APPARATUS AND METHOD FOR MANUFACTURING A COLLATED ARRAY OF TEMPORARY RAISED PAVEMENT MARKERS (TRPMS) FOR FACILITATING THE SERIAL APPLICATION OF SUCH TEMPORARY RAISED PAVEMENT MARKERS (TRPMS) TO ROADWAY SURFACES

Apparatus is disclosed for forming a serial array of temporary raised pavement markers (TRPMs), which are disposed upon a single, common release liner, into a collated and nested array of the temporary raised pavement markers (TRPMs) such that the collated and nested array of temporary raised pavement markers (TRPMs) can be supplied to apparatus for dispensing and applying the temporary raised pavement markers (TRPMs) onto pavement surfaces. In accordance with a first embodiment of the apparatus, the plurality of temporary raised pavement markers (TRPMs) are formed from a single temporary raised pavement marker (TRPM) extrusion, the extrusion is cut, and subsequently, the markers are mounted upon the single, common release sheet or release liner which has a plurality of adhesive patches previously disposed thereon. The assembly, comprising the plurality of temporary raised pavement markers (TRPMs) and the common release liner, is then formed into a collated and nested array. In accordance with a second embodiment of the apparatus, a plurality of pre-formed temporary raised pavement markers (TRPMs), having adhesive patches already disposed thereon, are serially deposited and adhered onto a single, common release liner, and subsequently, the assembly, comprising the plurality of temporary raised pavement markers (TRPMs) and the common release sheet or release liner, are formed into a collated and nested array.

FIELD OF THE INVENTION

The present invention relates generally to temporary raised pavement markers (TRPMs) which are adapted to be fixedly secured to roadway surfaces in order to, for example, temporarily define traffic lanes or the like within construction zones, work sites, or maintenance or repair areas, and more particularly to a new and improved apparatus and method for manufacturing a collated array of temporary raised pavement markers (TRPMs) so as to facilitate the serial application of such collated temporary raised pavement markers (TRPMs) to roadway surfaces in order to in fact temporarily define the traffic lanes or the like within the construction zones, work sites, or maintenance or repair areas.

BACKGROUND OF THE INVENTION

Various types of roadway markers have been utilized in connection with a variety of traffic control applications. Many roadway markers are adapted to be permanently attached or secured to the road surface so as to permanently delineate traffic lanes upon the roadway, while other roadway markers are adapted to be temporarily attached or secured to particular road surfaces in order to temporarily delineate traffic lanes within construction zones or other work areas. Accordingly, the latter type of roadway markers are known as temporary roadway markers and are usually attached or secured to the road surface by means of a suitable adhesive that can retain the roadway marker in its place upon the road surface during the temporary life of the roadway marker. More particularly, temporary roadway markers can serve, for example, as a means for identifying edge portions of the roadway, or alternatively, to delineate traffic lane lines and thereby demarcate separate lanes of traffic from each other in and around construction sites and other work zones. After the construction or other road work is completed, the temporary roadway markers are removed. To be effective the temporary roadway markers must clearly be capable of alerting motorists to the fact that they are nearing or entering a construction zone or work area, and therefore, the temporary roadway markers must in fact be effective both during daytime hours, nighttime hours, sunny conditions, cloudy conditions, inclement weather conditions, and the like. More particularly, one type of temporary roadway marker that has been extremely successful or effective in providing short-term temporary markings upon roadways both during daytime and nighttime hours, and which has also been able to adequately withstand the various impact forces that are normally impressed thereon by daily roadway vehicular traffic so as to in fact provide the desired service life required in connection with the installation of such temporary roadway markers, has been that type of temporary roadway marker which is known in the industry as a temporary raised pavement marker (TRPM).

Examples of such temporary raised pavement markers (TRPMs) are disclosed, for example, within U.S. Pat. No. 6,109,820 which issued to Hughes, Sr. on Aug. 29, 2000, U.S. Pat. No. 5,788,405 which issued to Beard on Aug. 4, 1998, U.S. Pat. No. 5,460,115 which issued on Oct. 24, 1995 to Speer et al., U.S. Pat. No. 4,991,994 which issued to Edouart on Feb. 12, 1991, and U.S. Pat. No. 4,445,803 which issued to Dixon on May 1, 1984. As can readily be appreciated fromFIG. 1, which corresponds substantially toFIG. 1of the Speer et al. patent, it is briefly noted that an exemplary temporary raised pavement marker (TRPM)10is seen to have a substantially L-shaped configuration wherein the horizontally disposed leg portion12thereof is adapted to be fixedly secured or attached to the road surface by means of a suitable adhesive which is allowed to set, while the vertically upstanding leg portion14is adapted to be visually seen by the oncoming motorist. A transition region26flexibly interconnects the vertically upstanding leg portion14to the fixed horizontally disposed leg portion or base member12. A pair of rib members or ledges28,28extend substantially perpendicular to the upstanding leg member14and serve to define a space or channel22therebetween. A suitable reflective strip23is adapted to be fixedly disposed within the space or channel22so as to reflect sunlight or a vehicle's lights in order to provide the oncoming motorist, as indicated by the arrow25, with a visual indication of a traffic lane, or alternatively, that the motorist is entering or approaching a construction zone or work area. Alternatively; in lieu of the reflective strip23, the entire marker10may simply be brightly colored so as to similarly provide the oncoming motorist with the necessary visual warning.

With reference being further made toFIG. 2, a typical, conventional, PRIOR ART temporary raised pavement marker (TRPM), which is similar to the temporary raised pavement marker (TRPM)10disclosed inFIG. 1of the present drawings, as well as withinFIG. 1of the Speer et al. patent, is disclosed at110and is seen to likewise have a substantially L-shaped configuration. In particular, the temporary raised pavement marker (TRPM)110comprises a horizontally disposed leg or base member112, and a vertically upstanding leg member114integrally connected to the horizontally disposed leg or base member112by means of a transitional region116. A block or slab of adhesive118is fixedly secured to an undersurface or lower face portion of the horizontally disposed leg or base member112, and in turn, a release sheet120is secured to an undersurface or lower face portion of the adhesive slab118so as to prevent the adhesive slab118from being inadvertently adhesively bonded to any surface, other than that particular location or portion of the roadway to which the temporary raised pavement marker (TRPM)110is to be fixedly secured, prior to the actual fixation of the temporary raised pavement marker (TRPM)110upon a selected location or portion of the roadway. As was the case with the temporary raised pavement marker (TRPM)10ofFIG. 1of the present drawings, as well as those of Speer et al., the upper end portion of the vertically upstanding leg member114of the temporary raised pavement marker (TRPM)110also comprises a pair of horizontally disposed rib members122,122which define a space or channel124therebetween for housing or accommodating a suitable reflector strip, not shown. Alternatively, the entire extrusion comprising the temporary raised pavement marker (TRPM)110may be fabricated from a suitable plastic material which is brightly colored, that is, it may be fabricated from a suitable resin material which is white or yellow.

The temporary raised pavement markers (TRPMs)110are normally placed upon the roadway surface during an extended period of time that construction or other road work is being performed upon the roadway surface, and therefore, the temporary raised pavement markers (TRPMs)110are normally placed upon the roadway surface prior to the completion of the entire construction or other road work as well as the application of the permanent traffic lane lines to the roadway surface. Accordingly, in order to protect the reflector strip, not shown, which is adapted to be disposed, housed, or accommodated within the space or channel124defined between the pair of horizontally disposed rib members122,122, or alternatively, in order to protect the upper portion of the vertically upstanding leg member114, when such portion of the temporary raised pavement marker (TRPM)110is to be used as the visual warning to oncoming motorists, from road paving materials, debris, and the like, a protective cover126, fabricated from a suitable clear plastic material and having a substantially inverted U-shaped configuration, is disposed over the upper free edge portion of the temporary raised pavement marker (TRPM)110and is secured thereto by means of a suitable fastener or staple128which is applied thereto by means of a suitable stitching process or operation.

