Abstract:
A system for controlling unwanted foliage growth about a post extending in an upright orientation from the ground comprises a mat having a first edge, a second edge separated from the first edge, a top surface, and a bottom surface. The weed mat further comprises at least one pre-formed cut portion therein for accommodating the post, so that the mat can be secured about the post. A molded-in cut line extends parallel to the edges of the weed mat. The weed mat also includes a molded-in scale system, wherein the molded-in scale system comprises a plurality of additional score lines extending from the molded-in cut line to one of the weed mat edges at pre-determined, measured increments.

Description:
This application claims the benefit under 35 U.S.C. 119(e) of the filing date of Provisional U.S. Application Ser. No. 61/304,213, entitled Weed Control Devices and Methods, filed on Feb. 12, 2010. This prior provisional application is expressly incorporated herein by reference, in its entirety. 
     This application is related to commonly assigned co-pending U.S. application Ser. No. 12/502,974, entitled Weed Control Devices and Methods for Traffic Safety Applications, filed on Jul. 14, 2009, and expressly incorporated herein, in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to weed mitigation systems, and more particularly to devices and methods for controlling weed growth under and around support posts for signs, guardrails, and other applications. 
     SUMMARY OF THE INVENTION 
     The invention described herein comprises pre-molded gaskets and mats which are adapted to fit around support posts for signs, guardrails and other applications, in the traffic safety field or otherwise. The gaskets are molded of rubber, or other suitable material, such as plastic. Portions of the gaskets and mats are pre-cut, or scored, either fully or partially though their thickness, in order to simplify ready installation of the gaskets and mats at the point of application. 
     More particularly, in one aspect of the invention, there is provided a system for controlling unwanted foliage growth about a post extending in an upright orientation from the ground. This system comprises a weed gasket having a first edge, a second opposing edge, a top surface, and a bottom surface. The gasket further comprises a first score line disposed in the top surface which is configured to closely surround the post, and an additional access score line which extends from the first score line to one of the edges. At least one of the edges is chamfered. In certain embodiments, the first score line is configured to accommodate an I-beam shaped post. The weed gasket is preferably comprised of rubber. 
     The access score line is preferably formed as a lap joint having overlapping edges, and the gasket is premolded with additional score lines sized to fit variously sized posts. 
     The inventive system preferably further comprises a weed mat disposed beneath the weed gasket, which has a first edge and a second opposing edge. The weed mat further comprises a molded-in cut line extending parallel to the edges of the weed mat. Advantageously, the weed mat further comprises a molded-in scale system, wherein the molded-in ruler scale system comprises a plurality of additional score lines extending from the molded-in cut line to one of the weed mat edges at pre-determined, measured increments. This plurality of additional score lines, in one currently preferred embodiment, positioned with 1 inch increments between them. 
     In another aspect of the invention, there is provided a system for controlling unwanted foliage growth about a post extending in an upright orientation from the ground, which comprises a mat having a first edge, a second edge separated from the first edge, a top surface, and a bottom surface. The weed mat further comprises at least one pre-formed cut portion therein for accommodating the post, so that the mat can be secured about the post. A molded-in cut line extends parallel to the edges of the weed mat. The weed mat also includes a molded-in scale system, wherein the molded-in scale system comprises a plurality of additional score lines extending from the molded-in cut line to one of the weed mat edges at pre-determined, measured increments. In a currently preferred embodiment, the plurality of additional score lines are positioned with 1 inch increments between them. 
     The weed control system advantageously further comprises a weed gasket having a first edge, a second opposing edge, a top surface, and a bottom surface, wherein the weed gasket further comprises a first score line disposed in the top surface which is configured to closely surround the post. The purpose of this weed gasket is to further control the growth of weeds right around the periphery of the post, which may otherwise protrude through gaps between the opening in the weed mat and the post. The weed gasket, when desired/required, is disposed atop the weed mat, such that the bottom surface of the weed gasket is adhesively attached to the top surface of the weed mat. Alternatively to the use of adhesive, the weed gasket and the weed mat may be mechanically secured together, such as by nails or spikes. In some applications, the weed gasket may be unnecessary. 
