed surface of the lens to provide a gap between the lens surface and the tire.

BACKGROUND OF THE INVENTION

[0003] Road markers having reflective lenses are used to delineate lanes of roads. In the past, road markers typically have a shell with a retroreflective lens. The interior side of the retroreflective lens is metallized and the interior of the shell is filled with a "potting" material to provide strength and rigidity to the shell. Recently, road markers having "solid" bodies have been produced to eliminate the need for "potting". These markers have not been successful in several ways. In some cases the bodies have fatigued. Some markers are formed with interior channels which are covered on the bottom wall with a plastic panel. However, the plastic panel has very low surface energy resulting in poor retention to the road surface. Additionally, the lens surface has been subjected to substantial degradation from abrasion of sand particles carried by the tires of vehicles. Accordingly, it remains desirable to have a road marker with a solid body operable to resist fatigue, has a greater road surface retention relative to current road markers, and withstand degradation from the passing of tires.

SUMMARY OF THE INVENTION AND ADVANTAGES

[0004] A road marker having a solid body, at least one lens, and lens protection in the form of vertical exterior ribs which extend beyond the exposed surface of the lens to provide a gap between the lens surface and the tire is provided. The road marker is configured to withstand the force of a tire of a vehicle travelling over the road marker. [0005] The road marker includes at least one lens having a reflective surface. The road marker further includes a body having a trapezoidal cross section. The body further includes a flat top, a bottom wall, a pair of angled sides with pockets for the lenses, and a pair of rounded ends.

[0006] A pocket is disposed on each of the angled sides. The pocket is formed to receive the lens. Each pocket extends from the top to the bottom wall and from one of the pair of rounded ends to the other of the pair of rounded ends. The road marker further includes a plurality of vertical exterior ribs which extend beyond the exposed surface of the lens to provide a gap between the lens surface and the tire.

[0007] In a first preferred embodiment, the road marker further includes a plurality of recesses extending downwardly an equal distance from the top and angled sides to the bottom wall. The recesses are generally rectangular. The bottom wall of each angled side is curved outwardly to provide additional area for the lens and to provide a smooth surface for the tires. Each of the pair of rounded ends are contoured from the top to the bottom wall, each of the pair of rounded ends further including a flange extending outwardly from each of the pair of rounded ends.

[0008] The bottom wall includes a lip bounding the peripheral edge of the bottom wall so as to define a recess in the center of the bottom wall, and a layer of polyurethane configured to fittingly engage the recess. The road marker further includes a plurality of grooves disposed on each of the pockets. The plurality of grooves extending axially from the top wall towards the bottom wall, the grooves are generally parallel with each other.

[0009] Each lens includes a plurality of vertically extending energy directors are also formed in the interior surface of the lens, the energy directors operable to facilitate ultrasonic welding of the lenses to the body. The plurality of vertical exterior ribs is disposed on each lens.

[0010] In a second preferred embodiment, the body is formed of cast aluminum and includes a center portion formed on the top, the center portion has an opening. The pocket is a plurality of pockets formed on each of the angled sides. Each of the plurality of pockets is formed by a vertical surface and a horizontal surface. The horizontal and vertical surfaces meet to form a plurality of corners and a plurality of steps.

[0011] The lens has a horizontal and vertical interior surface. The lens is configured to seat within one of the plurality of pockets. A plurality of ribs extends from the top to the bottom wall. The ribs form a plurality of pockets stacked on top of each other so as to form a stack of pockets. Each of the plurality of ribs extends beyond the corner formed by adjacent horizontal and vertical surfaces. Each of the vertical surfaces includes a concave depression so as to reduce mass of the road marker and help direct tire pressure transversely across the body of the road marker.

[0012] In an illustrative example, the horizontal and vertical surfaces are generally orthogonal to each other. Each lens has an outer surface which extends at an approximately 45 degree angle and the horizontal and vertical interior surface are orthogonal to each other. The lenses are mounted within each pocket. The outer surface of the lens is recessed slightly from ribs and corners which define each pocket.

[0013] The bottom wall surface of the marker is generally planar with a series of grooves with a tire tread like pattern formed in the surface to receive glue. The road marker may further include semicircular notches formed on each of the rounded ends to facilitate the gripping of the marker for insertion in the road surface. The road marker may further include a retroreflective sheeting disposed along the vertical surface of the lens.

