Portable roadway warning device with high-density filler and absent rigid metal ballast inserts

Abstract

A roadway warning device including a portable rumble strip that includes high-density filler material to achieve a desired overall density and roadway stability of the rumble strip such as for use in high-speed traffic conditions without the use of conventional rigid metal ballast inserts. In some embodiments, the filler is dispersed and embedded within a flexible polymer composite matrix of the rumble strip body. In some embodiments, the filler is in the form of discrete unbound pieces of material disposed within a cavity of the rumble strip body. In some embodiments, the filler is in the form of a frangible article disposed within the rumble strip body.

1 . A portable rumble strip comprising an elongated flexible body having an upper vehicle engagement surface, a lower roadway engagement surface, and a leading edge and trailing edge between the upper and lower engagement surfaces, the elongated flexible body having a length greater than width and the width greater than thickness, wherein the elongated flexible body incorporates a composite having a flexible polymeric material matrix and at least one filler dispersed in the matrix that enhances the density of the composite, wherein the at least one filler is included in an amount that provides an overall density of the elongated flexible body in a range from 0.06 lb/in 3  to 0.15 lb/in 3 . 
     
     
         2 . The portable rumble strip according to  claim 1 , wherein the flexible polymeric material matrix of the composite is co-vulcanized with the one or more additional portions of the body to form a unitary structure. 
     
     
         3 . The portable rumble strip according to  claim 1 , wherein the at least one filler is dispersed uniformly throughout the matrix of the composite such that the elongated flexible body is free to flex in multiple different directions at any location along the length of the body that corresponds with the composite. 
     
     
         4 . The portable rumble strip according to  claim 1 , wherein the at least one filler has a density greater than a density of the flexible polymeric material matrix. 
     
     
         5 . The portable rumble strip according to  claim 1 , wherein the at least one filler has a specific gravity of 3.0 or greater. 
     
     
         6 . The portable rumble strip according to  claim 5 , wherein the at least one filler is included in an amount from 100 parts to 1100 parts by weight per 100 parts by weight total polymer of the flexible polymeric material matrix of the composite. 
     
     
         7 . The portable rumble strip according to  claim 5 , wherein the flexible polymeric material matrix has a density of less than 0.060 lb/in 3 . 
     
     
         8 . The portable rumble strip according to  claim 7 , wherein the flexible polymeric material matrix includes a thermoset or thermoplastic elastomer. 
     
     
         9 . The portable rumble strip according to  claim 1 , wherein the at least one filler has greater corrosion resistance to sodium chloride than plain carbon steel. 
     
     
         10 . The portable rumble strip according to  claim 1 , wherein the at least one filler is in powder form, and an average particle size of the powder is in a range from 0.1 microns to 500 microns. 
     
     
         11 . The portable rumble strip according to  claim 1 , wherein the at least one filler is an oxide, carbide, nitride, sulfide, sulfate, silicate, inorganic, or mineral comprising at least one alkaline earth, transition, or post transition metal element. 
     
     
         12 . The portable rumble strip according to  claim 1 , wherein the at least one filler includes one or more of lead oxide (PbO), iron oxide (Fe3O4), zinc oxide (ZnO), or barium sulfate (BaSO4). 
     
     
         13 . The portable rumble strip according to  claim 1 , wherein the at least one filler that enhances the density of the composite is ZnO in an amount from 500 parts to 1100 parts by weight per 100 parts by weight total polymer of the flexible polymeric material matrix of the composite. 
     
     
         14 . The portable rumble strip according to  claim 1 , wherein the composite, the at least one filler, and/or the flexible polymeric material matrix includes one or more additional materials. 
     
     
         15 . The portable rumble strip according to  claim 1 , wherein the composite forms at least one flexible layer that cooperates with one or more additional flexible layers comprising polymeric material such that the elongated flexible body of the rumble strip is free to flex in multiple directions, bend in a direction of the length to bring longitudinal ends of the body toward each other, or roll into a spiral in a direction of the length. 
     
     
         16 . The portable rumble strip according to  claim 15 , wherein the density of the composite layer is greater than a density of the one or more additional flexible layers, and an overall average density of all layers of the elongated flexible body in a range from 0.06 lb/in 3  to 0.15 lb/in 3 . 
     
     
         17 . The portable rumble strip according to  claim 15 , wherein the composite forms an upper layer including at least the upper vehicle engagement surface, and wherein the one or more additional flexible layers includes a lower layer including at least the lower roadway engagement surface. 
     
     
         18 . The portable rumble strip according to  claim 17 , wherein the lower layer is co-vulcanized and unitary with the upper layer to form a single unitary elongated flexible body that is portable as a single unit. 
     
     
         19 . The portable rumble strip according to  claim 17 , wherein the upper layer formed by the composite is harder than the lower layer. 
     
     
         20 . The portable rumble strip according to  claim 1 , wherein an entirety of the elongated flexible body bounded by its outer surfaces is formed by the composite having the flexible polymeric material matrix and the at least one filler dispersed in the matrix that enhances the density of the composite. 
     
     
         21 . The portable rumble strip according to  claim 1 , wherein the composite and/or the elongated flexible body is devoid pure iron, cast iron, plain carbon steel, or other non-stainless iron-based materials. 
     