When the temporary raised pavement markers (TRPMs)110are to be subsequently used in conjunction with, for example, their traffic lane delineation functions, the protective covers126are removed, and still further, when the need for the temporary raised pavement markers (TRPMs)110is no longer required in view of the completion of the construction or other roadwork, and the application of the permanent traffic lane lines to the roadway surface has been performed, the temporary raised pavement markers (TRPMs)110themselves will obviously be removed from the roadway surface. Until now, the process for mounting and securing the temporary raised pavement markers (TRPMs)110upon the road-way surfaces has been accomplished manually whereby, for example, construction workmen or other personnel would have to manually deposit the temporary raised pavement markers (TRPMs)110onto the roadway surface as a result of, for example, removing the release sheet120from the undersurface portion of the adhesive slab118and pressing the temporary raised pavement marker (TRPM)110onto the roadway surface so as to cause the adhesive bonding of the temporary raised pavement marker (TRPM)110to the roadway surface. In view of the fact that the construction workmen or other personnel are physically present upon the particular roadway surface during the performance of such temporary raised pavement marker (TRPM) application operations onto the roadway surface, the workmen or personnel are undesirably exposed to dangerous vehicular conditions present upon the roadway. In addition, the temporary raised pavement marker (TRPM)110application procedures are quite tedious, time-consuming, and problematic.

More particularly, it is noted that in connection with one conventional technique for currently fabricating temporary raised pavement markers (TRPMs), the temporary raised pavement markers (TRPMs) are initially manufactured as elongated structures having the aforenoted substantially L-shaped cross-sectional configuration, and the adhesive material and release liner components are then applied to the undersurface portions of the relatively short, normally horizontally disposed leg members thereof. Subsequently, the elongated structures are cut at predetermined locations thereof so as to provide finalized temporary raised pavement markers (TRPMs) having predetermined width dimensions. As can be readily appreciated, however, as a result of such cutting or severing operations, the adhesive material and release liner components, as disposed upon the finalized temporary raised pavement markers (TRPMs), will have the same lateral extents, and therefore, the end portions of the release liner will not project laterally beyond the end portions of the adhesive material. Accordingly, the end portions of the adhesive material are effectively uncovered and exposed which presents problems in connection with the mechanical feeding of the temporary raised pavement markers (TRPMs) within automated machinery, as well as in connection with the packaging of the temporary raised pavement markers (TRPMs). Still further, it is to be noted and appreciated that when the adhesive material is applied to or deposited upon the undersurface portion of the relatively short leg of the elongated temporary raised pavement marker (TRPM) structure, the adhesive is applied or deposited in a heated state.

Subsequently, the adhesive material will cool, and as a result of the cooling process, the adhesive material undergoes a predetermined amount of shrinkage or contraction. Such shrinkage or contraction effectively forms a bond between the primary mass of the adhesive material and the release liner which effectively defines a line of demarcation or boundary which is known as a feather-edge bond. The feather-edge bond is very flexible and tends to bend along with the release liner. Accordingly, when it is attempted to remove the release liner from the adhesive material, in preparation for the application of each one of the temporary raised pavement markers (TRPMs) to the pavement surface, the feather-edge bond structure is placed in tension, and it has been noted that the tensile strength characteristics of the feather-edge bond structure are greater than the force levels normally required to peel the release liner from the adhesive material as well as the tensile or shear strength characteristics of the release liner per se. It can therefore be appreciated further that when the release liner is desired to be removed from its associated temporary raised pavement marker (TRPM), not only is such an operation difficult to achieve, but it often happens that the release liner and/or the adhesive material disposed upon the undersurface portion of the temporary raised pavement marker (TRPM) is damaged which can render the use of the particular temporary raised pavement marker (TRPM) unsuitable.

A need therefore existed in the art for a new and improved collated assembly of temporary raised pavement markers (TRPMs), and a system and method for automatically applying such collated assemblies of temporary raised pavement markers (TRPMs) to the roadway surfaces, and this need was met by means of the new and improved collated assembly of temporary raised pavement markers (TRPMs), and the system and method for automatically applying such collated assemblies of temporary raised pavement markers (TRPMs) to the roadway surfaces, as are disclosed within the previously noted related U.S. patent application Ser. No. 10/302,994 which was filed on Nov. 25, 2002 and which is entitled COLLATED ROAD MARKER ASSEMBLY, AND SYSTEM AND METHOD FOR AUTOMATICALLY APPLYING COLLATED ROAD MARKERS TO ROADWAY SURFACES, wherein the aforenoted structural and operational drawbacks and disadvantages characteristic of conventional or PRIOR ART temporary raised pavement markers (TRPMs), and the methods and techniques for applying such conventional or PRIOR ART temporary raised pavement markers (TRPMs) to roadway surfaces, were effectively overcome. Accordingly, however, a need still exists in the art for an apparatus or system, and method, for manufacturing collated assemblies of such temporary raised pavement markers (TRPMs) which will enable the new and improved collated assemblies of such temporary raised pavement markers (TRPMs) to be advantageously fabricated and packaged in such a manner as to subsequently enable the temporary raised pavement markers (TRPMs) to be automatically applied to the roadway surfaces, by means of the system and method disclosed within the previously noted related U.S. patent application Ser. No. 10/302,994 which was filed on Nov. 25, 2002 and which is entitled COLLATED ROAD MARKER ASSEMBLY, AND SYSTEM AND METHOD FOR AUTOMATICALLY APPLYING COLLATED ROAD MARKERS TO ROADWAY SURFACES.

OBJECTS OF THE INVENTION

Accordingly, it is an object of the present invention to provide a new and improved apparatus and method for manufacturing a collated array of temporary raised pavement markers (TRPMs) so as to facilitate the serial application of such collated temporary raised pavement markers (TRPMs) to roadway surfaces in order to in fact temporarily define traffic lanes or the like within construction zones, work sites, or maintenance or repair areas.

Another object of the present invention is to provide a new and improved apparatus and method for manufacturing a collated array of temporary raised pavement markers (TRPMs), for facilitating the serial application of the collated temporary raised pavement markers (TRPMs) to roadway surfaces in order to in fact temporarily define traffic lanes or the like within construction zones, work sites, or maintenance or repair areas, such that the manufactured collated array of temporary raised pavement markers (TRPMs) will effectively overcome the various operational drawbacks and disadvantages characteristic of conventional PRIOR ART temporary raised pavement markers (TRPMs).

An additional object of the present invention is to provide a new and improved apparatus and method for manufacturing a collated array of temporary raised pavement markers (TRPMs), for facilitating the serial application of the collated temporary raised pavement markers (TRPMs) to roadway surfaces in order to in fact temporarily define traffic lanes or the like within construction zones, work sites, or maintenance or repair areas, wherein the apparatus of the present invention can either place a plurality of serially spaced individual temporary raised pavement markers (TRPMs), having blocks or pads of adhesive already disposed upon a bottom surface portion thereof, upon a single release sheet common to all of the temporary raised pavement markers (TRPMs), or alternatively, can successively apply leading end portions of a single temporary raised pavement marker (TRPM) extrusion onto pads or blocks of adhesive material, predisposed upon a single or common release sheet, while substantially simultaneously severing such leading end portions of the single temporary raised pavement marker (TRPM) extrusion from the residual portion of the single temporary raised pavement marker (TRPM) extrusion so as to define the plurality of serially spaced individual temporary raised pavement markers (TRPMs).

A further object of the present invention is to provide a new and improved apparatus and method for manufacturing a collated array of temporary raised pavement markers (TRPMs), for facilitating the serial application of the collated temporary raised pavement markers (TRPMs) to roadway surfaces in order to in fact temporarily define traffic lanes or the like within construction zones, work sites, or maintenance or repair areas, wherein the apparatus of the present invention can either place a plurality of serially spaced individual temporary raised pavement markers (TRPMs), having blocks or pads of adhesive already disposed upon a bottom surface portion thereof, upon a single release sheet common to all of the temporary raised pavement markers (TRPMs), or alternatively, can successively apply leading end portions of a single temporary raised pavement marker (TRPM) extrusion onto pads or blocks of adhesive material, predisposed upon a single or common release sheet, while substantially simultaneously severing such leading end portions of the single temporary raised pavement marker (TRPM) extrusion from the residual portion of the single temporary raised pavement marker (TRPM) extrusion so as to define the plurality of serially spaced individual temporary raised pavement markers (TRPMs), whereby the plurality of serially spaced individual temporary raised pavement markers (TRPMs) can be properly collated so as to effectively avoid any problems in connection with the development of the featheredge bond region between the release sheet and the blocks or pads of adhesive.