     In yet another aspect of the invention, there is described a method of installing a system for controlling unwanted foliage growth about a post extending in an upright orientation from the ground. The method comprises steps of placing a first weed mat adjacent to the post, orienting the mat so that a first edge thereof, having a pre-cut portion of material abuts the post, and removing the pre-cut portion of material from the first edge of the mat to form an opening large enough to fit about the post. Once the first mat is positioned as desired, a second edge of a second weed mat is slid over the first edge of the first mat, so that a pre-cut portion of material abuts an opposing side of the post. The pre-cut portion of material is removed from the second edge of the second mat to form an opening large enough to fit about the post from its opposing side. Then a weed gasket is secured snugly about the post and to the top surfaces of each of the first and second weed mats. 
     Each of the first and second weed mats have scale lines molded therein. The method further comprises steps of using the scale lines to properly locate the first and second mats. 
     The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top isometric view of one embodiment of a weed control gasket constructed in accordance with the principles of the present invention; 
         FIG. 2  is an isometric view of the device of  FIG. 1 , from an opposed orientation, illustrating the lap joint of the gasket in an opened state for fitting around a post; 
         FIG. 3  is an isometric view similar to  FIG. 2 , from still another orientation; 
         FIG. 4  is a side view illustrating the thickness of the device of  FIGS. 1-3 ; 
         FIG. 5  is a top view of a weed control device, namely a mat, constructed in accordance with the principles of the present invention, illustrating a series of scale marks molded into the device along two parallel edges; 
         FIG. 6  is a perspective view illustrating a plurality of the weed control mats shown in  FIG. 5  deployed in a typical traffic safety application; 
         FIG. 7  is a perspective view showing the weed control mats of  FIG. 5  deployed in a typical traffic safety application and further showing a weed control gasket, like that illustrated in  FIGS. 1-4 , disposed around the post and above the weed control mat; and 
         FIG. 8  is a side view of a portion of the arrangement of  FIG. 7  showing a weed control gasket like that shown in  FIGS. 1-4  disposed over a weed control mat like that shown in  FIGS. 5 and 6 , with both devices being disposed about a typical post. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring more particularly to the drawings, there is shown in  FIGS. 1-4  a weed control device or gasket  10 . As illustrated, the gasket  10  is molded of rubber, preferably vulcanized rubber, though other suitable materials may be used, including recycled tire (crumb) rubber, or a suitable mixture. The preferred color is black, though it may be molded in almost any color, if desired. In the illustrated embodiment, the gasket  10  is approximately 12 or 14 inches square, having a thickness of approximately ⅜ inch, as shown in  FIG. 4 . Of course, these dimensions are presently preferred, but not required, and various materials and dimensions may be employed within the scope of the inventive concept. 
     The gasket  10  is pre-molded according to any number of configurations that will accommodate a quick installation around a support beam or post with minimal field (or on-site) cutting required. According to a first illustrated embodiment, the gasket  10  is pre-molded with a centrally located I-beam-shaped score line  12 , extending through the entire thickness of the gasket, for accommodating an I-beam-shaped post commonly used, for example, to support highway guardrails. An access score line  14 , preferably formed as a lap joint having overlapping edges, as shown particularly in  FIGS. 2 and 3 , extends from one end of the score line  12  to the edge of the gasket  14 , as illustrated, for permitting the gasket to be fitted closed around an I-beam-shaped post. In the first illustrated embodiment, the gasket  10  is also pre-molded with three additional square or rectangular score lines  16 ,  18 ,  20 , respectively, in decreasing sizes, which are sized to accommodate three of the most commonly sized wooden posts currently used in the traffic sign industry, and extend part of the way through the gasket thickness. Of course, the number, shape, and size of the pre-molded score lines is not particularly critical to the invention, as it is the concept of providing a plurality of pre-molded, pre-sized, pre-shaped score lines which is both inventive and advantageous. Part of the inventive concept is that these score lines can be changed over time to accommodate new or additional applications. 
     In the illustrated embodiment, the four edges  22  of the gasket  10  are chamfered, as illustrated particularly in  FIG. 4 . The chamfered edges  22  are approximately ¼ inch in width, and extend from an inner thickness of approximately ⅜ inch to an outer thickness of approximately ⅛ inch. The corners of the gasket  10  may also be radiused, as shown. 
