Protective and Reflective Guardrail Post Cap

Abstract

A protective and reflective post cap is disclosed herein. The post cap is preferably comprised of a generally dome-shaped anodized aluminum body with a reflective and UV resistant outer surface, and an adhesive inner surface for attaching to a post, such as a guardrail post, for preserving the useful life thereof. The post cap is also preferably comprised of a precipitation diverting skirt which directs precipitation away from the body of the wooden post, thereby preserving the useful life thereof. The post cap of the present invention prevents precipitation and ultraviolet radiation from permeating into and damaging the wooden post to which it is attached.

Description

BACKGROUND

The present invention relates generally to a protective and reflective post cap for attaching to a wooden post, such as the wooden posts that are used to support guardrail along a roadside. More specifically, the invention relates to a guardrail post cap that is comprised of anodized aluminum and/or a ultraviolet (UV) resistant plastic and having a reflective finish, an inner surface that is coated with an adhesive for adhering to a wooden post, and a precipitation deflection skirt to direct the elements, such as rain, snow, sleet, etc., away from the wooden post, thereby prolonging its useful life. Accordingly, the present specification makes specific reference thereto. However, it is to be appreciated that aspects of the present invention are also equally amenable to other like applications, devices and methods of manufacture.

Guardrail is a longitudinal barrier that is commonly used to protect motorists from roadside hazards by reducing the severity of collisions, and preventing a vehicle from veering off of a roadway and into an embankment or other object. Semi-rigid guardrails, such as metal beam guardrails supported by a plurality of spaced apart metal or wooden posts, are the typical type of guardrail installed along streets, roads, highways, interstates, and the like. A multitude of differing anchoring posts are commonly employed to anchor such guardrails to the ground and support the same. More specifically, a plurality of metal or wood anchor posts are driven a certain minimum distance into the ground (i.e., typically below the frost line) alongside a roadway, and lengths of guardrail are then attached to one another in series, as well as to the anchor posts, via a plurality of fasteners. Additionally, specially designed guardrail end caps may also be attached to the ends of a length of guardrail, particularly on the ends of guardrail that are facing oncoming traffic, to absorb, or at least reduce, the force of the impact caused by a car striking the end of the guardrail.

While metal anchor posts, such as those comprised of galvanized steel, used in the erection of guardrails are typically more immune to the effects of weather and precipitation, such as rust and water saturation/permeation, that can occur as a result of rain, snow and exposure to the elements, their use is oftentimes cost prohibitive. For example, it has been reported that the annual cost of ownership of galvanized steel guardrail posts per mile is as much as 80% more than the annual cost of ownership of wooden guardrail posts.

Unfortunately, while wooden guardrail posts are cheaper to own and maintain, wooden guardrail posts, such as wooden round or domed top anchor posts, are far more susceptible to the detrimental effects of, for example, rain, snow, UV rays from the sun, mold, infestation, freeze-thaw cycles, etc. than their galvanized steel counterparts. Additionally, when a wooden post is cut and rounded, the cross-sectional grain surface that forms the top of the post is often left with imperfections caused by the stress undergone by the wood when being cut and shaped into a post. These imperfections, along with the general propensity of wood posts to deteriorate over time from their exposure to the elements, can lead to the permeation of moisture into the body of the wooden post. This permeation of moisture through the wooden post through precipitation, such as rain, snow and the like, can over time lead to the pre-mature rotting or weakening of the wooden anchor posts. Additionally, the wooden anchor post may further be weakened as the moisture within the post undergoes the various freeze/thaw cycles associated with the seasons of the year. More specifically, when coupled with below freezing temperatures, the moisture trapped within the wooden posts has the ability to undergo various cycles of freezing and thawing, and the resulting expansion can crack the wooden post and compromise its structural integrity. In addition, the continuous exposure of the wooden anchor posts to the sun's harmful UV rays can further degrade an already partially compromised wooden anchor post.

