Abstract:
A plastic barricade assembly and a method of constructing it. The assembly includes two leg and panel units pivotally interconnected. Each leg and panel unit comprises first and second leg members and a plurality of panel members. The members are separately blow molded of plastic. The first leg members of each leg and panel unit are identical to each other and, at the same time, different than the second leg members of each leg and panel unit which are, in turn, identical to each other. Each leg and panel unit is assembled by bolting a first and second leg member together with a plurality of panel members. The leg and panel members of each unit are bolted together in interlocking relationship.

Description:
RELATED APPLICATION 
     This application is a division of application Ser. No. 09/005,119, filed Jan. 9, 1998, now U.S. Pat. No. 6,101,967. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to traffic barricades. It relates particularly to molded plastic traffic barricades. 
     BACKGROUND OF THE INVENTION 
     Traffic barricades are commonly used to warn vehicular and pedestrian traffic of danger, and block off restricted areas. Barricades made of molded plastic have now been known for some time. Examples are found in the Stehle, et al. U.S. Pat. Nos. 3,880,406 and 3,950,873, the Glass U.S. Pat. Nos. 4,298,186 and 4,624,210. Barricades illustrated in these patents include barricades made with two panel units hinged together so that they can be spread apart for use and collapsed for storage or transport. The individual panel units are one piece, integral, hollow plastic panels, formed by rotational or blow molding. The lower hollow sections may contain ballast. 
     These and other plastic traffic barricades have proven to be a great improvement over conventional steel and wood barricades. They are rugged, yet cause less damage to vehicles if inadvertently struck. Through the use of ballast in the units, the center of gravity of the barricade is lower than either wood or metal barricades. The result is a barricade less susceptible to being blown over by wind. Other features typically incorporated in such barricades are bright colored reflective horizontal panels, flashing lights or signs, and a structural member near the bottom where a sand bag can be placed if additional ballast is required. 
     Problems linger with many plastic barricades on the market today, however. Internally ballasted plastic barricades have proven to be marginally acceptable on high speed highways because they are not heavy enough to remain in place when buffeted by vehicle induced drafts. All to frequently, on the other hand, externally ballasted barricades deform under the weight of sandbags. When barricade assemblies are struck by a moving vehicle, for example, their structural integrity also leaves something to be desired. When components are damaged, they cannot be readily cannibalized for use in other barricade assemblies. Many of them are not sufficiently compact to permit stacking large quantities of assembled barricades together for transport. 
     SUMMARY OF THE INVENTION 
     A primary object of the present invention is to provide an improved plastic barricade assembly. 
     Another object is to provide a plastic traffic barricade assembly which has a high degree of structural integrity. 
     Yet another object is to provide a plastic traffic barricade assembly which can be easily cannibalized for parts if it is damaged in use. 
     Still another object is to provide a plastic traffic barricade assembly which, although employing ruggedly substantial leg components, collapses into a narrow profile for storage and shipping. 
     A further object is to provide a plastic traffic barricade assembly comprising separately blow molded leg and panel members fastened together in interlocking relationship. 
     Yet a further object is to provide a plastic traffic barricade assembly wherein said separately molded leg and panel members are rigidly interconnected after molding to form two substantially identical leg and panel units which are then pivotally connected. 
     Still a further object is to provide a new and improved method of constructing a plastic traffic barricade assembly. 
     The foregoing and other objects are realized in accord with the present invention by providing a barricade assembly comprising separate leg and panel members blow-molded of high molecular weight polyethylene plastic. Two identical leg and panel units are assembled, each from first and second different leg members and a plurality of panel members. The first leg members of each unit are identical to each other. The second leg members of each unit are, in turn, identical to each other. 
     The leg members are all molded with body sections which have I-beam shaped cross-sections, including opposed inner and outer flanges interconnected by a web. This configuration permits the leg members to be quite narrow, i.e., the flanges are one-and-one-half (1½″) inch wide in a conventional size barricade. 