A last object of the present invention is to provide a new and improved apparatus and method for manufacturing a collated array of temporary raised pavement markers (TRPMs), for facilitating the serial application of the collated temporary raised pavement markers (TRPMs) to roadway surfaces in order to in fact temporarily define traffic lanes or the like within construction zones, work sites, or maintenance or repair areas, wherein the apparatus of the present invention can either place a plurality of serially spaced individual temporary raised pavement markers (TRPMs), having blocks or pads of adhesive already disposed upon a bottom surface portion thereof, upon a single release sheet common to all of the temporary raised pavement markers (TRPMs), or alternatively, can successively apply leading end portions of a single temporary raised pavement marker (TRPM) extrusion onto pads or blocks of adhesive material, predisposed upon a single or common release sheet, while substantially simultaneously severing such leading end portions of the single temporary raised pavement marker (TRPM) extrusion from the residual portion of the single temporary raised pavement marker (TRPM) extrusion so as to define the plurality of serially spaced individual temporary raised pavement markers (TRPMs) upon the single release sheet, whereby the plurality of serially spaced individual temporary raised pavement markers (TRPMs) can be properly collated so as to effectively avoid any problems in connection with the packaging of the collated temporary raised pavement markers (TRPMs) within a magazine to be utilized for serially supplying the plurality of temporary raised pavement markers (TRPMs) toward the roadway surface.

SUMMARY OF THE INVENTION

The foregoing and other objectives are achieved in accordance with the teachings and principles of the present invention through the provision of a new and improved apparatus and method for manufacturing a collated array of temporary raised pavement markers (TRPMs), for facilitating the serial application of the collated temporary raised pavement markers (TRPMs) to roadway surfaces in order to in fact temporarily define traffic lanes or the like within construction zones, work sites, or maintenance or repair areas, wherein, in accordance with a first embodiment of the apparatus of the present invention, leading end portions of a single temporary raised pavement marker (TRPM) extrusion are serially applied onto pads, blocks, or patches of adhesive material, predisposed upon a single or common release sheet, while substantially simultaneously therewith, the leading end portions of the single temporary raised pavement marker (TRPM) extrusion are severed from the residual portion of the single temporary raised pavement marker (TRPM) extrusion so as to define the plurality of serially spaced individual temporary raised pavement markers (TRPMs) disposed upon the single release sheet, whereas alternatively, in accordance with a second embodiment of the apparatus of the present invention, a plurality of serially spaced individual temporary raised pavement markers (TRPMs), having blocks, patches, or pads of adhesive already disposed upon a bottom surface portion thereof, are placed upon a single release sheet common to all of the temporary raised pavement markers (TRPMs). In connection with either embodiment of the apparatus of the present invention, the plurality of temporary raised pavement markers (TRPMs), serially spaced upon the single release sheet, are then collated and disposed within a suitable container so as to effectively form a supply magazine of temporary raised pavement markers (TRPMs).

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Referring now to the drawings, and more particularly toFIG. 3thereof, a first embodiment of a new and improved apparatus or system constructed in accordance with the principles and teachings of the present invention for manufacturing a collated array of temporary raised pavement markers (TRPMs), and showing the cooperative parts thereof, is disclosed and is generally indicated by the reference character210. More particularly, it is seen that the new and improved apparatus or system210for manufacturing the collated array of temporary raised pavement markers (TRPMs) comprises a framework212upon which there is disposed a longitudinal, axially oriented support surface or table214. At least two, longitudinally spaced support stands or mounting blocks216,218, as best seen in FIGS.4,7, and10, are fixedly mounted at respective upstream and downstream locations upon the support surface or table214so as to fixedly support a longitudinal, axially oriented guide track220thereon. In turn, the guide track220is provided so as to support a continuous, longitudinal temporary raised pavement marker (TRPM) extrusion222which is adapted to be axially conveyed along an axially extending conveyor flow path224after being extruded from an extruder mechanism226.

As can best be appreciated fromFIGS. 4 and 7, the temporary raised pavement marker (TRPM) extrusion222has a substantially L-shaped cross-sectional configuration, comprising an upstanding or vertically oriented leg portion228and a horizontally oriented leg portion230, whereby the temporary raised pavement marker (TRPM) extrusion222is similar in structure to the temporary raised pavement markers (TRPMs)10,110as respectively disclosed withinFIGS. 1 and 2. In a similar manner, the guide track220is likewise seen to have a substantially L-shaped cross-sectional configuration, comprising an upstanding or vertically oriented leg portion232and a horizontally oriented leg portion234. In addition, it is seen that the vertically oriented or upstanding leg portion232has a substantially inverted U-shaped vertical channel portion236integrally connected thereto at predetermined longitudinally spaced locations, while the horizontally oriented leg portion234likewise has a substantially C-shaped channel portion238integrally connected thereto. In this manner, the upstanding or vertically oriented leg portion228of the temporary raised pavement marker (TRPM) extrusion222is adapted to be conveyingly supported upon the upstanding or vertically oriented leg portion232of the guide track220, with the upper edge section of the upstanding or vertically oriented leg portion228of the temporary raised pavement marker (TRPM) extrusion222being disposed within the vertical channel portion236of the guide track220, while the horizontally oriented leg portion230of the temporary raised pavement marker (TRPM) extrusion222is adapted to be conveyingly supported upon the horizontally oriented leg portion234of the guide track220, with the horizontal edge section of the horizontally oriented leg portion230of the temporary raised pavement marker (TRPM) extrusion222being disposed within the horizontal channel portion238of the guide track220.

In order to in fact convey the temporary raised pavement marker (TRPM) extrusion222along the conveyor path224, first and second, upstream and downstream, temporary raised pavement marker (TRPM) extrusion drive means are provided along the conveyor path224. More particularly, as can best be seen in FIGS.4,7, and10, the first upstream temporary raised pavement marker (TRPM) extrusion drive means comprises a servo motor240which is fixedly attached to a mounting bracket242that has a substantially Z-shaped cross-sectional configuration, while the second downstream temporary raised pavement marker (TRPM) extrusion drive means comprises a servo motor244which is fixedly attached to a mounting bracket246that likewise has a substantially Z-shaped cross-sectional configuration. The mounting brackets242,246are both adapted to be fixedly secured to the table or support surface214in an adjustable manner, and the servo motors240,244are respectively provided with dependent rotary drive couplers248,250which are respectively adapted to drivingly engage drive rollers for engaging the back or rear side surface of the upstanding or vertically oriented leg portion228of the temporary raised pavement marker (TRPM) extrusion222. Only the drive roller252, operatively associated with the rotary drive coupler248of the servo motor240, is visible, as can in fact be seen inFIG. 7, and the drive roller252, as well as the drive roller, not shown but operatively associated with the rotary drive coupler250of the servo motor244, is adapted to be rotatably mounted within a pair of vertically spaced support plates254,256which are respectively attached to the mounting brackets242,246, it being additionally noted that only the support plate254for the drive coupler250is visible in FIG.10. It is also noted that the upstanding or vertical oriented leg portion232of the guide track220is provided with suitable apertures, not shown, in order to permit each one of the drive rollers252to project therethrough in order to drivingly engage the back or rear side surface of the upstanding or vertically oriented leg portion228of the temporary raised pavement marker (TRPM) extrusion222.

Continuing further, idler rollers258are also provided for operative cooperation in conjunction with the drive rollers252, it being noted that only the idler roller258, for operative cooperation in conjunction with the drive roller252operatively driven by means of the rotary drive coupler248of the servo motor240, is visible as shown in FIG.7. The idler rollers258are respectively adapted to be rotatably mounted within a pair of vertically spaced support plates260,262, and264,266, and each pair of vertically spaced support plates260,262, and264,266, are respectively attached to substantially L-shaped mounting brackets268,270which are adapted to be fixedly secured to the table or support surface214in an adjustable manner. As a result of the adjustable fixation of the L-shaped mounting brackets268,270upon the table or support surface214, each one of the idler rollers258is able to properly engage the front side surface of the upstanding or vertically oriented leg portion228of the temporary raised pavement marker (TRPM) extrusion222and thereby operatively cooperate with the drive rollers252in conveying the temporary raised pavement marker (TRPM) extrusion222along the conveyor path224.