Once the rotting and/or freezing/thawing cycles have compromised the structural integrity of the wooden post, it may no longer be able to support the weight of the guardrail or serve as a sufficient roadside barrier, thereby necessitating its replacement to ensure public safety. Unfortunately, in a time of increasing costs and shrinking construction/maintenance budgets, the need to replace or repair damaged wooden guardrail posts burdens all levels of responsible government.

Accordingly, there exists a long felt need in the art for a method of slowing down the historic deterioration of wooden posts, such as wooden guardrail anchor posts, and prolonging their useful life. More specifically, there exists in the art a long felt need for a guardrail post cap or cover that protects the uppermost portion of the wooden guardrail post from the elements, such as, rain, snow, sleet, road salt and the like, and that prevents significant moisture from infiltrating the wooden posts and deteriorating the same via rot or freeze/thaw cycling. Additionally, there is also a long felt need in the art for a guardrail post cap or cover that protects the wooden anchor post from harmful UV rays, and that is reflective so that it can be easily seen by oncoming motorists. Finally, there is a long felt need in the art for a wooden guardrail post cap that is relatively inexpensive to manufacture, and that is safe and easy to install and use.

The present invention, in one exemplary embodiment, discloses a protective post cap that is preferably comprised of a generally dome-shaped anodized aluminum body with a reflective and UV resistant outer surface, and an adhesive inner surface for attaching to a wooden post, such as a wooden guardrail anchor post, for preserving the useful life thereof. The protective post cap is also preferably comprised of a precipitation diverting skirt which directs precipitation and moisture away from the body of the wooden post, thereby preserving the useful life thereof. In an alternative embodiment of the present invention, the protective cap may be comprised of a generally dome-shaped UV resistant plastic body to protect against UV exposure from the sun, or a UV resistant coating that can be applied to the anodized aluminum body.

In this manner, the wooden guardrail post cap of the present invention accomplishes all of the forgoing objectives, thereby preserving the structural integrity of wooden guardrail anchor posts by shielding them from all forms of precipitation and the elements, and diverting said precipitation away from the wooden post as a whole. Additionally, the reflective nature of the wooden guardrail post cap of the present invention increases driver visibility of the guardrail by reflecting light from a vehicle's headlights. Finally, the adhesive coating on the inner surface of the wooden guardrail post cap of the present invention ensures a secure bond between the protective cap and the wooden post, and will prevent the cap from being unintentionally removed from the post by, for example, the wind.

SUMMARY

The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

The subject matter disclosed and claimed herein, in one embodiment thereof, comprises a generally dome-shaped anodized aluminum cap with a reflective and UV resistant outer surface, and an adhesive inner surface for attaching to a wooden post, such as a wooden guardrail anchor post, for preserving the useful life thereof. The protective post cap is also preferably comprised of a precipitation diverting skirt along the lower circumference of the post cap for directing precipitation and moisture away from the body of the wooden post, thereby preserving the useful life thereof.

To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a prior art and generally cylindrical wooden post with a plurality of rails attached thereto, wherein the post and the rails exhibit signs of deterioration in the forms of cracks and the like.

FIG. 2A illustrates a perspective top view of one potential embodiment of the guardrail post cap of the present invention in accordance with the disclosed architecture.

FIG. 2B illustrates a perspective side view of the wooden guardrail post cap of FIG. 2A about to be placed atop of a generally cylindrical wooden guardrail anchor post in accordance with the disclosed architecture.

FIG. 3 illustrates a perspective side view of an alternative embodiment of the guardrail post cap of the present invention about to be placed atop of a generally cylindrical wooden guardrail anchor post, and having a precipitation diverting skirt around the lower circumference of the side portion of the post cap in accordance with the disclosed architecture.

FIG. 4 illustrates a perspective bottom view of the wooden guardrail post cap of FIG. 3, and having a precipitation diverting skirt around the lower circumference of the side portion of the post cap in accordance with the disclosed architecture.

FIG. 5 illustrates a cross-sectional view of the wooden guardrail post cap of FIG. 3 at cut line 3-3 and attached to the wooden anchor post in accordance with the disclosed architecture.

DETAILED DESCRIPTION

The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof.