     The outer flange on each leg member in a leg and panel unit has a flat outer surface and several elongated depressions formed therein, each for receipt of a panel. The inner flange on each leg member has a flat inner surface. 
     Each panel has a one-and-one-half inch (1½″) wide channel formed in its back face for mating, in interlocking fashion, with a leg member depression. The panel members are bolted to each of first and second leg members in this relationship to form a leg and panel unit. 
     Two leg and panel units are then mated with each other, panel members facing outwardly, by interconnecting bearing elements and bearing bores molded unitarily into the head sections of first and second leg members, respectively. The bearing element and bore of corresponding pairs of head sections contain cam action limit stops which then limit spreading of the leg and panel units to a degree desirable for use. The head section of each of the first leg elements also has an ear formed in it which is adapted to engage the upper edge of a panel member on the opposite leg and panel unit to provide a second limit stop for unit opening. 
     The leg and panel units are bolted together on common axes which are offset from the centerlines of corresponding leg members by a distance corresponding to the panel members&#39; thickness. This permits the leg and panel units to nest flat against each other with the back face of each panel flush against the flat inner surface of the inner flange in each leg member when the barricade assembly is collapsed for storage or use. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side elevational view of a barricade assembly embodying features of the present invention; 
     FIG. 2 is a front elevational view of the barricade assembly; 
     FIG. 3 is a front elevational view of one leg and panel unit for the barricade assembly; 
     FIG. 4 is a side elevational view of the leg and panel unit of FIG. 3; 
     FIG. 5 is a side elevational view of a first leg member for the leg and panel unit of FIG. 3; 
     FIG. 6 is a front elevational view of the first leg member seen in FIG. 5; 
     FIG. 7 is an enlarged side view (from the back) of the head section in the leg member seen in FIG. 6; 
     FIG. 8 is a sectional view taken along line  8 — 8  of FIG. 5; 
     FIG. 9 is a front plan view of a panel member from the leg and panel unit of FIG. 3; 
     FIG. 10 is an edge elevational view of the panel member seen in FIG. 9; 
     FIG. 11 is a bottom plan view of the panel member seen in FIG. 9; 
     FIG. 12 is a side elevational view of the second leg member for the leg and panel unit of FIG. 3; 
     FIG. 13 is a front elevational view of the second leg member seen in FIG. 12; 
     FIG. 14 is an enlarged side view (from the back) of the head section in the leg member seen in FIG. 13; 
     FIG. 15 is a vertical sectional view through the head sections of first and second leg members, as assembled; 
     FIG. 16A is a diagrammatic view of the pivot bearing and locking cam relationship, open position; 
     FIG. 16B is a view similar to FIG. 16A showing the closed position relationship; 
     FIG. 17 is an enlarged side elevational view of the assembly of FIGS. 1 and 2, but in its closed relationship; and 
     FIG. 18 is a sectional view taken along line  18 — 18  of FIG. 17, with parts removed. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to the drawings, and particularly to FIGS. 1 and 2, a plastic barricade assembly embodying features of the present invention is seen generally at  5 . The assembly  5  is comprised of a pair of identical leg and panel units  10  and  110 . Only leg and panel unit  10  will be described in detail, it being understood that the leg and panel unit  110  is identical to it. Throughout the specification, all parts of the leg and panel unit  110  are numbered exactly as their counterparts in leg and panel unit  10 , with an added 100 digits. 
     Each leg and panel unit  10  comprises three horizontal panel members  21 ,  22  and  23 , and two vertical leg members  31  and  32 . Each of the members  21 ,  22  and  23 , and  31  and  32  is separately blow molded of a high molecular weight polyethylene plastic. The members  21 ,  22  and  23 , and  31  and  32 , and corresponding members  121 ,  122  and  123 , and  131  and  132 , are assembled in a manner hereinafter discussed to create the assembly  5 . 
     Referring now to FIGS. 3 and 4, a separate leg and panel unit  10  is shown. The panel members  21 ,  22 , and  23 , and the leg members  31  and  32  of the leg and panel unit  10  are rigidly interconnected, according to the invention, to assemble the unit  10 . 