     The purpose of the gasket  10  is to prevent the growth of foliage around sign posts, guard rail, cable barrier systems, and any other applications wherein it is desired, for the purpose of simplifying landscaping, to prevent weed growth, such as mail boxes, and the like. Other advantages of the product are the resultant reduced need to utilize herbicides to prevent weeds, and, as mentioned above, reduced maintenance costs. 
     To install the gasket  10 , according to the illustrated embodiment, about a particular post, a worker transports it to the desired location, and selects the appropriate score lines for fitment to the desired post. For example, if the post is an I-beam, the installer merely separates the pre-cut score line  14  and scores lines  12 , which opens up the gasket  10  as shown in  FIGS. 2 and 3 . Then, the gasket  10  may merely be slipped about the post, so that it surrounds and closely contacts the post along the score lines  12 . If the post is shaped as provided by one of the other three score lines  16 ,  18 , or  20 , then some simple cutting will be required. Using a suitable cutting implement, such as a hook linoleum cutting knife, the worker makes the desired cuts through the appropriate score lines ( 16 ,  18 , or  20 ), and the appropriate score line is cut out, to form an opening approximately the size of the periphery of the post. Then, as noted above, the score line  14  is separated, so that the gasket may be slipped about the post. 
     Once the gasket  10  is installed, the lap joint closes, and can be bonded with a suitable adhesive. 
     As will be described below, in addition to its separate use and utility, as discussed above, the weed gasket  10  can also be used in conjunction with the use of weed mats. 
       FIGS. 5 and 6  illustrate a modified embodiment of a weed mat  30 , which is similar to that disclosed in prior U.S. application Ser. No. 12/502,974, herein already expressly incorporated by reference. The weed mat  30  has pre-molded score lines  38  at regular intervals (for example, every inch) along its edges as shown in  FIG. 6 . These scaled score lines  38  perpendicularly intersect molded in cut lines  40 ,  42  parallel to the side edges  44  of the mat. Preferably, the molded in cut lines  40 ,  42  are positioned at 6 inches and 8 inches inward from the mat&#39;s edge, respectively. The side edges  44  of the weed mat  30  according to the illustrated embodiment may or may not be chamfered (as are the edges  22  of the gasket  10  according to the embodiment of  FIGS. 1-4 ). This configuration is adapted for quickly cutting a square shaped hole into the surface of the mat  30  with 3 straight cut lines  36 , as described in greater detail below. A square cut minimizes field cutting and fits posts of any shape so long as the square length and width are bigger than the post dimensions such that the post fits into and through the square. At the same time, some field cutting permits more accurate placement of the weed mat relative to the roadside. A plurality of pre-scored lines  32 ,  34 ,  36 ,  38 ,  40 ,  42  provides options for quick on-site or field cutting and facilitates accurate on-site alignment and positioning despite lack of uniformity from one site to the next. 
     Further advantages of the weed mat  30  are as follows:
         (i) Scale marks  38  at 1 inch intervals along the edges  44  of the weed mat  30  allow the installer to locate the mat to the guardrail posts without having to guess where to make the cuts if the three pre notched “I” beam locations  32  are not suitable. This feature is beneficial for situations where guardrail posts are staggered or along a curved road;   (ii) A 6 inch notch  40  and an 8 inch notch  42  are disposed parallel to the sides  44  for the mat to accept guardrail posts of these sizes;   (iii) To meet a prevalent guardrail standard of 12′6″ long with 3 posts per guardrail (posts are spaced 75″ from post center to post center), the mat overlap flaps have been extended out an additional inch per side (2 inches per mat) to fit 2 mats between posts without any gaps in between the mats over the distance of a long install. This increases the mat width from 43½″ to 45½″;   (iv) The “I” beam profile can be difficult to cut and install around the beam and too time consuming on-site. Therefore, instead of the “I” profile being a complete recessed profile, a notched outline outside of the profile with an additional ⅛″ clearance has been added to make it easier to cut and peel out the profile and install. The notch marks for this profile preferably go to a ⅛″ depth. This reduces the installation time of the mat;   (v) At every 6″ there are extended notches  46  to denote that it is a 6″ mark, and halfway along the mat at a centerline thereof, there is a further extended notch  48  that denotes that this is the middle of the mat. These features are also used to align the mat with guardrail posts for installation; and   (vi) The length of the flap has been extended inwards to provide an 8 inch flap.       