As noted above, there exists a long felt need in the art for a method of slowing down the historic deterioration of wooden posts, such as wooden guardrail anchor posts, and prolonging their useful life. More specifically, there is a long felt need in the art for a guardrail post cap that protects the uppermost portion of the wooden guardrail anchor post from the elements, such as, rain, snow, sleet, road salt and the like, and that prevents significant moisture from infiltrating the wooden posts and deteriorating the same via rot or freeze/thaw cycling. There is also a long felt need in the art for a guardrail post cap that protects the wooden anchor post from harmful UV rays, and that is reflective so that it can be seen by oncoming motorists via the reflection of their vehicle's headlights. Finally, there is a long felt need in the art for a wooden guardrail post cap that is relatively inexpensive to manufacture, and that is easily secured to the wooden guardrail anchor post.

Referring initially to the drawings, FIG. 1 illustrates a perspective view of a prior art wooden guardrail anchor post 10 with a plurality of rails 20 attached thereto. More specifically, guardrail anchor post 10 is comprised of a rounded or domed shaped top portion 14 and a generally cylindrical body 16 that is attached to a plurality of rails 20. As is typical with such prior art wooden anchor posts that have been in the field for some time and exposed to the elements (e.g., rain, snow, sleet, wind, UV rays from the sun), each of wooden guardrail anchor post 10 and the plurality of rails 20 show signs of deterioration in the form of openings or cracks 12 in the surface thereof.

As explained above, when a wooden post is cut and rounded, the cross-sectional grain surface that forms the top of the post is often left with imperfections caused by the stress undergone by the wood when being cut and shaped into a post. More specifically, when a rounded contour cut is made, the end grains and wood fibers that are typically protected by the outer surfaces of the wood are thereby exposed. These end grains/fibers are extremely susceptible to the permutation/absorption of water and, once this process occurs, cracks/rotting begin to form.

These imperfections, along with the general propensity of wooden posts 10 to deteriorate over time from their exposure to the elements (e.g. wind, rain, snow, sleet, etc.) and other harmful substances (e.g., road salt, pesticides, etc.) can lead to the permeation of moisture throughout the entirety of the wooden post 10. This permeation of moisture throughout the wooden post 10 will, over time, lead to the additional rotting or weakening of the wooden post 10.

Additionally, wooden post 10 may further be weakened as the moisture within the wooden post 10 undergoes the various freeze/thaw cycles associated with the seasons of the year, and from the sun's harmful UV rays. More specifically, as the permeation and freezing/thawing process repeats, the cracks 12 become bigger and bigger due to the expansion/contraction of the saturated wood fibers until said cracks 12 ultimately compromise the structural integrity of wooden post 10. Once the structural integrity of the wooden post 10 has been compromised, it may no longer be able to support the weight of the guardrail 20, or serve as a sufficient roadside barrier, thereby necessitating its replacement to ensure public safety.

FIG. 2A illustrates a perspective top view of one potential embodiment of the guardrail post cap 100 of the present invention in accordance with the disclosed architecture. More specifically, guardrail post cap 100 is generally cylindrical in shape, and is preferably comprised of an anodized aluminum or other anti-corrosive or corrosion resistant material to resist the elements (e.g. wind, rain, snow, sleet, etc.) and harmful chemicals (e.g., road salt, debris, herbicides, pesticides, etc.) that can be encountered along a roadside. Anodized aluminum in particular has been proven to exhibit increased anti-corrosive and anti-wear properties, and is very durable. Nonetheless, it is also contemplated that guardrail post cap 100 may be comprised of a UV resistant plastic or other material having a UV protective coating thereon, as explained more fully below, to protect the post cap 100 device from the sun's harmful UV rays, as well as the above referenced elements, chemicals and contaminants.

As best shown in FIGS. 2A and 2B, the guardrail post cap 100 of the present invention is also preferably comprised of a top 110, a side portion 112, an opening 114, and an interior surface 116. Top 110 is generally rounded or dome shaped, and preferably mirrors or mimics the angle and contour of the top surface 14 of wooden post 10. Nonetheless, it is contemplated that the actual angle/degree of the contour of the top portion 110 of the guardrail post cap 100 may differ slightly from the angle/degree of the contour of the post 10 to allow the guardrail post cap 100 to encapsulate the entirety of the post top surface 14.