     As will be seen, the panel members  21 ,  22  and  23  are mounted on, and interconnected with, the leg members  31  and  32 . The leg members  31  and  32  are spaced approximately twenty inches (20″) apart in a standard size barricade. 
     The panel member  21  is fastened, adjacent one of its ends, to the leg member  31  by bolts  21   a  and nuts  21   b . Similarly, the panel member  22  is fastened to the leg member  31  adjacent one end of the panel member by bolts  22   a  and nuts  22   b . Likewise, the panel member  23  is fastened to the leg member  31  adjacent one end of this panel member by bolts  23   a  and nuts  23   b.    
     The panel member  21  is, in turn, fastened to the leg member  32  by bolts  21   c  and nuts  21   d . In turn, the panel member  22  is fastened to the leg member  32  by bolts  22   c  and nuts  22   d . Finally, the panel member  23  is fastened to the leg member  32  by bolts  23   c  and nuts  23   d . In contrast to their attachments to the leg member  31 , however, the panels members  21 ,  22  and  23  are fastened to the leg member  32  at a greater distance from the opposite ends of corresponding panel members, as will be seen. This distance is greater by an amount corresponding to the width of a leg member  31  or  32 , as seen in FIG. 3; and one-and-one inch (1½″) in a barricade of standard size. Thus, the panel members  21 ,  22  and  23  are mounted in laterally offset relationship relative to the leg members  31  and  32 . As a result, when the panel units  10  and  110  are assembled in face to face relationship, in a manner hereinafter discussed, the panel members  21 ,  22  and  23  on opposed panel units have their opposite ends aligned with each other, as seen in FIG.  2 . 
     The bolts  21   a  and  21   c ,  22   a  and  23   a  and  23   c  extend from their low-profile heads (seen in FIG.  3 ), which engage the panels  21 ,  22  and  23 , respectively, through.suitably formed apertures in the panels and corresponding legs  31  or  32 , in a manner hereinafter discussed in detail. The free ends of the bolts are threaded and receive corresponding nuts,  21   b  and  21   d ,  22   b  and  22   d , and  23   b  and  23   d.    
     Referring now to FIGS. 5-8, a disassembled leg member  31  is illustrated. The leg member  31 , which is blow molded in one piece, includes an elongated center section  41 , a foot section  42  and a head section  43 . As is characteristic of blow molding, of course, the leg member  31  is essentially hollow, with a wall thickness of approximately 0.125 inches. 
     The center section  41  is molded with an I-beam cross-section, as best seen in FIG.  8 . The I-beam cross-section is defined by outer flange  45  and inner flange  46  connected by web  47 . The wall which forms the leg member  31 , in its center section  41 , is spaced apart along most of the central section. However, in the blow molding process, a plurality of inwardly extending offsets or “tacks”  48  and  49  are formed in the web  47 , from one side thereof and those tacks become welded to the other side of the web during the molding process. The tacks  48  help to rigidify the center section  41 . The tacks  49  bracket bolt holes, hereinafter discussed, to strengthen the center section  41  at these bolt holes. 
     The outer flange  45  of the center section  41  has a flat outer surface  50  extending along its length, which is molded with three elongated, inwardly extending offsets in it which form three elongated depressions  51 ,  52  and  53  formed perpendicular inward of this surface. The lengths of each of these depressions corresponds to the height of a corresponding panel member  21 ,  22  and  23 , a subject hereinafter discussed. The depth of each of these depressions  51 ,  52  and  53  is one-half the thickness of each panel member, but each depression has at least one deeper cut-out (see  51   a  in FIG. 5, for example), for reasons hereinafter discussed. According to the invention, this configuration permits a highly effective, interlocking relationship of panel members  21 ,  22  and  23  and leg member  31  when a panel unit  10  is assembled. 
