Patent Application
20220275593
This disclosure relates to crash attenuator systems, and in particular crash attenuator systems comprising an array of segments.
Conventional crash attenuator systems include plastic segments that may or may not be filled with a weighting material that are designed to absorb or transfer the energy of an impact from a vehicle. The systems are typically installed on the end of “jersey” or “k-rail” barriers that may serve as permanent or temporary medians or guiderails on the side of a roadway. Conventional systems are commonly molded in a process known as rotational molding, which results in a thick plastic element. Rotational molding is a time-consuming manufacturing technique, which can take upwards of forty minutes per segment.
Conventional systems commonly include metal reinforcement that may be either rigid or flexible running through an interior of the plastic segments. This metal reinforcement must be molded into the plastic via over-molding techniques and results in a permanent affixation between the multiple plastic segments that make up the system.
Such techniques are impractical because should a single segment become damaged in the field or during shipment, repair is challenging and replacement is costly because entire subassemblies may need to be replaced. Not only is this costly, but time consuming. Accordingly, there is a need for a system that can be easily repaired and quickly and economically manufactured.
The present disclosure includes a modular crash attenuator system including an array of attenuator segment pair assemblies. Each attenuator segment pair assembly includes a first attenuator segment and a second attenuator segment, a tensioning assembly configured to removably couple the first attenuator segment adjacent to the second attenuator segment, and a coupling assembly configured to removably couple the attenuator segment pair assembly to at least one other attenuator segment pair assembly.
The crash attenuator system additionally includes a barrier attachment assembly disposed at a first end of the array and coupled to at least one attenuator segment pair and an end cap assembly disposed at a second end of the array, the second end being opposite the first end.
Each of the first attenuator segment and the second attenuator segment includes an upper side, a lower side disposed opposite the upper side, a first lateral side extending between the upper side and the lower side, a second lateral side extending between the upper side and the lower side, the second lateral side disposed opposite the first lateral side, a first surface extending between the first lateral side and the second lateral side, and a second surface extending between the first lateral side and the second lateral side, the second surface disposed opposite the first surface. Furthermore, a first cavity is disposed on the first surface adjacent the first lateral side and a first protrusion is disposed on the first surface adjacent the second lateral side. The first cavity on the first attenuator segment is disposed to substantially accommodate the first protrusion on the second attenuator segment such that the first surface on the first attenuator segment is substantially flush with the first surface on the second attenuator segment when the first attenuator segment and the second attenuator segment are in a deployed state.
In some embodiments, the first lateral side and the second lateral side of each of the first attenuator segment and the second attenuator segment are further configured with at least two grooves configured to accommodate the tensioning assembly.
In another embodiment, a second cavity is disposed on the first surface adjacent the first lateral side and a second protrusion is disposed on the first surface adjacent the second lateral side. The second cavity on the first attenuator segment is disposed to substantially accommodate the second protrusion on the second attenuator segment such that the first surface on the first attenuator segment is substantially flush with the first surface on the second attenuator segment when the first attenuator segment and the second attenuator segment are in the deployed state.
In another embodiment, the second surface of each of the first attenuator segment and the second attenuator segment is further configured with a recess to accommodate the coupling assembly.
In some embodiments, the coupling assembly includes a slotted tube configured to receive a securement bar for coupling the attenuator segment pair assembly to at least one other attenuator segment pair assembly. The slotted tube contains at least two securement holes on opposing surfaces of the slotted tube for receiving a securement pin. The other attenuator segment pair assembly includes a complementary slotted tube configured to align with the slotted tube of the coupling assembly in order to receive the securement bar. The securement bar contains a securement channel that aligns with the securement holes for receiving the securement pin, which secures the securement bar to the slotted tube.
In some embodiments, the securement pin is a quick-release style pin.
In some embodiments, the tensioning assembly comprises a plurality of tensioning cables configured to contact at least the first lateral sides and the second lateral sides of the first attenuator segment and the second attenuator segment, and the tensioning cable are removably affixed to the coupling assembly.
In some embodiments the tensioning cables are removably affixed to the coupling assembly through a variable-tensioning assembly and are configured to provide a resultant compressive force between the first and second attenuator segments when the variable-tensioning assembly is in a deployed state.
In some embodiments, the variable-tensioning assembly comprises one or more eye-bolts threaded to one or more plates in the coupling assembly.
In some embodiments, the first attenuator segment and the second attenuator segment are hollow and configured to be filled with water. The attenuator segments also include a fill location disposed on each of the upper sides of the first attenuator segment and the second attenuator segment and a drain disposed on at least one of the first lateral sides or the second lateral sides of the first attenuator segment and the second attenuator segment.
In some embodiments, the first attenuator segment and the second attenuator segment expand when filled with water.
In some embodiments, the first attenuator segment and the second attenuator segment comprise blow-molded high-density polyethylene.