     The weed mat  30  provides a skid resistant surface, and functions to retard foliage growth by preventing sunlight from reaching the ground surface, thus retarding seed germination. The mat  30  also restricts water contact with the underlying ground surface. 
     Optionally, the weed mat  30  may be a percolation mat of increased porosity to permit some percolation of water through the mat. A mat of increased porosity may be formed, for example, by using less rubber per mold and/or larger shreddings or buffings of rubber in the mold. 
     In certain embodiments, including an embodiment of the weed mat  30  as otherwise disclosed above, optionally, the mat may be a filtration mat that permits passage of some materials through it while preventing the passage of other materials. Materials that are not transmitted through the mat may be left on the surface of the mat or retained or absorbed by the mat material. The mat material may be treated to give it additional properties in order that it may react with or treat some of the materials that are caught by the filter and left on the surface of the mat or absorbed by it. For example, the mat may be used to restrict the passage of heavy metals or toxic chemicals into farmland adjacent the highway or into the groundwater, or nearby oceans, lakes, rivers, streams, etc. The mat design may also be adapted for covering sewers near construction zones to prevent construction debris or paint from entering the sewer and interconnected water systems. In this manner, the mat may reduce municipal water treatment costs and ecological cleanup costs. 
     In certain embodiments, optionally, the weed mat may be used to encourage the growth of certain desirable species of ground cover vegetation in the vicinity of it. For example, ice plant or marathon grass may be considered desirable species for some applications. This may be accomplished by loading the mat with seeds of certain preferred species known to be suitable for an area prior to installation of the mat over guardrail posts, or for other applications. The mat may have percolation and/or filtration features to optimize growth of the preferred plant species. Post-installation germination and growth of the plant species may serve to further root and stabilize the mat on the roadside. Preferred species growing out of the mat may also be used to improve the aesthetics so that the roadside landscape otherwise covered by weed mats look more natural with low level ground cover developing over the mats. The low level ground cover may, in turn, provide greater separation between auto exhaust (and other chemicals) from the road and roadside agriculture or natural areas. 
     Any one or more of these features (percolation, filtration, selective seed germination) may be combined in a single weed mat for multiple functionality. 
     In order to more accurately position the weed mat  30  relative to the paved edge of the road&#39;s shoulder or median such that an edge  44  of the mat aligns along and parallel to the paved edge, it is desirable to have more score lines  32 ,  34 ,  36 ,  38 ,  40 ,  42  in the mat  30  to accommodate varying conditions at sites of installation (such as curved roads or a lack of uniformity) and varying positions of the roadside relative to the posts. The mat  30 , according to the embodiment shown in  FIG. 5 , comprises more score lines  32 ,  34 ,  36 ,  38 ,  40 ,  42 . With more score lines, the roadside edge of the mat can be positioned first and then the proper score lines,  32  or  36 , selected for further cutting. 
     According to a presently preferred embodiment, the surface of the weed mat  30  has a series of 1 inch scale marks  38  molded into it along one or more edges  44 , as shown in  FIG. 6 . The 1 inch scale marks  38  are up to 8 inches long (distance from mat edge  44  to inner molded-in cut line  42 ). The 1 inch scale marks intersect two continuous molded in cut lines  40 ,  42  that extend the full length of the mat from top to bottom. According to a preferred embodiment, the 1 inch scale marks  38  intersect the two continuous molded in cut lines  40 ,  42  at 6 inches and 8 inches, respectively, from the edge  44  of the mat  30 . 
     One of the chief advantages of this molded-in scale system  38  is that it enables the installer to shift the location of the weed mat  30  in relation to the guard rail support posts in the direction of the highway in 1″ increments as desired or needed. Consequently, the installer is able to position the mats  30  where desired relative to the road&#39;s edge, then simply make 3 straight cuts  36  the proper distance in from the edges  44  of the mat to the post&#39;s position along the pre-scored lines  36 . 