     The inner flange  46  of the center section  41  has a flat inner surface  54  extending along its length. As will hereinafter be discussed, these inner surfaces seat flush against a panel member  21  when the barricade assembly&#39;s leg and panel units  10  and  110  are nested against each other. 
     The center section  41  of the leg member  31  also has the aforementioned bolt holes  55  formed vertically through it, from flange  45  to flange  46 , inside the web  47 . Bolt holes  55  are formed through the leg member  31  in each of the three depressions  51 ,  52  and  53 . As will hereinafter be discussed, the panel numbers  21 ,  22  and  23  are fastened to the leg member  31  with corresponding bolts which extend through these bolt holes  55 . 
     The foot section  42  of the leg member  31  is defined by a thickened end flange  56  formed in the molding process. The flange  56  defines a ground engaging surface for the leg member  31 . 
     The head section  43  of the leg member  31  includes a radially extending ear  58 . As will also hereinafter be discussed, the ear  58  is arranged to engage the upper edge of the panel member  121  when the barricade assembly  5  is opened for operation and serve as a limit stop for opening travel of the two panel sections  10  and  110  as they are spread for use. 
     Referring to FIGS. 6 and 7, the head section  43  also has an annular stub bearing  60  formed outwardly from one side. The axis of the stub bearing  60 , which serves as a pivot axle for the panel units  10  and  110  when they are connected, is spaced from the centerline C/L of the leg member  31  by a distance d corresponding to the thickness of each of the panel members  21 ,  22  and  23 ; the centerline of a panel unit being defined here as a line extending longitudinally of the leg member half-way between the flanges  45  and  46 . This offset, which is toward the inner surface  54  of the leg member  31 , permits the panel units  10  and  110  to nest flat against each other when they are collapsed, also in a manner hereinafter discussed. 
     The annular stub bearing  60  has a radially protruding cam  61  formed unitarily with it. This cam  61  acts as another limit stop for opening travel of the two panel sections, in a manner hereinafter discussed. 
     The annular stub bearing  60  has a bolt hole  62  formed through it on its axis. This bolt hole  62  also extends through the wall of the head section  32  opposite the bearing  60 . The function of this bolt hole  62  in the barricade assembly  5  will be hereinafter discussed. 
     Referring now to FIGS. 9-11, a separate panel member  21  is illustrated. The panel member  21  is blow molded of plastic so that its walls are also about 0.125 inch thick. The panel, itself, is one-half inch (½″) thick. As such, a cavity  65  is defined within the panel member  21 . 
     The outer wall  66  of the panel member  21  has an essentially smooth front face, although outwardly extending ridges  66   a  are formed horizontally along its upper and lower edges. This facilitates the surface-to-surface fastening of reflective sheeting, for example, between the ridges  66   a.    
     The inner wall  67  of the panel  21  has two discontinuous mounting channels  68  and  69  molded into its back face. One of these channels, channel  68 , is formed into the wall  67  three-quarters of an inch (¾″) from an end  70   a  of the panel  21 . This channel  68  is one-quarter inch (¼″) deep and one and one-half inch (1½″) wide, except where it is discontinuous, at  68   a ,  68   b  and  68   c , the discontinuities creating air passages through the channel  68  for molding purposes. The other channel, channel  69 , is formed into the back face of the wall  67  one-and-three quarters of an inch (1¾″) from the other end  70   b  of the panel  21 . This channel  69  is also one-quarter inch (¼″) deep and one inch (1″) wide, except where it is discontinuous, at  69   a ,  69   b  and  69   c , the discontinuities creating internal air passages for blow-molding purposes. 
     The panel member  21  also has two bolt holes  71  formed through it in the channel  68 . These bolt holes  71  are for the bolts  21   a  which attach the panel member  21  to the leg member  31 . Two more bolt holes  72  are formed through the panel member  21  in the channel  69 . These bolt holes  72  are for the bolts  21   c.    