As was disclosed in connection with the temporary raised pavement markers (TRPMs)10,110respectively disclosed withinFIGS. 1 and 2, reflective strips or tapes were adapted to be fixedly mounted within the channels22,124defined upon the opposite sides of the upstanding or vertically oriented leg portions14,114of the temporary raised pavement markers (TRPMs)10,110, and in a similar manner, adhesive-backed reflective strips or tapes are adapted to be fixedly mounted within channels272which are defined upon the upper opposite sides of the upstanding or vertically oriented leg portion228of the temporary raised pavement marker (TRPM) extrusion222as is best seen inFIGS. 5 and 7. More particularly, as can best be seen inFIGS. 4-7, separate supply rolls of the reflective tape or strip laminates are disclosed at274and276, and the supply rolls274,276are disposed upon support disks278,280. The support disks278,280are rotatably mounted upon support plates282,284which are bolted to the upstream end of the table or support surface214, and it is seen that the reflective tape or strip laminate being conveyed toward the temporary raised pavement marker (TRPM) extrusion222from the supply roll274actually comprises an adhesive-backed reflective tape or strip286and a release liner288, while the reflective tape or strip laminate being conveyed toward the temporary raised pavement marker (TRPM) extrusion222from the supply roll276actually comprises an adhesive-backed reflective tape or strip290and a release liner292. The release liners288,292are separated from the reflective tapes or strips286,290shortly after the reflective tape or strip laminates are unreeled from the supply rolls274,276, and in this manner, the reflective tapes or strips286,290can in fact be conveyed toward the respective sides of the temporary raised pavement marker (TRPM) extrusion222while the release liners288,292are conveyed away from the temporary raised pavement marker (TRPM) extrusion222so as to ultimately be discarded.

In particular, each reflective tape or strip286,290is routed through an arcuate guide channel which is respectively defined between a pair or set of vertically spaced guide rollers294,296which are respectively disposed upon opposite sides of the conveyor flow path224along which the temporary raised pavement marker (TRPM) extrusion222is conveyed. As best seen inFIG. 5, the pair or set of guide rollers296is rotatably disposed upon a slotted mounting bracket298, and the slotted mounting bracket298is adjustably mounted upon an upstanding post300which is fixedly mounted upon the support plate284. In this manner, the pair or set of guide rollers296can be optimally positioned with respect to the temporary raised pavement marker (TRPM) extrusion222so as to in fact properly guide the reflective tape or strip290toward the temporary raised pavement marker (TRPM) extrusion222. It is noted that while only the slotted mounting bracket298and the upstanding post300operatively associated with the pair or set of guide rollers296are visible, a similar mounting bracket and upstanding post are of course operatively provided in conjunction with the pair or set of guide rollers294.

Still further, it is seen that an application roller302,304is respectively disposed upon each side of the conveyor flow path224along which the temporary raised pavement marker (TRPM) extrusion222is conveyed, and that each one of the application rollers302,304is respectively mounted upon one end of an arm306,308which is respectively pivotally mounted upon each one of the support plates282,284by means of a pivot pin310,312. A coil spring314,316is respectively connected at a first end thereof to the opposite end of each arm306,308by means of a first suitable eyehook fastener318,320, and the second end of each coil spring314,316is fixedly connected to a respective one of the support plates282,284by means of a second suitable eyehook fastener, only the second eyehook fastener operatively associated with the coil spring314being visible inFIG. 5at322. In this manner, the arms306,308are caused to pivot around their respective pivot pins310,312so as to effectively bias the application rollers302,304into operative engagement with the channels272of the temporary raised pavement marker (TRPM) extrusion222whereby as a result of the operative cooperation between the application rollers302,304and the channels272of the temporary raised pavement marker (TRPM) extrusion222, the reflective strips or tapes286,290are forced into and adhered within the channels272of the temporary raised pavement marker (TRPM) extrusion222as the temporary raised pavement marker (TRPM) extrusion222is conveyed along the conveyor flow path224by means of the servo motor drive assemblies240,244. It is of course also noted, as can best be appreciated fromFIG. 5, that a portion of the substantially inverted U-shaped vertical channel portion236of the guide track220is effectively discontinued so as to in fact permit the application rollers302,304to operatively engage the channels272of the temporary raised pavement marker (TRPM) extrusion222and thereby apply and adhere the adhesive-backed reflective strips or tapes286,290within the channels272of the temporary raised pavement marker (TRPM) extrusion222. It is also noted, as best seen inFIG. 5, that suitable photodetector mechanisms323,323are disposed upon opposite sides of the conveyor flow path224, along which the temporary raised pavement marker (TRPM) extrusion222is being conveyed, so as to in fact confirm that the reflective strips or tapes286,290have in fact been deposited within the channels272of the temporary raised pavement marker (TRPM) extrusion222.

It is to be appreciated still further that means are also provided for effectively discarding or removing the release liners288,292once they have effectively been separated from the adhesive-backed reflective strips or tapes286,290. More particularly, as can best be appreciated fromFIGS. 4 and 6, a pair of drive disks324,326are disposed upon opposite sides of the conveyor flow path224and are rotatably mounted upon first end portions of first support arms328,330which have second opposite ends thereof respectively bolted to the support plates282,284by means of a suitable bolt fastener, although only the bolt fastener operatively associated with the first support arm328is visible at332inFIG. 5. Adrive motor is disposed beneath each one of the first support arms328,330and is respectively drivingly connected to each one of the drive disks324,326, although only the drive motor operatively connected to the drive disk324is visible inFIG. 6as at334. In addition, a pair of flanged idler rollers336,338are likewise disposed upon opposite sides of the conveyor flow path224and are rotatably mounted upon first end portions of second support arms340,342which have second opposite ends thereof likewise bolted to the support plates282,284by means of the same bolt fasteners securing the first support arms328,330to the support plates282,284, such as, for example, bolt fastener332. It is to be noted that the outer peripheral edge portion of each drive disk324,326is adapted to be disposed within, and operatively engaged with, the annular recess portions defined between the upper and lower flanges of the flanged idler rollers336,338, and in this manner, when the release liners288,292are interposed between the outer peripheral edge portions of the drive disks324,326and the flanged idler rollers336,338, the release liners288,292will effectively be drivingly separated and removed from the adhesive-backed reflective strips or tapes286,290so as to ultimately be discarded.

Continuing still further, it will also be recalled, in connection with the discussion of the second embodiment of the conventional PRIOR ART temporary raised pavement marker (TRPM)110as disclosed withinFIG. 2, that a substantially inverted U-shaped protective covering126was adapted to be disposed over the upper end portion of the temporary raised pavement marker (TRPM)110so as to effectively protect the reflective strips or tapes until the temporary raised pavement markers (TRPMs)110were actually ready to be used upon the roadway surfaces. Accordingly, in conjunction with the temporary raised pavement marker (TRPM) extrusion222, a protective covering, similar to the protective covering126utilized in conjunction with the temporary raised pavement marker (TRPM)110, is adapted to be positioned over the upper end portion of the temporary raised pavement marker (TRPM) extrusion222so as to effectively protect the reflective strips or tapes286,290which have been previously applied within the channel regions272defined upon the opposite sides of the temporary raised pavement marker (TRPM) extrusion222as has been heretofore described and disclosed withinFIGS. 5 and 6. More particularly, as disclosed withinFIG. 1, a supply roll of protective covering material is disclosed at344, and a drive motor346is operatively connected to the supply roll344of the protective covering material so as to periodically cause rotation of the same in order to unreel a suitable supply of the protective covering material348, as disclosed within FIGS.5,6, and8, which is to be conveyed toward and applied onto the temporary raised pavement marker (TRPM) extrusion222.

The drive motor346is, in turn, under the control of a programmable logic controller (PLC)350, and it is noted further that the programmable logic controller (PLC)350is utilized to control all of the motor drive or operative movements of all of the various components, which have already been disclosed and described, which will hereinafter be disclosed and described, and which comprise the new and improved apparatus or system210of the present invention for manufacturing the collated array of temporary raised pavement markers (TRPMs). As disclosed withinFIG. 6, and with additional reference also being made to FIGS.5and8-10, the drive motor346is operated so as unreel a suitable amount of the protective covering material348from the supply reel344in order to form a slack amount or dependent loop portion352of the protective covering material348. The protective covering material348, which forms the dependent loop portion352, is then conducted upwardly over a horizontally disposed idler roller354, and subsequently, the protective covering material348is further conducted in the downstream direction between a pair of upstanding idler rollers356,356. The protective covering material348can therefore be appropriately guided further in the downstream direction in order to ultimately be engaged with and mounted upon the temporary raised pavement marker (TRPM) extrusion222so as to thereby cover or overlie the reflective strips or tapes286,290which were previously deposited and adhered within the channels272of the temporary raised pavement marker (TRPM) extrusion222.