[0014] In a third preferred embodiment, the bottom wall includes a plurality of grooves operable to increase the retention ability of the road marker to the road surface. The plurality of grooves includes a plurality of horizontal grooves extending in a longitudinal direction. A pair of radially extending grooves extending radially from a respective point on the center of the longitudinal axis to a respective end portion of the body.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0016] Figure 1 is a perspective view of a first preferred embodiment of a road marker of the present invention;

[0017] Figure 2 is a perspective view of the road marker of Figure 1, taken from the opposite side;

[0018] Figure 3 is a perspective view of the underside of the road marker of Figure 1 ;

[0019] Figure 4 is a perspective view of road marker of Figure 3, showing the road marker fitted with a thin layer of polyurethane;

[0020] Figure 5 is a perspective view of the exterior surface of a lens;

[0021] Figure 6 is a perspective view of the interior surface of a lens; [0022] Figure 7 is an illustrative view of a second preferred embodiment of a road marker of the present invention;

[0023] Figure 8 is an illustrative view of the road marker of Figure 7 without the lens inserted into the pockets;

[0024] Figure 9 is an isolated view of a lens for use in the road marker of Figure 8;

[0025] Figure 10 is a perspective view showing the underside of the road marker of Figure 8;

[0026] Figure 11 is an illustrative view of another embodiment of the road marker of the second preferred embodiment;

[0027] Figure 12 is an illustrative view of a third preferred embodiment of a road marker of the present invention;

[0028] Figure 13 is an illustrative view of the road marker of Figure 12 taken from the opposite side; and

[0029] Figure 14 is a view of the underside of the road marker of Figure 12. DETAILED DESCRIPTION OF THE INVENTION

[0030] Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a road marker 10 having a solid body 12, at least one lens 14, and lens 14 protection in the form of vertical exterior ribs 16 which extend beyond the exposed surface of the lens 14 to provide a gap between the lens 14 surface and the tire is provided.

[0031] The body 12 has a generally rectangular footprint with a trapezoidal cross section. The body 12 has a flat top 18, bottom wall 20, a pair of angled sides 22 with pockets 24 for the lenses 14, and a pair of ends 26. Each angled side 22 has at least one pocket 24, each are formed to receive the lens 14. The pockets 24 extend from the top 18 to the bottom wall 20 and from end 26 to end 26.

[0032] With reference now to Figures 1-6, a first preferred embodiment of the road marker 10 is provided. The marker has a body 12 molded of a plastic material such as ABS, a pair of lens 14 for insertion into a respective pocket 24, and a thin layer 28 of polyurethane formed on the bottom wall 20 of the body 12.

[0033] With reference now to Figure 1, the pockets 24 are formed to receive the lens 14. Each pocket 24 extends from the top 18 to the bottom wall 20 and from end 26 to end 26. The pockets 24 are formed recessed from the outer surface of the angled sides 22. The pockets 24 are configured to fittingly hold a lens 14. [0034] The bottom wall 20 of each angled side 22 is curved outwardly to provide additional area for the lens 14 and to provide a smooth surface for the tires. The pockets 24 are also countoured. Likewise, the ends 26 are contoured from the top 18 to the bottom wall 20 where a flange 30 extends from each end 26.

[0035] As shown in Figures 1 and 2, the body 12 has a plurality of elongated recesses 32 extending downwardly an equal distance from the top 18 and angled sides 22 to a bottom wall 20. The elongated recesses 32 are generally rectangular and are formed to provide sufficient strength to the body 12 to help the road marker 10 resist the impact of vehicles. It has been found during testing that when the marker is subjected to a load from a vehicle, there is flexural stress. The tensile portion of the stress is focused on the marker. The bottom wall 20 extends transversely to absorb the tensile stress properly.

[0036] With reference now to Figure 3 a view of the bottom wall 20 is provided. The bottom wall 20 has a generally rectangular recessed surface 34 which extends inwardly into the bottom wall 20. The bottom wall 20 includes a lip 36 bounding the peripheral edges of the bottom wall 20. The lip 36 extends beyond the surface of the center of the bottom wall 20 so as to define the recessed surface 34 in the center of the bottom wall 20. The recessed surface 34 may be displaced .020" from the outer surface of the lip 36.

[0037] There are additional depressions 38 formed on the underside of the body 12 where there are large portions of material of the body 12 such as under the ends 26. The depressions 38 are formed to eliminate unneeded plastic material.