     In the back face of the inner wall  67  of the panel member  21 , a pattern of cup-shaped indentations  73  are formed inwardly. These indentations  73  extend into engagement with the inner surface of the outer wall  66  of the panel member  21 , and form “tacks” between the walls  66  and  67  by bonding during molding. Four of the cup-shaped indentations in the back face, seen at  74 , serve an additional purpose, as will hereinafter be discussed. 
     Panel members  22  and  23  are identical in construction to panel member  21 , except for their width dimensions and number of bolt holes. The panel member  21  is twenty four inches (24″) long and twelve inches (12″) wide. The panel member  22  is eight and one quarter inches (8 ¼″) wide. The panel member  23  is three inches (3″) wide. 
     Turning now to FIGS. 12-14, the leg member  32  is also seen separately. FIG. 12 illustrates the leg member  32  as it would be seen from the right in FIG.  2 . FIG. 13 shows the same leg members  32  from the front. FIG. 14 is an enlarged view of the head section  75  of the leg member  32 . 
     As has previously been pointed out, the leg member  32  is identical to the leg member  31 , except for the construction of the head section  75 . Accordingly, except for the head section  75 , all components of the leg member  32  bear the same reference numerals as the leg member  31 . 
     The head section  75  of the leg member  32  includes an elongated crown  76  which forms a bracket for attachment of a flasher warning light unit (not shown). To this end, it will be seen that the crown  76  has a well  77  formed in one side for receipt of a light unit mounting base and attachment bolt (not shown). A bolt hole  78  is formed through the crown  76  in the well  77  for receipt of a bolt (not shown) which attaches the light unit. 
     Referring to FIG. 14, the head section  75  also has an annular bearing bore  80  formed inwardly from one side. The bearing bore  80 , which serves as a pivot axle bearing for the panel units  10  and  110  when they are connected has, like the stub bearing  60  on the leg member  31 , an axis which is offset from the centerline C/L of the leg member  32  by the distance d hereinbefore referred to, and for the same purpose. 
     The annular bearing bore  80  has a radially extending lobe  81  covering an arcuate distance corresponding generally to the travel which the aforedescribed cam  61  is permitted when the panels  10  and  110  are spread to operational relationship. The mating of the stub bearing  60  and bore  80 , cam  61  and bore lobe  81 , will hereinafter be further discussed. 
     The annular bearing bore  80  also has a bolt hole  82  formed through its base, at its axis. The bolt hole  82  also extends through the wall of the head section  75  opposite the bearing bore  80 . 
     All of the components of a leg and panel unit  10  and their method of manufacture have now been described and illustrated. In effect, then, all the components of the leg and panel unit  110  have also been described and illustrated, since they are identical. Now, the method of assembly of the leg and panel units  10  and  110  and, finally, the mating of those units to form the assembly  5 , will be described. 
     A leg and panel unit  10  is assembled by seating three panel members  21 ,  22  and  23  on the leg members  31  and  32  and securely fastening them with bolts  21   a  and  21   c ,  22   a  and  22   c , and  23   a  and  23   c , and with nuts  21   b  and  21   d ,  22   b  and  22   d , and  23   b  and  23   d . The channels  68  and  69  in each of the panels  21 ,  22  and  23  are seated in corresponding elongated depressions  51 ,  52  and  53  in the leg members  31  and  32 . Because the depth of each channel  68  and  69  is one-half the thickness of the panel member (except at the discontinuities  68   a  and  69   a ), and the depth of each depression  51 ,  52  and  53  is the same (except for discontinuities  51   a , etc.), the panel members  21 ,  22  and  23  seat in interlocking relationship with the leg members  31  and  32  while, at the same time, their outer surfaces are substantially flush with the flat outer surfaces  50  of the flanges  45  between those recesses. The discontinuities  68   a ,  68   b ,  68   c  and  69   a ,  69   b  and  69   c  in the channels  68  and  69  in panel member  21 , for example, mate with corresponding discontinuous cut-outs  51   a  (see  51   a  in FIG. 6) molded into the depression  51 . The panel members  22  and  23  seat in the same way. This interlocking relationship of panel members and leg members creates leg and panel units which can absorb great impact loads without breaking up. 