More particularly, as can best be appreciated fromFIG. 1, and as best disclosed withinFIGS. 8-10, a second set of application rollers358,360,362are rotatably mounted upon a support plate364which is disposed at a position, along the conveyor flow path224, which is located downstream from the reflective strip or tape application rollers302,304. As can best be appreciated fromFIG. 9, the protective covering material application rollers358,360,362are adapted to be adjustably mounted upon the support plate364as a result of suitable fasteners or pins, not shown, respectively passing through the rollers358,360,362and being adjustably movable within vertically oriented slots366,368,370formed within the support plate364. In this manner, the relative elevational disposition of each application roller358,360,362upon and with respect to the support plate364can be appropriately determined. Accordingly, as can best be appreciated fromFIG. 8, the incoming protective covering material348can be properly guided toward the temporary raised pavement marker (TRPM) extrusion222being conveyed in the downstream direction, and it is particularly noted that the last or third protective covering material application roller362is operatively engaged with the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222so as to effectively form a nip therewith. The protective covering material348is therefore disposed within such nip so as to effectively be forced onto and applied over the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222in order to protect the previously applied and adhered reflective strips or tapes286,290.

As has been previously noted in connection with the reflective strip or tape application rollers302,304, and as can be clearly appreciated fromFIGS. 8-10, a portion of the substantially inverted U-shaped vertical channel portion236of the guide track220is again effectively discontinued so as to in fact permit the protective covering material application rollers358,360,362to guide the protective covering material toward the temporary raised pavement marker (TRPM) extrusion222, and in particular, to permit the third or downstream application roller362to form the aforenoted nip with the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222. It is noted still further that the presence of the substantially inverted U-shaped vertical channel portion236of the guide track220is again effectively continued at a location immediately downstream of the third or last application roller362in order to effectively cooperate with the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222. In this manner, the protective covering material348is effectively retained at its desired position upon the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222whereby the same can truly cover the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222so as to protect the reflective strips or tapes286,290disposed within the channels272thereof.

Subsequent to the aforenoted disposition of the protective covering material348upon the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222, it is desired to fixedly secure the protective covering material348upon the upper edge portion of the temporary raised pavement marker (TRPM) extrusion222by means of a suitable fastener or the like which may be similar to the fastener or staple128as disclosed withinFIG. 2in connection with the conventional PRIOR ART temporary raised pavement marker (TRPM)110. Accordingly, as can be seen in FIGS.3,8,10, and11, a stitcher or stitching mechanism372is utilized. The stitcher or stitching mechanism372is seen to be disposed immediately downstream of the third or last protective covering material application roller362, and it is further seen that a supply roll of stitching wire, disclosed at374, is rotatably mounted upon the housing of the stitching mechanism372by means of a pair of laterally spaced mounting brackets376,376. The front side of the stitching mechanism372is provided with an arcuately configured chute member378, as best seen inFIG. 8, for guiding the fastening wire, as the same is unreeled from the supply roll of stitching wire374, to the entrance380into the base of the stitching mechanism372.

As can best be seen fromFIG. 11, a wire stitch former382is disposed upon a lower rear surface portion of the stitching mechanism372, and it is to be appreciated that the stitch former382is disposed in front of the temporary raised pavement marker (TRPM) extrusion222and the guide track220. An anvil mechanism384, which is provided upon the lower end portion of a substantially C-shaped mounting bracket or arm386which is fixedly mounted in a cantilevered manner upon the rear surface of the stitching mechanism372, is disposed rearwardly of the back side of the guide track220. The anvil mechanism384is effectively aligned with the wire stitch former382in order to operatively cooperate therewith so as to form a stitch, which is similar to the staple or other fastener as disclosed withinFIG. 2in connection with the conventional PRIOR ART temporary raised pavement marker (TRPM)110, and in this manner, the protective covering material348will be fixedly secured to the temporary raised pavement marker (TRPM) extrusion222. It is noted that, along with the other operative components of the apparatus or system210of the present invention, the stitching mechanism372is operatively coupled to the programmable logic controller (PLC)350such that when the programmable logic controller (PLC)350cyclically energizes the stitching mechanism372, in conjunction with the longitudinal conveyance of the temporary raised pavement marker (TRPM) extrusion222along the conveyor flow path224, a plurality of wire stitches will be serially inserted into the temporary raised pavement marker (TRPM) extrusion222so as to fixedly secure the protective covering material348thereon. It is lastly noted that, in conjunction with the formation of the wire stitches as a result of the operative cooperation between the stitch former382and the anvil mechanism384, the guide track220is provided with an aperture388whereby the stitch former382and the anvil mechanism384can in fact operatively cooperate with each other, upon opposite sides of the temporary raised pavement marker (TRPM) extrusion222, so as to form and insert the wire stitches into the temporary raised pavement marker (TRPM) extrusion222so as to fixedly secure the protective covering material348thereon.

With reference continuing to be made toFIGS. 10 and 11, it is further noted, in connection with the disposition of the stitching mechanism372within the apparatus or system210of the present invention, that the stitching mechanism372is capable of being pivotally moved between a first lowered operative position as illustrated withinFIGS. 10 and 11, and a second elevated non-operative position, not illustrated, at which, for example, maintenance operations may be performed upon the stitching mechanism372, such as, for example, the removal of a depleted supply roll374of the stitching wire, and the installation of a new or fresh supply roll374of the stitching wire. More particularly, as can best be appreciated fromFIG. 11, a shaft member390is mounted within an upstanding stanchion392in such a manner as to be rotatable, around its axis, with respect to the upstanding stanchion392, but is incapable of undergoing axial movement with respect to the upstanding stanchion392. A mounting plate394has an ear member396integrally attached to the shaft member390whereby the mounting plate394is fixed in position with respect to the upstanding stanchion as considered in the axial direction defined by means of the shaft member390, and a pair of laterally spaced rubber bumper pads398,398are also fixedly mounted upon the rear surface of the stitching mechanism372so as to effectively define a framed space400therebetween. A secondary plate, not shown, is fixedly mounted upon the front surface, not visible, of the mounting plate394and is adapted to be disposed within the framed space400defined between the laterally spaced rubber bumper pads398,398.

It is further seen that the substantially C-shaped mounting arm or bracket386has an upstanding post402integrally connected to the upper leg portion thereof, and that an externally threaded adjustment or positioning rod404is threadedly engaged within an internally threaded passageway defined within the upper end portion of the upstanding post402. One end of the adjustment or positioning rod404is provided with a substantially X-shaped manipulation knob406, and the opposite end of the adjustment or positioning rod404is provided with a bumper element408which is adapted to engage the axially fixed mounting plate394when, for example, the manipulation knob406is rotated in the clockwise direction as viewed in FIG.11. Accordingly, in order to operatively mount the stitching mechanism372onto the upstanding stanchion392, the stitching mechanism372is positioned as illustrated withinFIG. 11such that the secondary plate, not shown but fixedly mounted upon the front surface of the mounting plate394, will be aligned with and preliminarily positioned within the framed space400defined between the laterally spaced rubber bumper pads398,398. Subsequently, as the manipulation knob406is rotated in the clockwise direction as viewed inFIG. 11such that the threaded positioning or adjustment rod404will threadedly advance relative to the upstanding post402of the substantially C-shaped mounting arm or bracket386, the bumper element408will ultimately or eventually engage the rear surface of the mounting plate394.