Side portions 112 are generally cylindrical in shape, and are also sized to accommodate an average sized guardrail anchor post 10, as explained more fully below. Each of the top portion 110 and the side portion 112 of guardrail post cap 100 may further comprise a reflective finish or coating 120 thereon, such as Hi-Viz retro-reflective powder coatings available from Halo Coatings in Akron, Ohio or similar reflective products. Nonetheless, it is also contemplated that reflective materials can be integrally formed within the anodized aluminum or plastic compositions referenced above, or be in the form of a reflective tape such as that which is manufactured and sold by 3M of St. Paul, Minn. The presence of reflective material or coating 120 on guardrail post cap 100 enables oncoming motorists to see the guardrail post caps 100, and the guardrail anchor posts 10 that they are attached to, via the reflection of their vehicle's headlights.

Additionally, each of the top portion 110 and the side portions 112 of guardrail post cap 100 may further comprise a UV protective finish or coating thereon or therein, such as NanoMyte UV protective coatings that are available from NEI Corporation in Somerset, New Jersey, or similar UV protective materials. The presence of a UV protective coating on guardrail post cap 100 resists the harmful UV rays of the sun that could lead to the premature failure of the guardrail post caps 100.

As stated above, guardrail post cap 100 further comprises an opening 114 therein and an interior surface 116. Opening 114 is shaped and sized to accommodate the top 12 and body 16 of a typically sized wooden anchor post 10, and form a friction fit therebetween to prevent unintended removal of the guardrail post cap 100 from the wooden anchor post 10 once installed. More specifically, it is contemplated that the interior diameter of opening 114 will typically be between 5″ to 8″ to accommodate a standard sized wooden anchor post 10. Nonetheless, it is also foreseeable that the opening 114 could be of any conceivable diameter, size and/or shape to accommodate any and all diameters, sizes and/or shapes of wooden anchor posts 10 including, without limitation, circular, oval, square, rectangular, and the like.

When properly fitted, the interior surface 116 of guardrail post cap 100 will be in contact with the top 12 and/or the body 16 of wooden anchor post 10. Accordingly, the interior surface 116 of guardrail post cap 100 may further comprise an adhesive coating 1162, as best shown in FIG. 4, to more securely attach guardrail post cap 100 to wooden anchor post 10 once installed. Adhesive coating 1162 may be any type of adhesive known in the art for securing two articles together in an outdoor environment, such as the adhesives manufactured and sold by Sika Corporation of Lyndhurst, N.J. Further, adhesive coating 1162 may be provided with a protective liner (not shown) that can be removed just prior to application of the post cap 100 to anchor post 10 to prevent the adhesive coating from drying out.

FIG. 3 illustrates a perspective side view of an alternative embodiment of the guardrail post cap 100 of the present invention about to be placed atop of a generally cylindrical wooden guardrail post 10, and having a precipitation diverting skirt 118 around the lower circumference of the post cap 100 in accordance with the disclosed architecture. More specifically, the precipitation diverting skirt 118 may be integrally formed within the sides 112 of guardrail post cap 100 during the manufacturing process. Alternatively, precipitation diverting skirt 118 may be manufactured separately, and then fixedly attached around the lower circumference of the guardrail post cap 100 by, for example, an adhesive (not shown) or other suitable fastening means (also not shown), such as may be the case when retrofitting a guardrail post cap 100 that has already been attached to a guardrail post 10 in the field. Suitable fastening means may include, but are not limited to, a tongue and groove channel or screw/bolt fastening means (not shown).

The precipitation diverting skirt 118 is comprised of a beveled edge that directs any precipitation that may come in contact with the surface of the guardrail post cap 100 away from the rest of the guardrail post 10 to which it is attached. The exterior diameter of the precipitation diverting skirt 18 is between two and twenty percent larger than the exterior diameter of side portion 112. This ensures that any precipitation that has already been deflected away from the top surface 14 of the post 10 by the presence of guardrail post cap 100 is also directed away from the body 16 of the guardrail post to prevent permeation therein.