     With the panel members  21 ,  22  and  23  bolted in place on the leg members  31  and  32 , the nuts  21   b  and  21   d ,  22   b  and  22   d , and  23   b  and  23   d  protrude inwardly of flat inner surfaces  54  of the flanges  46 , as do the threaded bolt ends to which they are attached. At the same time, the heads of each bolt  21   a  and  21   c ,  22   a  and  22   c , and  23   a  and  23   c  are relatively low in profile so that they protrude only slightly. The implication of this construction in the context of the invention will shortly be discussed. 
     Next, another leg and panel unit is assembled of identical components, in this case the leg and panel unit  110 . The two identical leg and panel units  10  and  110  are then placed in face-to-face relationship, so-to-speak, with their respective panel members  21 - 23  and  121 - 123  facing outwardly. The stub bearings  60  and  160  on the leg members  31  and  131  are introduced into the bearing bores  180  and  80  on the leg members  132  and  32 , respectively, by moving the leg and panel units  18  and  110  traversely of each other. The ears  61  on the stub bearings  60  then lie within the confines of the corresponding bore lobes  81 . 
     At this point, referring to FIG. 15, a bolt  85  is passed through the aligned bolt holes  62  and  82  in the head sections  32  and  75  of each mated pair of leg members, i.e. leg members  31 ,  132  and  32 ,  131 . A nut  86  is turned onto the threaded end of each nut  85 . The panel units  10  and  110  are securely connected in this way to form the barricade assembly  5 . 
     FIGS. 1 and 2 show the completed assembly  5  in its open position, ready for use. In this position, the ear  58  on the head section  32  of the leg member  31  has engaged and is stopped against the upper edge of the panel member  121  in the leg and panel unit  110 . At the same time, the ear  158  on the head section  132  of the leg member  131  has engaged and is stopped against the upper edge of the panel member  21  in the leg and panel unit  10 . 
     At the same time, further spreading of the leg and panel units  10  and  110  is also stopped by the cams  61  and  161 . These cams  61  and  161  reach the limit of their travel in corresponding lobes  81  and  181  of mating bearing bores  80 , as is illustrated in FIG.  16 A. Thus, integrity of the assembly  5  is insured by providing dual limit stops associated with each mating pair of leg members. 
     The construction of the leg members  31 ,  32  and  131 ,  132 , and the manner in which they are connected to corresponding panel members produces, according to the invention, particularly high resistance to deformation under load. As a result, external weights in the form of sandbags, for example, do not cause the assembly  5  to sag over time. 
     When it is desired to collapse and store or ship the assembly  5 , the leg and panel units are pivoted toward each other, about the co-axial axes of the bearings  60 ,  160  and bearing bores  80 ,  180  (which are also the axes of the bolts  85 ). Because these axes are offset from the centerlines of corresponding leg members by the thickness of the panel members  21 - 23  and  121 - 123 , the leg and panel units  10  and  110  can collapse into the nested relationship seen in FIG.  17 . In this configuration, the cams  61  and  161  are in the positions shown in FIG.  16 B. 
     The intimacy of the nested relationship is enhanced by mating of the nuts  21   b  and  121   b ,  22   b  and  122   b , and  23   b  and  123   b  with corresponding cup-shaped depressions  74  formed in the back of each panel member  21 - 23  and  121 - 123 . This relationship is shown in FIG. 18, where it will be seen that when the leg and panel units  10  and  110  are collapsed against each other so that the back face on the inner wall in each panel member is flush against the flat outer surfaces  50  of the outer flanges in the leg members, corresponding nuts  21   b , etc. (with associate bolt ends) are, in effect, housed within corresponding depressions  74 . 
     The preferred embodiment of the barricade assembly has been discussed in terms of a traffic barricade. However, it should be understood that the invention might also take the form of some other kind of barricade or sign support assembly, for example. Regardless of which, the structure is compact, highly resistant to impact load, able to easily support sand-bag weights without deforming and readily cannibalized for components.