However, since the mounting plate394is axially fixed in position, as a result of the mounting plate394being integral with the shaft member390, and as a result of the shaft member390being axially confined with respect to the upstanding stanchion392, further clockwise rotation of the manipulation knob406and the threaded adjustment or positioning rod404will effectively cause the upstanding post of the substantially C-shaped mounting arm or bracket386, and therefore the substantially C-shaped mounting arm or bracket386per se, as well as the stitching mechanism372fixedly attached thereto, to move rearwardly. As a result of such movement, the secondary plate, not shown but fixedly mounted upon the front surface of the mounting plate394, will effectively be entrapped within the framed space400defined between the laterally spaced rubber bumper pads398,398, and the peripheral edge portions of the mounting plate394will effectively be compressively embedded within the laterally spaced rubber bumper pads398,398, thereby fixedly securing the stitching mechanism372upon the mounting plate394and the upstanding stanchion392.

It is therefore to be appreciated that the entire assembly, comprising the stitching mechanism372and the substantially C-shaped mounting arm or bracket386, can be pivotally moved relative to the upstanding stanchion392, as a result of the pivotal movement afforded by means of the shaft member390, between the illustrated lowered operative position and a non-illustrated elevated non-operative position.

It is noted that the mounting plate394has an aperture410defined therein, and as illustrated withinFIGS. 3 and 10, a similar aperture412is defined within a vertically oriented bracket414which is, in turn, fixedly secured upon a transversely oriented vertical support plate416. The support plate416is fixedly secured upon an upstanding post418which projects upwardly from the support surface or table214. Accordingly, when the entire stitching assembly is pivotally moved to its elevated, non-operative position, a suitable pin fastener, not shown, can be inserted through both apertures410,412so as to maintain the entire stitching assembly at its elevated, non-operative position. Removal of the pin fastener, not shown, from the aperture410defined within the mounting plate394of course permits the entire stitching assembly to be pivotally moved to the lowered operative position as illustrated withinFIGS. 10 and 11. Accordingly, when the entire stitching assembly is located at its lowered operative position, the ear member396will engage the transversely oriented support plate416whereby the entire stitching assembly will be disposed in a stabilized position so as to be capable of performing its stitching function.

Having completed a cyclical stitching operation, wherein as a result of a plurality of such cyclical stitching operations having been performed, the protective covering material248is fixedly secured upon the temporary raised pavement marker (TRPM) extrusion222by means of a plurality of serially arranged, longitudinally spaced stitching fasteners similar to the fastener or staple128as disclosed withinFIG. 2, the temporary raised pavement marker (TRPM) extrusion222, having the protective covering material248fixedly secured thereon, is then indexably advanced by means of the first and second servo motor drives240,244, under the control of the programmable logic controller (PLC)350, so as to move the temporary raised pavement marker (TRPM) extrusion222in the downstream direction toward an operational station at which the temporary raised pavement marker (TRPM) extrusion222will be successively severed, in accordance with suitable cyclical operations, into a plurality of individual temporary raised pavement markers (TRPMs) similar to the temporary raised pavement marker (TRPM)110as disclosed within FIG.2. Furthermore, the plurality of individual temporary raised pavement markers (TRPMs) will also be fixedly secured upon a common release sheet in preparation for the formation of the plurality of temporary raised pavement markers (TRPMs), as disposed upon the common release sheet, into the desired collated array of temporary raised pavement markers (TRPMs) as disclosed within U.S. patent application Ser. No. 10/302,994 which was filed on Nov. 25, 2002 and which is entitled COLLATED ROAD MARKER ASSEMBLY, AND SYSTEM AND METHOD FOR AUTOMATICALLY APPLYING COLLATED ROAD MARKERS TO ROADWAY SURFACES.

More particularly, then, as can be best appreciated from FIGS.3,10, and12, a supply roll of the continuous common release sheet or release paper is disclosed at420whereby the continuous common release sheet or release paper422is adapted to be unreeled from the supply roll420and conveyed along a support tray424by means of a conveying or withdrawal means, to be described shortly hereinafter, along a release paper conveying path PCP, the support tray424being supported upon a second support surface or table425. The release sheet422is provided with a plurality of adhesive patches426which are disposed upon the release sheet422in a longitudinally extending serial array wherein each adhesive patch426is separated from each adjacent adhesive patch426by means of a predetermined distance, such as, for example, one and one-half inches (1.50″), one and five-eighths inches (1.625″), one and three-quarters inches (1.75″), or the like, depending upon the predetermined spacing desired to be defined between successive ones of the individual temporary raised pavement markers (TRPMs)428, as adhesively attached to the release sheet422, in accordance with the ultimate desired dispensing of the temporary raised pavement markers (TRPMs)428onto the roadway surface. It is noted that the width dimension of the release sheet or release paper422is greater than that of each adhesive patch426, and that the release sheet or liner422is further provided with a top sheet, not shown and adapted to be removed just prior to the release sheet or liner422being operatively conveyed onto the support tray424, for effectively covering the individual adhesive patches426such that the adhesive patches426do not stick to successive layers of the release sheet or liner422when the release sheet or liner422is disposed upon the supply roll420.

It is additionally noted that the oppositely disposed edge portions of the support tray424are respectively provided with upstanding side walls430,432in order to effectively guide the release paper or release sheet422as the same is conveyed in the downstream direction from the supply roll420and along the release paper conveying path PCP over the support tray424. Still further, it is to be remembered that the continuous, longitudinal temporary raised pavement marker (TRPM) extrusion222is being axially conveyed along the conveyor flow path224, and it is therefore to be appreciated that the extrusion conveyor flow path224is oriented substantially perpendicular with respect to the release paper conveying path PCP. Still yet further, in order to permit the leading or downstream end portion of the temporary raised pavement marker (TRPM) extrusion222to be moved into position immediately above the release paper422, with only a vertical clearance of, for example, 0.05 inches, therebetween, so as to ultimately be able to be deposited and adhered thereon by means of one of the adhesive patches426, the upstanding side wall432is effectively discontinued as at434. Concomitantly therewith, the upstanding side wall430also effectively serves as a stop member against which the leading end portion of the temporary raised pavement marker (TRPM) extrusion222is disposed so as to properly position the leading end portion of the temporary raised pavement marker (TRPM) extrusion222in preparation for the severance of the leading end portion of the temporary raised pavement marker (TRPM) extrusion222, from the residual or remaining continuous temporary raised pavement marker (TRPM) extrusion222, and the formation of an individual temporary raised pavement marker (TRPM)428to be deposited and adhered upon the release sheet422.

Continuing further, and in order to in fact form the individual temporary raised pavement markers (TRPMs)428, and to achieve the deposition and adherence of the same upon the single common release sheet422, a cutting blade mechanism or assembly436is disposed downstream from the stitching mechanism372, and is likewise disposed immediately upstream of the vertical plane within which the upstanding side wall432of the support tray424is disposed, so as to sever the leading end portion of the temporary raised pavement marker (TRPM) extrusion222from the remaining or residual continuous temporary raised pavement marker (TRPM) extrusion222. In addition, an applicator mechanism or assembly438is positioned directly above the support tray424so as to be capable of acting upon the leading end portion of the temporary raised pavement marker (TRPM) extrusion222in order to deposit and adhere the leading end portion of the temporary raised pavement marker (TRPM) extrusion222onto one of the adhesive patches426disposed upon the single common release sheet422. More particularly, as can best be seen inFIGS. 10 and 12, the cutting blade mechanism or assembly436is seen to comprise a cutting blade element440which is bolted, as at442, to a lower end portion of a piston rod444of an air cylinder mechanism446so as to be movable within a vertical plane. The air cylinder mechanism446is fixedly mounted upon a support platform448, and it is seen that a pair of cutter blade guide members450,450are fixedly mounted upon the side of the support platform448so as to effectively guide the cutting blade element440during its upward and downward movements attendant its cutting operations. Operatively associated with the cutting blade element440and the piston rod444, the cutting blade mechanism or assembly436further comprises a hold-down implement452.