[0038] With reference now to Figure 4, the road marker 10 may further include a thin layer 28 of polyurethane. The thin layer 28 of polyurethane is configured to be fittingly engaged within the recessed surface 34. The thin layer 28 of polyurethane has better retention with adhesives than the ABS plastic of the body 12, and thus improves the overall road retention of the road marker 10 relative to road markers 10 with ABS plastic bottom walls 20. In instances where the lip 36 extends beyond the surface of the center of the bottom wall020", the thin layer 28 of polyurethane has a thickness of approximately .020" so as to form a generally flush and even bottom wall 20 surface.

[0039] With reference now to Figures 5 and 6, each lens 14 is generally rectangular, and has a generally planar outer surface and cube corners 40 formed on the interior surface. With reference first to Figure 6, a view of the back angled side 22 of the lens 14 is provided. As shown, a plurality of vertically extending energy directors 42 are also formed in the interior surface of the lens 14. The energy directors 42 are used to facilitate ultrasonic welding of the lenses 14 to the body 12.

[0040] With reference now to Figure 5, a view of the front angled side 22 of the lens 14 is provided. A plurality of vertical ribs 16 is formed on the exterior surface of the lens 14. Preferably, the ribs 16 are opposite each respective energy director 42. The ribs 16 extend outwardly beyond the exposed surface of the lens 14 to keep the surface of a tire passing over the lens 14 from abrading the exposed surface. The ribs 16 are generally triangular in cross section and extend over the energy directors 42 to minimize the loss of cube corners 40 which occurs from the formation of the energy directors 42.

[0041] With reference now to Figures 7-11, a second preferred embodiment of a road marker 110 of the present invention is provided, wherein like parts are indicated by numerals offset by 100. The body 112 may be formed of durable and rigid material. For instance, the body 112 may be formed of aluminum or a moldable material such as molded, suitable plastic such as ABS, reinforced glass, fiberglass, or other composite material aluminum. The road marker 110 includes a plurality of replaceable lens 114 configured in segments. The lens 114 segments are protected by vertical ribs 116 which extend between the lens 14.

[0042] With reference first to Figure 8, the body 112 of the marker may be formed in one piece of cast aluminum. Aluminum is more resistant to wear than plastics. The body 12 has a generally rectangular footprint and a trapezoidal cross section. The body 112 has a bottom wall 120, two angled sides 122 extending between a pair of ends 126, and a center portion with an opening 44. Accordingly, the opening 44 is formed in the center to reduce the amount of material used to form the marker.

[0043] With reference now to Figure 11, the body 112 is formed from a moldable plastic. The pockets 124 are formed along the angled sides 122 of the road marker 110. Each pocket 124 has a generally vertical surface 48 and a horizontal surface 50 to support a lens 114. A plurality of ribs 116 extend from the top 118 to the bottom wall 120. The horizontal and vertical surfaces 50, 48 form a pocket 124 for a respective lens 14. Though Figure 11, shows the angled sides 122 including a row of three pockets 124 separated by ribs 116 extending from the top 118 to the bottom wall 120, it should be appreciated by those skilled in the art that the angled sides 122 may include multiple pockets 124 arranged in various configurations such as stacked on top 18 of each other so as to form columns of pockets 124 in a side-by-side relationship, as shown in Figure 8. [0044] With reference again to Figure 8, each angled side 122 wall of the body 112 includes a plurality of pockets 124 stacked on top 118 of each other so as to form a stack of pockets 52. The ribs 16 extend beyond the corner 54 formed by adjacent horizontal surfaces 50 and vertical surfaces 48. Each pocket 124 within the stack of pockets 52 are formed by horizontal and vertical surfaces 50, 48 which meet at a corner 54 so as to form a step 56. The ribs 116 compartmentalize the stack of pockets 52 so as to form three stacks of pockets 24 arranged in a side-by- side relationship.

[0045] The ribs 116 are further operable to support tranverse walls 46 forming the opening 44 of the body 112. The figure shows the horizontal and vertical surfaces 50, 48 being generally orthogonal to each other. However, it should be appreciated that angle of the surface is selected in accordance with the angle walls of lens 114 as discussed below. Each of the vertical surfaces 48 includes a concave depression 58 so as to reduce mass of the road marker 10. Further, the concave depressions 58 help direct tire pressure transversely across the body 112 of the road marker 110.

[0046] As shown in Fig. 9, each lens 114 element has an outer surface 114a which extends at approximately a forty-five degree angle with respect to horizontal and vertical interior surfaces 114b, 114c which are generally orthogonal to each other. The lenses 114 are mounted within each pocket 124. The outer surface of the lens 114 is recessed slightly from ribs 116 and corners 54 which define each pocket 124.