     When the support post around which the mat is placed has a periphery other than square-shaped, for example an I-beam shape, it can be too labor intensive (and cost ineffective) to make the necessary number of cuts in the mat on site in order to provide a proper tight fit of the mat around the irregularly shaped, for example I-beam shaped, post. Therefore, when the post has an I-beam shape, the access score line  34  can be used to open up the pre-cut “I” shaped score line  32  for wrapping around the post. 
     Another often preferred way to handle the issue of non-square shaped posts (rather than making a minimum of 8 cuts on site to fit the I-beam) is to make a square cutout in the mat  30  with 3 straight cuts  36 . Subsequently, a weed gasket  10  (see  FIG. 7  and  FIG. 8 ), pre-cut to fit an irregularly shaped post (for example, I-beam) is placed over the weed mat  30 . The weed gasket  10  may be constructed as illustrated in  FIGS. 1-4 , and can be secured to the weed mat  30  with an adhesive (for example, TrafFix Devices™ rubber adhesive) or nailed in place through both the weed mat  30  and gasket  10  (for example, with a 6 inch long galvanized ground spike). The gasket  10  may also be manufactured from vulcanized rubber. According to a preferred embodiment, the gasket  10  fits an I-beam shaped post and is a 14″×14″ square having a pre-molded 6″×6″ “I” beam opening therethrough, with an overlapping assembly joint, again, as generally discussed in connection with the gasket embodiment shown in  FIGS. 1-4 . 
     In this manner, a procedure that further cuts pre-scored lines  36  to form a square shape (with just 3 straight cuts  36 ) can be used as a time sensitive and cost effective way to fit the weed mat  30  about a post of any shape and size. The pre-scored lines  36  may be selected from a plurality of pre-scored lines  38  at regular intervals along a surface of the mat  30  after proper placement of the weed mat&#39;s edge  44  along the roadside edge. 
     As discussed above, when necessary, a tighter fit can be achieved around non-square shaped posts by the subsequent positioning of a weed gasket  10  (as shown in  FIG. 7  and  FIG. 8 ), placed over the weed mat  30 , designed to fit the unique shape of the post precisely. That is, the weed gasket  10  may be custom-designed with a pre-cut opening to match a horizontal cross-section of the post. In a preferred embodiment, the weed gasket  10  has an I-beam shape to accommodate the relatively common I-beam shape post. However, according to different embodiments, the weed gasket  10  could have an infinite number of different types of support post/beam openings of different shapes, molded using different weed gasket molds, customized for specific support post designs regardless of post shape or size. 
     The function of the weed gasket  10 , in this context, is to provide a better seal around the post by filling the space between the larger square-shaped outline of the hole cut into the weed mat  30  and the smaller non-square periphery of the post. This gap-filling improves aesthetics and prevents weed growth in the area immediately surrounding the post. To provide this functionality the weed gasket  10  may, but need not, have greater density or thickness in the region immediately surrounding the cut-out (to match post shape) as compared to other areas of the weed gasket  10  farther away from the cut-out, such as along the edges. The other areas of the gasket, excluding the gap-filling region surrounding the cut-out, are already covered by the weed blocking mat  30  so they need not be as thick or dense. In these other areas, the thickness or density simply needs to be sufficient to adequately secure the weed gasket  30  to the surface of the weed mat, as through adhesive bonding or nailing, without damaging the integrity of either component. 
     Thus, the customized weed gasket therefore can be quickly and easily installed over the weed mat cut with a square opening at the support beam locations. The gasket  10  can easily be placed tightly around any shaped post and then glued or nailed in place at the post joint, effectuating a tight, no field-cutting, weed-resistant joint. 
     While the invention is disclosed for use with the posts of traffic safety barriers, such as traffic signs, guardrails, and the like, it is useful for any other application wherein weed control, percolation, filtration, and/or selective seed germination are desired, both on and off roadway, such as for signs, playground equipment, walls, fences, sewers, and the like. If the pre-formed score lines are not suited to a particular application, the gasket  10  may be cut to customize its application. Crack sealant may be advantageously used to fill any holes or tears surrounding the posts  62 , etc., to minimize penetration of the mat by water, sunlight, or growing foliage. 
     Accordingly, although an exemplary embodiment of the invention has been shown and described, it is to be understood that all the terms used herein are descriptive rather than limiting, and that many changes, modifications, and substitutions may be made by one having ordinary skill in the art without departing from the spirit and scope of the invention.