The applicator mechanism or assembly438is seen to comprise a pneumatic or air cylinder housing or mechanism454within which there is movably guided a pair of piston rods456,456, and upon the lower free end portions of the piston rods456,456, there is fixedly mounted an applicator piston458. The air-cylinder housing454is fixedly mounted upon a support bracket460, and it is seen that the support bracket460is, in turn, fixedly mounted upon a support plate462. As has been noted hereinbefore in connection with all of the motorized or actuated components of the apparatus or system210of the present invention, the air cylinder mechanisms446,454are adapted to be controlled in accordance with timely modes of operation by means of the programmable logic controller (PLC)350. Therefore, in accordance with such modes of operation, after the temporary raised pavement marker (TRPM) extrusion222has been indexably advanced by means of the servo drive motors240,244such that the leading end portion of the temporary raised pavement marker (TRPM) extrusion222has been abutted up against the upstanding side wall430of the release paper support tray424, the air cylinder mechanism454will be activated so as to move the applicator piston458downwardly into contact with the leading end portion of the temporary raised pavement marker (TRPM) extrusion222whereby the leading end portion of the temporary raised pavement marker (TRPM) extrusion222will be forced into contact with that one of the plurality of adhesive patches426, disposed upon the release sheet422, which has been indexably moved beneath the applicator piston458such that the leading end portion of the temporary raised pavement marker (TRPM) extrusion222will be adhesively bonded to that particular adhesive patch426.

At substantially the same time, or immediately thereafter, the air cylinder mechanism446is activated in accordance with a two-stage movement or actuation mode whereby in accordance with the first-stage movement or actuation of the air cylinder mechanism446, the hold-down implement452is moved into contact with that portion of the temporary raised pavement marker (TRPM) extrusion222which is disposed immediately upstream of the release paper support tray424, while in accordance with the second-stage movement or actuation of the air cylinder mechanism446, the cutting blade element440is moved downwardly against, for example, the force of a spring-biasing mechanism, not shown. In view of the fact that the temporary raised pavement marker (TRPM) extrusion222is respectively securely held or retained upon both the release sheet support tray424, as well as upon the guide track220, by means of the applicator piston458and the hold-down implement452, the cutting blade element440is able to operatively cooperate with the side edge portion of the release sheet support tray424and thereby sever the leading end portion of the temporary raised pavement marker (TRPM) extrusion222from the remaining or residual portion of the temporary raised pavement marker (TRPM) extrusion222so as to form one of the individual temporary raised pavement markers (TRPMs)428. Upon retraction of the air cylinder mechanisms446,454, the release sheet or paper422, having one or more of the temporary raised pavement markers (TRPMs)428disposed thereon, and the temporary raised pavement marker (TRPM) extrusion222are able to be respectively advanced whereby the foregoing operation for forming the individual temporary raised pavement markers (TRPMs)428is able to again be cyclically achieved.

Having formed the individual temporary raised pavement markers (TRPMs)428and serially disposed the same upon the single, continuous, common release sheet422, the assembly, comprising the individual temporary raised pavement markers (TRPMs)428and the single, continuous, common release sheet422, must now be conveyed in the downstream direction along the release paper conveyance path PCP so as to ultimately be formed into the collated array of temporary raised pavement markers (TRPMs) as shown within FIG.16. More particularly, as can best be appreciated from FIGS.3and12-15, a pair of timing belts464,466, disposed upon opposite sides of the paper conveying path PCP, are respectively operatively engaged with two sets of rotatable timing wheels468,470,472, and474,476,478so as to effectively be driven thereby. More specifically, a pair of servo motors480, only ore of which is visible inFIGS. 12 and 15, are respectively operatively connected to the central ones of the timing wheels470,476such that the timing wheels470,476are driving wheels, while in turn, the central ones of the timing wheels470,476are operatively connected to the downstream timing wheels472,478through means of suitable gearing and pulley belts, not shown, respectively disposed within transmission housings482,484, such that timing wheels472,478are driven wheels, timing wheels468,474comprising idler wheels.

As can best be seen fromFIG. 13, the outer periphery of each timing wheel468-478is provided with a plurality of timing teeth486, and it is appreciated that the inner surfaces of each timing belt464,466are similarly provided with corresponding timing teeth whereby the timing belts464,466can in fact be operatively engaged with and driven by the timing wheels468-478. In a similar manner, it can be appreciated fromFIGS. 12 and 13that the outer surfaces of each timing belt464,466are likewise provided with timing teeth whereby the inner loop portions of the timing belts464,466can effectively engage the opposite sides of the vertically oriented leg sections of the individual temporary raised pavement markers (TRPMs)428so as to convey the assembly, comprising the individual temporary raised pavement markers (TRPMs)428and the single, continuous, common release sheet422, along the support tray424. It is of course noted that the servo motors480are activated and controlled by means of the programmable logic controller (PLC) in an indexably timed manner whereby, for example, the assembly, comprising the individual temporary raised pavement markers (TRPMs)428and the single, continuous, common release sheet422, is moved along the support tray424, in a step-wise manner, a distance which is equivalent to the spacing defined between successive ones of the individual temporary raised pavement markers (TRPMs)428, as disposed upon the single, continuous, common release sheet422, in order to in fact correspond with the formation of the individual temporary raised pavement markers (TRPMs)428upon the single, continuous, common release sheet422as has been previously described. Still yet further, it is noted that in conjunction with the indexable movement of the assembly, comprising the individual temporary raised pavement markers (TRPMs)428and the single, continuous, common release sheet422, along the support tray424, a suitable braking mechanism, not shown, may be utilized in conjunction with the release sheet or release paper supply roll420such that a predetermined amount of slack is maintained within the release sheet422as the same is conveyed along the support surface424.

Continuing further, in order to actually cause the plurality of individual temporary raised pavement markers (TRPMs)428, as disposed upon the single, continuous, common release sheet422, as disclosed withinFIG. 12, into the collated assemblage as disclosed withinFIG. 16, it is further seen that a substantially inverted L-shaped bracket488is fixedly mounted upon the second support surface or table425so as to extend transversely across the paper conveyance path PCP, and in turn, another bracket490is fixedly connected to and support by the L-shaped bracket488. Still further, a deflector plate492, having a substantially ski-shaped configuration, is suspendingly supported from the bracket490, and it is noted that both of the brackets488,490are respectively provided with slotted adjustment means494,496whereby, ultimately, the disposition of the deflector plate492can be positionally adjusted with respect to the paper conveyance path PCP. Accordingly, as the plurality of temporary raised pavement markers (TRPMs)428are conveyed downstream, the upturned upstream end portion of the ski-shaped deflector plate492will successively encounter the upper end portion of each temporary raised pavement marker (TRPM)428so as to initially cause a tilting of each temporary raised pavement marker (TRPM)428whereby the conveyance of the plurality of temporary raised pavement markers (TRPMs)428will be permitted to continue as a result of the upper end portion of each temporary raised pavement marker (TRPM)428now being disposed beneath the longitudinally extending planar section of the deflector plate492.

The downstream conveyance of each one of the plurality of temporary raised pavement markers (TRPMs)428is continued until each one of the plurality of temporary raised pavement markers (TRPMs)428reaches the downstream end of the support tray424at which position there is located a collating mechanism498which effectively comprises an open-ended container into which the plurality of temporary raised pavement markers (TRPMs)428are conveyed. As can best be appreciated fromFIGS. 13 and 15, the bottom surface or floor500of the container498is disposed at an elevational level which is beneath that of the support tray424. In addition, it is seen that the upstream end of each side wall502,504of the collating container498is also provided with an upturned deflector portion506,508, and in this manner, as each one of the temporary raised pavement markers (TRPMs)428encounters the deflector portions506,508, the temporary raised pavement markers (TRPMs)428are tilted still further so as to be guided into the collating container498. As a result of such tilting of the temporary raised pavement markers (TRPMs)428, and in view of the fact that the floor500of the collating container498is disposed beneath the level of the support tray424, each one of the temporary raised pavement markers (TRPMs)428will drop down onto the floor portion500of the collating container, and a successive upstream one of the temporary raised pavement markers (TRPMs)428will be disposed atop the preceding or downstream one of the temporary raised pavement markers (TRPMs)428so as to achieve the collated and nested array of the temporary raised pavement markers (TRPMs)428as disclosed withinFIG. 16, and as more fully discussed within the aforenoted U.S. patent application Ser. No. 10/302,994 which was filed on Nov. 25, 2002 and which is entitled COLLATED ROAD MARKER ASSEMBLY, AND SYSTEM AND METHOD FOR AUTOMATICALLY APPLYING COLLATED ROAD MARKERS TO ROADWAY SURFACES.