In some embodiments, a width of the array is approximately 24 inches and a height of the array is between 32 inches and 42 inches.
In some embodiments, the first attenuator segment and the second attenuator segment are hollow and have an outer wall thickness of between approximately 0.188 inches and 0.438 inches.
Additionally, disclosed is a crash attenuator segment for use in a modular crash attenuator system. The crash attenuator segment includes an upper side, a lower side disposed opposite the upper side, a first lateral side extending between the upper side and the lower side, a second lateral side extending between the upper side and the lower side, the second lateral side disposed opposite the first lateral side, a first surface extending between the first lateral side and the second lateral side, and a second surface extending between the first lateral side and the second lateral side, the second surface disposed opposite the first surface. A first cavity is disposed on the first surface adjacent the first lateral side and a first protrusion is disposed on the first surface adjacent the second lateral side. The first cavity on the attenuator segment is disposed to substantially accommodate a first protrusion on a paired attenuator segment such that the first surface on the attenuator segment is substantially flush with a first surface on the paired attenuator segment when the attenuator segment and the paired attenuator segment are in a deployed state.
In some embodiments, the first lateral side and the second lateral side of the crash attenuator segment are further configured with at least two grooves configured to accommodate a tensioning assembly.
In some embodiments, the crash attenuator segment additionally includes a second cavity disposed on the first surface adjacent the first lateral side and a second protrusion is disposed on the first surface adjacent the second lateral side. The second cavity on the attenuator segment is disposed to substantially accommodate a second protrusion on the paired attenuator segment such that the first surface on the attenuator segment is substantially flush with the first surface on the paired attenuator segment when the attenuator segment and the paired attenuator segment are in the deployed state.
In some embodiments, the second surface of the attenuator segment is further configured with a recess to accommodate a coupling assembly.
In some embodiments, the crash attenuator segment is made of blow-molded high-density polyethylene.
In some embodiments, a width of the attenuator segment is approximately 24 inches and a height of the attenuator segment is between 32 inches and 42 inches. Furthermore, the attenuator segment is hollow and has an outer wall thickness of between approximately 0.188 inches and 0.438 inches.
The accompanying drawings, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings:
In one or more implementations, not all of the depicted components in each figure may be required, and one or more implementations may include additional components not shown in a figure. Variations in the arrangement and type of the components may be made without departing from the scope of the subject disclosure. Additional components, different components, or fewer components may be utilized within the scope of the subject disclosure.
In addition, each of the drawings is a schematic diagram and thus is not necessarily strictly illustrated. In each of the drawings, substantially the same structural components are assigned with the same reference signs, and redundant descriptions will be omitted or simplified.
The detailed description set forth below is intended as a description of various implementations and is not intended to represent the only implementations in which the subject technology may be practiced. As those skilled in the art would realize, the described implementations may be modified in various different ways, all without departing from the scope of the present disclosure. For example, while the crash attenuator systems discussed herein may be implemented in many different forms, the disclosure will show in the drawings, and will herein describe in detail, implementations with the understanding that the present description is to be considered as an exemplification of the principles of the modular crash attenuator system and is not intended to limit the broad aspects of the disclosure to the implementations illustrated. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.
The size of the crash attenuator system 100 is typically 24 inches in width due to the standard dimension of jersey barriers. In some embodiments, the length of the system 100 is between 20 feet and 34 feet long, and between 32 inches to 42 inches tall. In a preferred embodiment, the system is approximately 32 inches tall.
The exemplary crash attenuator system 100 consists of an array of segment pairs 200. Among the segment pairs including a front attenuator segment pair 200a that is coupled to the end cap 600 and a terminal attenuator segment pair 200b that is coupled to the barrier attachment assembly 500. Intermediate segment pairs between the front attenuator segment pair 200a and the terminal attenuator segment pair 200b are coupled to each other via a coupling assemblies 300. Each attenuator segment pair comprises a first attenuator segment 210a, a second attenuator segment 210b, a tensioning element 400, and a coupling assembly 300 (not shown in
Barrier attachment assembly 500 additionally contains a terminal side coupling assembly 520 that is configured to cooperate with terminal coupling assembly 300a to secure terminal attenuator segment pair 200b to the barrier attachment assembly 500. In the embodiment shown in
In a preferred embodiment, the attenuator segment 210 comprises a hollow container formed by a blow molding process. The material of the attenuator segment 210 may be any form of plastic, but preferably is composed of high-density polyethylene (HDPE) or other such materials commonly used in the art of blow-molding manufacturing. In some embodiments the attenuator segment 210 has a thickness between approximately 0.078 inches and 0.625 inches. In a preferred embodiment, the thickness is between approximately 0.188 inches and 0.438 inches. The thickness may vary at different locations of the attenuator segment 210. The blow molding manufacturing process provides many advantages over traditional molding processes such as rotational molding. For example, blow-molding is a much faster process than rotational molding, which can take upwards of 40 minutes to complete a single segment, allowing for more product to be made in a given time period. As described previously, blow-molding results in a product with a wall thickness between 0.078 inches and 0.625 inches. This is generally thinner than a rotationally molded segment, which promotes ease of shipment and installation. The thinner materials also equate to savings in materials costs.