[0047] As shown in Fig. 10, the surface of the bottom wall 120 of the marker is generally planar with a series of second grooves 60 with a tire tread like pattern formed in the surface to receive glue. Semicircular notches 62 extend into each end 126 surface to facilitate the gripping of the marker for insertion in the road surface.

[0048] Each lens 114 may further include a retroreflective sheeting 64 along the vertical surface 48 of the lens 114. The lens 114 is glued into the pocket 124. The use of independent lens 114 segments permits replacement of the segments of lens 114 to prevent crack propagation along the entire width of the road marker 110 relative to road markers with single lenses spanning the width of the road marker. The ribs 116 prevent cracks will not propagate the entire width of the body 12 of the road marker 110. Additionally, the segment of lenses 14 may be replaced if damaged.

[0049] The lens 114 may be formed of plastic or glass. The vertical wall or the outer wall of the lens 114 can be set at a desired angle to maximize the reflectivity of the reflective sheeting according to the Snell principle as discussed in provisional patent application no. 61/288,687. [0050] With reference now to Figures 12-14, a third embodiment of the road marker 210 is provided, wherein like parts are indicated by numerals offset by 200. The body 212 is molded in a single piece of plastic such as ABS. The body 212 has a generally rectangular footprint and a trapezoidal cross section. The body 212 has a bottom wall 220, two angled sides 222 extending between a pair of ends 226. The body 212 includes a raised center portion with an opening 244 extending downwardly from a top 218. The opening 244 is formed in the center to reduce the amount of material used to form the marker.

[0051] The body 212 has a plurality of vertical elongated recesses 232 surrounding the opening 244. The vertical elongated recesses 232 extend downwardly to the bottom wall 220 as in the first embodiment. The elongated recesses 232 are generally rectangular and extend through the lens 214 pocket 224 as well as the center portion of the road marker 210. These elongated recesses 232 are also intended for not to exceed the maximum wall thickness of the plastic injection molding, varying from plastic to plastic approximately to 0.145"of wall thickness.

[0052] Each angled side 222 has at least one pocket 224, each are formed to receive the lens 214. The pockets 224 extend from the top 218 to the bottom wall 220 and from end 226 to end 226 of the body 212. The pockets 224 may include a plurality of has a plurality of elongated recesses 232 extending downwardly from the outer surface of the pockets 224 towards the bottom wall 220 of the body 212. The elongated recesses 232 are generally rectangular and are formed to provide sufficient strength to the body 212 to help the road marker 210 resist the impact of vehicles.

[0053] The bottom wall 220 of each angled side 222 is curved outwardly to provide additional area for the lens 214 and to provide a smooth surface for the tires. Likewise, the ends 226 are contoured from the top 218 to the bottom wall 220 where a flange 230 extends from each end 226.

[0054] With reference again to Figures 5 and 6, the road marker 210 of the third preferred embodiment includes a pair of lenses 214. Each lens 214 is generally rectangular in shape, having a generally planar outer surface and cube corners 240 formed on the interior surface. With reference first to Figure 5, a view of the back side 222 of the lens 214 is provided. As shown, a plurality of vertically extending energy directors 242 are also formed in the interior surface of the lens 214. The energy directors 242 are used to facilitate ultrasonic welding of the lenses 214 to the body 212. [0055] With reference now to Figure 6, a view of the front side of the lens 214 is provided. A plurality of vertical ribs 216 is formed on the exterior surface of the lens 214. Preferably, the ribs 216 are opposite each respective energy director 242. The ribs 216 extend outwardly beyond the exposed surface of the lens 214 to keep the surface of a tire passing over the lens 214 from abrading the exposed surface. The ribs 216 are generally triangular in cross section and extend over the energy directors 242 to minimize the loss of cube corners 240 which occurs from the formation of the energy directors 242.

[0056] As shown in Fig. 14, the bottom wall 220 surface of the marker has a specially formulated arrangement of third grooves 66 to increase the retention ability of the road marker 210 to the road surface. Across most of the surface of the bottom wall 220 of the base are a plurality of horizontal third grooves 68 extending in a longitudinal direction. However, each end 226 is provided with a fan of radially extending third grooves 70. The radially extending third grooves 70 extend radially from a point on the center of the longitudinal axis to the end 226. The horizontal third grooves 68 resist displacement of the marker by push from a tire and the fans of radial grooves 66, 68, 70 resist displacement from twist. Thus disclosed are embodiments of novel solid body road marker.

[0057] It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.