     
         22 . The portable rumble strip according to  claim 1 , wherein the rumble strip is devoid of rigid metal inserts, such as those having a minimum size of greater than 10 mm, and/or
 wherein the rumble strip is devoid of a housing that contains the elongated flexible body and/or the composite, and more particularly a housing that is more rigid than that of the composite.   
     
     
         23 . The portable rumble strip according to  claim 1 , wherein the overall density of the elongated flexible body in a range of: from 0.07 lb/in 3  to 0.15 lb/in 3 , from 0.08 lb/in 3  to 0.15 lb/in 3 , from 0.09 lb/in 3  to 0.15 lb/in 3 , from 0.10 lb/in 3  to 0.15 lb/in 3 , from 0.11 lb/in 3  to 0.15 lb/in 3 , from 0.12 lb/in 3  to 0.15 lb/in 3 , from 0.13 lb/in 3  to 0.15 lb/in 3 , from 0.08 lb/in 3  to 0.14 lb/in 3 , from 0.09 lb/in 3  to 0.14 lb/in 3 , or any range or subrange below the stated values. 
     
     
         24 . The portable rumble strip according to  claim 1 , wherein the elongated flexible body has sufficient strength and flexibility to withstand direct impact from a vehicle weighing at least 3,000 pounds at 50 mph or greater, and more particularly at least about 80,000 lbs. at speeds greater than 80 mph, without failure. 
     
     
         25 . The portable rumble strip according to  claim 1 , wherein the elongated flexible body has sufficient strength and flexibility to withstand direct impact from a vehicle weighing at least 3,000 pounds at 50 mph or greater, and more particularly at least about 80,000 lbs. at speeds greater than 80 mph, without significant movement relative to pavement upon which the rumble strip rests, such as less than 1 inch of movement per impact. 
     
     
         26 . A portable rumble strip comprising an elongated flexible body having an upper vehicle engagement surface, a lower roadway engagement surface, and a leading edge and trailing edge between the upper and lower engagement surfaces, the elongated flexible body having a length greater than width and the width greater than thickness, wherein the elongated flexible body incorporates a composite having:
 a flexible elastomeric matrix,   at least one filler dispersed in the matrix, wherein:   the at least one filler has a density greater than a density of the flexible elastomeric material matrix;   the at least one filler has a specific gravity of 3.0 or greater; and   the at least one filler is included in the composite in an amount that enhances the density of the composite, such that an overall density of the elongated flexible body is in a range from 0.06 lb/in 3  to 0.15 lb/in 3 .   
     
     
         27 . The portable rumble strip according to  claim 26 , wherein the composite is devoid of pure iron, cast iron, plain carbon steel, or other non-stainless iron-based filler material, and more particularly wherein the elongated flexible body is devoid of such filler materials. 
     
     
         28 . The portable rumble strip according to  claim 26 , wherein the at least one filler is an oxide, carbide, nitride, sulfide, sulfate, silicate, inorganic, or mineral comprising at least one alkaline earth, transition, or post transition metal element. 
     
     
         29 . (canceled) 
     
     
         30 . A portable rumble strip comprising an upper vehicle engagement surface, a lower roadway engagement surface, and a leading edge and trailing edge between the upper and lower engagement surfaces, wherein the portable rumble strip includes a composite having a polymeric material matrix and a filler dispersed in the matrix in an amount from 100 parts to 1100 parts by weight per 100 parts by weight total polymer of the polymeric material matrix, wherein the density of the filler is greater than a density of the polymeric material matrix. 
     
     
         31 . The portable rumble strip according to  claim 30 , wherein the filler includes zinc oxide (ZnO) in an amount between 500 parts to 1100 parts by weight per 100 parts by weight total polymer of the polymeric material matrix of the composite. 
     
     
         32 . (canceled) 
     
     
         33 . A portable rumble strip comprising an elongated body having an upper vehicle engagement surface, a lower roadway engagement surface, and a leading edge and trailing edge between the upper and lower engagement surfaces, the elongated body having a length greater than width and the width greater than thickness, wherein the elongated body includes at least one cavity, and at least one filler in the form of discrete unbound pieces of material is disposed within the cavity. 
     
     
         34 - 46 . (canceled) 
     
     
         47 . A portable rumble strip comprising an elongated body having an upper vehicle engagement surface, a lower roadway engagement surface, and a leading edge and trailing edge between the upper and lower engagement surfaces, the elongated body having a length greater than width and the width greater than thickness, wherein one or more frangible articles are disposed in the elongated body. 
     
     
         48 - 54 . (canceled) 
     
     
         55 . A portable rumble strip for placement on a roadway in a roadway warning system, the rumble strip comprising filler material within a body of the rumble strip, the filler material being of a type and in an amount that increases the density of a rumble strip such that its mass can exert a pressure on the roadway to withstand impact from a vehicle, such as a passenger vehicle or heavy truck, without movement of the rumble strip relative to the roadway. 
     
     
         56 . The portable rumble strip according to  claim 55 , wherein the filler is dispersed and embedded within a polymer composite matrix. 
     
     
         57 - 59 . (canceled)