The elements of this disclosure can be formed of any number of polymers, rubbers, foams, metals, metal alloys, ceramics, woods or any other suitable material known to those skilled in the art. The blow molding process requires no drilling and allows the attenuator segments 210 to define a continuous, sealed and waterproof cavity therein.
In a deployed state, two attenuator segments 210 are designed to be paired into an attenuator segment pair 200. Within each attenuator segment pair 200, the first surface 215 of each attenuator segment 210 face each other and are designed to contact each other. In order to reduce movement between the attenuator segments 210 within the attenuator segment pair 200, a variety of mating features are disposed on the first surface 215 of each attenuator segment 210. For example, as shown in
As shown in
In some embodiments, each attenuator segment 210 holds approximately 40 gallons of weighting substance. Conventional systems include subassemblies that hold a much larger amount of weighting fluid. Utilizing a larger number of attenuator segments 210 with a smaller fill volume provides an advantage that each individual segment may be fine tuned to control the center of mass of the system 100. Having more accurate control over the center of mass of the system 100 provides the ability to accurately tailor the deceleration profile of an impacting vehicle to the needs of the particular application while maintaining vehicle operator safety.
At least one of the lateral sides 214 contain a draining hole 221 configured to allow the weighting substance to be drained from an attenuator segment 210. However, it is understood that draining hole 221 may be located elsewhere on the attenuator segment 210, such as on the lower side 213, first surface 215, or second surface 216. Draining hole 221 may be capped to prevent unintentional release of the weighting substance.
As additionally shown in
As additionally shown in
The tensioning elements 400 are preferably cables made of metal. The selected metal is preferably of the type which can withstand substantial corrosion due to weather, such as stainless steel. The selected metal may also be a coated in a material such as paint, or may have undergone a coating process such as galvanization, to prevent or reduce the effects of corrosion of the underlying metal. The tensioning element 400 may be comprised of a flexible material, where “flexible” means that the cables can easily bend under their own weight. Such flexible materials include steel cabling, also referred to a “wire rope,” composed of multiple smaller wire strands. However, the flexible material may also consist of a single metallic wire strand such as steel wire. Alternatively, the tensioning element 400 may consist of a substantially rigid metal, such that each tensioning element 400 is pre-formed in substantially the final shape it will attain after installation of the crash attenuator system 100. In a preferred embodiment, the tensioning elements 400 are daisy chained together so as to maintain their structural integrity during an impact, but also fly free of the segment pairs 200, in order to transfer energy away from the impact.
As tensioning elements 400 may be variably tensioned through the use of the eye bolt 320, it is possible to remove one or more attenuator segments 210, without disassembling the entire crash attenuator system 100. This serves multiple advantages, including eliminating the need to replace the entire system 100 should a single segment 210 be damaged. A maintenance operator may simply replace the damaged segment 210 with a new segment. This modular construction is beneficial from both a cost and time perspective.
While some implementations have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the disclosure, and the scope of protection is only limited by the scope of the accompanying claims. Terms such as “top,” “bottom,” “front,” “rear” and the like as used in this disclosure should be understood as referring to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, a top surface, a bottom surface, a front surface, and a rear surface may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference. Furthermore, to the extent that the term “include,” “have,” or the like is used in the description or the claims, such term is intended to be inclusive in a manner similar to the term “comprise” as “comprise” is interpreted when employed as a transitional word in a claim.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.
A reference to an element in the singular is not intended to mean “one and only one” unless specifically stated, but rather “one or more.” Pronouns in the masculine (e.g., his) include the feminine and neuter gender (e.g., her and its) and vice versa. The term “some” refers to one or more. Underlined and/or italicized headings and subheadings are used for convenience only, do not limit the subject technology, and are not referred to in connection with the interpretation of the description of the subject technology. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. All structural and functional equivalents to the elements of the various configurations described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and intended to be encompassed by the subject technology. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the above description.
While this specification contains many specifics, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of particular implementations of the subject matter. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
The subject matter of this specification has been described in terms of particular aspects, but other aspects can be implemented and are within the scope of the following claims. For example, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. The actions recited in the claims can be performed in a different order and still achieve desirable results. As one example, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the aspects described above should not be understood as requiring such separation in all aspects, and it should be understood that the described program components and systems can generally be integrated together in a single product or packaged into multiple products.
The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, inventive subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.
The claims are not intended to be limited to the aspects described herein, but are to be accorded the full scope consistent with the language claims and to encompass all legal equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirements of the applicable patent law, nor should they be interpreted in such a way.
The disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular implementations disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative implementations disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each article of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