FIG. 4 illustrates a perspective bottom view of the wooden guardrail post cap 100 of FIG. 3, and having a precipitation diverting skirt 118 around the lower circumference of the side surface 112 of the post cap 100 and an adhesive coating 1162 on the interior surface 116 of the post cap 100 to secure the same to the top 14 of a guardrail post 10 in accordance with the disclosed architecture. Likewise, FIG. 5 illustrates a cross-sectional view of the wooden guardrail post cap 100 of FIG. 3 at cut line 3-3, and attached to the wooden guardrail post 10 in accordance with the disclosed architecture. More specifically, the presence of precipitation diverting skirt 118 on the lower circumference of the side surface 112 of the post cap 100 serves to direct any precipitation that may come in contact with the surface of the guardrail post cap 100 away from the rest of the guardrail post 10 to which it is attached.

Notwithstanding the forgoing, the wooden guardrail post cap 100 of the present invention can by any suitable size, shape, and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above stated objectives. One of ordinary skill in the art will appreciate that the shape and size of the wooden guardrail post cap 100 and its various components, as show in the FIGS. are for illustrative purposes only, and that many other shapes and sizes of wooden guardrail post cap 100 are well within the scope of the present disclosure. Although dimensions of the wooden guardrail post cap 100 and its components (i.e., length, width, and height) are important design parameters for good performance, the wooden guardrail post cap 100 and may be any shape or size that ensures optimal performance during use and/or that suits user need and/or preference.

What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.

Claims

1. A post cover cap for an anchor post comprising: a top portion;a side portion integrally formed with the top portion; andan opening for receipt of a portion of the anchor post

2. The post cover cap of claim 1, wherein the top portion is dome-shaped.

3. The post cover cap of claim 1, wherein the post cover cap is comprised of anodized aluminum.

4. The post cover cap of claim 1 further comprising an adhesive on an interior surface of the post cover cap.

5. The post cover cap of claim 1 further comprising an reflective material on an exterior surface of the post cover cap.

6. The post cover cap of claim 1 further comprising an ultraviolet light protective coating on an exterior surface of the post cover cap.

7. The post cover cap of claim 1 further comprising a skirt.

8. The post cover cap of claim 7, wherein the skirt is positioned along a circumference of the side portion opposite the top portion.

9. The post cover cap of claim 7, wherein the skirt has a diameter that is larger than an exterior diameter of the side portion.

10. The post cover cap of claim 10, wherein the diameter of the skirt is between two and twenty percent larger than the exterior diameter of the side portion.

11. A post cover cap for an anchor post comprising: a top portion;a side portion, wherein each of the top and side portions are comprised of a reflective outer surface;an opening for receipt of a portion of the anchor post; andan interior surface.

12. The post cover cap of claim 11, wherein the top portion is dome-shaped.

13. The post cover cap of claim 11, wherein the post cover cap is comprised of anodized aluminum or a ultraviolet resistant plastic.

14. The post cover cap of claim 11, wherein the interior surface is coated with an adhesive.

15. The post cover cap of claim 11 further comprising an ultraviolet light protective coating on an exterior surface of the post cover cap.

16. The post cover cap of claim 11 further comprising a skirt positioned along a circumference of the side portion opposite the top portion.

17. The post cover cap of claim 16, wherein the skirt has a diameter that is larger than an exterior diameter of the side portion.

18. The post cover cap of claim 17, wherein the diameter of the skirt is between two and twenty percent larger than the exterior diameter of the side portion.

19. The post cover cap of claim 16, wherein the skirt is removably attached to the side portion.

20. A post cover cap for an anchor post comprising: a dome-shaped top portion;a cylindrical shaped side portion extending from the dome-shaped top portion;an opening in an end of the cylindrical shaped side portion that is opposite the dome-shaped top portion;a reflective and corrosion resistant outer surface;an adhesive coated inner surface for contacting the anchor post; anda precipitation diverting skirt positioned along a circumference of the side portion adjacent to said opening.