With reference again being made briefly to FIG.8, it can be seen that once a predetermined number of the temporary raised pavement markers (TRPMs)428have been conveyed toward the collating container498for deposition therein so as to form the collated and nested array of the temporary raised pavement markers (TRPMs)428as disclosed withinFIG. 16, the collated and nested array of the temporary raised pavement markers (TRPMs)428can then be manually transferred from the collating container498into a suitable container or carton510which will serve as a supply magazine for providing the collated and nested array of the temporary raised pavement markers (TRPMs)428to the dispensing apparatus as disclosed within the aforenoted U.S. patent application Ser. No. 10/302,994 which was filed on Nov. 25, 2002 and which is entitled COLLATED ROAD MARKER ASSEMBLY, AND SYSTEM AND METHOD FOR AUTOMATICALLY APPLYING COLLATED ROAD MARKERS TO ROADWAY SURFACES. It is further noted that in order to properly process different sized temporary raised pavement markers (TRPMs)428for disposition within correspondingly sized magazine containers or cartons510, the collating container498is longitudinally split into halves such that the side walls502,504of the collating container498are respectively mounted upon substantially L-shaped, adjustable brackets512,514so as to adjustably alter the width dimensions of the collating container498as best seen inFIG. 13, and in a similar manner, each side wall502,504is split into vertical halves, as disclosed at504a,504binFIG. 15, which are also adjustably mounted upon the brackets512,514.

It is lastly noted that in order to actually predetermine the number of temporary raised pavement markers (TRPMs)428that are to be ultimately disposed within the magazine container or carton510, a suitable optical sensor516, as can best be seen inFIGS. 13 and 15, is provided at the intersection of the extrusion conveyor flow path224and the release paper conveyance path PCP. The sensor516detects the temporary raised pavement markers (TRPMs)428as they are effectively formed and deposited upon the release sheet422, counts the same, and transmits such count to the programmable logic controller (PLC)350. The programmable logic controller (PLC)350, in turn, controls the activation of a cutting blade implement, not shown, which is mounted upon the piston of a double-acting piston-cylinder assembly518which is disposed at the downstream end of the support tray424, and which is disposed transversely with respect thereto and the paper conveyance path PCP.

Accordingly, when the predetermined number of temporary raised pavement markers (TRPMs)428, as disposed upon the common release sheet422, have been detected by means of the sensor/counter516, the programmable logic controller (PLC)350will activate the piston-cylinder assembly518so as to sever the assembly, comprising the release sheet422and the plurality of temporary raised pavement markers (TRPMs)428disposed thereon, at a predetermined location such that the predetermined number of temporary raised pavement markers (TRPMs)428are delivered into the collating container498and ultimately into the magazine container510. In connection with the feeding or conveyance of the collated assembly, comprising the plurality of temporary raised pavement markers (TRPMs)428as disposed upon the release sheet422, it is to be remembered that in view of the fact that the width dimension of the release sheet422is greater than that of the individual adhesive patches426disposed thereon, the presence of such adhesive patches426does not in any way hinder the conveyance or feeding of the collated assembly, comprising the plurality of temporary raised pavement markers (TRPMs)428and the release sheet422, either within the collating container498or within the magazine container510.

Referring again to the drawings, and more particularly toFIG. 17thereof, a second embodiment of a new and improved apparatus or system constructed in accordance with the principles and teachings of the present invention for manufacturing a collated array of temporary raised pavement markers (TRPMs), and showing the cooperative parts thereof, is disclosed and is generally indicated by the reference character610. It is to be noted that this second embodiment of the new and improved apparatus or system610of the present invention is to be differentiated from the first embodiment of the new and improved apparatus or system210of the present invention in that while the first embodiment apparatus or system210manufactured or fabricated the plurality of temporary raised pavement markers (TRPMs)428from a continuous, single, temporary raised pavement marker (TRPM) extrusion222, subsequently deposited and adhered the individual temporary raised pavement markers (TRPMs)428onto the continuous, single, common release sheet422, and still further formed the assembly, comprising the plurality of temporary raised pavement markers (TRPMs)428and the single common release sheet422into the collated, nested array of temporary raised pavement markers (TRPMs)428, to the contrary, the second embodiment apparatus or system610deposits and adheres temporary raised pavement markers (TRPMs), previously manufactured by conventional fabrication techniques, onto a single, common release sheet, and subsequently forms the assembly, comprising the plurality of temporary raised pavement markers (TRPMs) as disposed upon the single common release sheet, into the collated, nested array of temporary raised pavement markers (TRPMs).

More particularly, as can be generally appreciated fromFIG. 17, and as will be further appreciated fromFIGS. 18-30, the second embodiment of the new and improved apparatus or system610of the present invention is seen to comprise apparatus for mounting individual, pre-existing or pre-formed temporary raised pavement markers (TRPMs) onto a common release sheet or release liner, and for subsequently collating the same in a manner similar to that previously disclosed in connection with the first embodiment of the new and improved apparatus or system210as has been disclosed withinFIGS. 12-16. As disclosed withinFIG. 17, a conventional or existing extruder mechanism612forms a temporary raised pavement marker (TRPM) extrusion which also has a pair of reflective strips disposed upon the opposite sides thereof, a protective covering disposed over the pair of reflective strips so as to protect the same prior to the use of the temporary raised pavement markers (TRPMs), and an adhesive strip applied to the undersurface portion thereof. A cutter mechanism614is operatively disposed at the downstream end of the extruder mechanism612so as to continuously cut the temporary raised pavement marker (TRPM) extrusion into a plurality of serially conveyed individual temporary raised pavement markers (TRPMs), all of which are similar to the conventional temporary raised pavement marker (TRPM)110as disclosed withinFIG. 2except for the fact that none of the plurality of individual temporary raised pavement markers (TRPMs) have individual release sheets or release liners applied to the undersurface portions of their adhesive strips.

After the temporary raised pavement marker (TRPM) extrusion has been cut into the plurality of serially conveyed individual temporary raised pavement markers (TRPMs) by means of the cutter mechanism614, the individual temporary raised pavement markers (TRPMs) are conveyed through a conventional temporary raised pavement marker (TRPM) discharge tunnel616so as to effectively be grasped, and conveyed further in the downstream direction, by means of a conveyor mechanism618, constructed in accordance with the principles and teachings of the present invention, toward a station620at which the individual temporary raised pavement markers (TRPMs) can be operationally mated with, and deposited and adhered upon, a single, continuous, common release sheet or liner. Subsequently, the assembly, comprising the plurality of temporary raised pavement markers (TRPMs) as adhered upon the single common release sheet or liner, is conveyed by means of a conveyor mechanism622, similar to that disclosed withinFIGS. 12-15, toward a collating mechanism, not shown but similar to the collating mechanism also disclosed withinFIGS. 12-15, whereby the collated array of temporary raised pavement markers (TRPMs) is able to likewise be deposited within a suitable container or magazine, similar to the container or magazine510as disclosed withinFIG. 8, for use in connection with the dispensing apparatus as disclosed within the aforenoted U.S. patent application Ser. No. 10/302,994 which was filed on Nov. 25, 2002 and which is entitled COLLATED ROAD MARKER ASSEMBLY, AND SYSTEM AND METHOD FOR AUTOMATICALLY APPLYING COLLATED ROAD MARKERS TO ROADWAY SURFACES.

With reference therefore now being made to FIGS.18-21,25, and26, the conveyor mechanism618, constructed in accordance with the principles and teachings of the present invention, and by means of which the plurality of individual temporary raised pavement markers (TRPMs) are conveyed toward the station620at which the individual temporary raised pavement markers (TRPMs) are operationally mated with, and deposited and adhered upon, the single, continuous, common release sheet or liner, will be described. More particularly, as can best be appreciated fromFIGS. 18 and 19, the plurality of individual temporary raised pavement markers (TRPMs) are transported through, and discharged from, the conventional temporary raised pavement marker (TRPM) discharge tunnel616so as to be grasped, and conveyed in the downstream direction624, by the conveyor mechanism618. As can best be seen fromFIG. 19, the conventional temporary raised pavement marker (TRPM) discharge tunnel616comprises a through-passage626which has a substantially L-shaped cross-sectional configuration with the long-legged section628of the passage626being disposed horizontally while the short-legged section630of the passage being disposed vertically. In this manner, the individual temporary raised pavement markers (TRPMs) are transported through the passage626with their normally vertically oriented long leg portions disposed horizontally and their normally horizontally oriented short leg portions disposed vertically.

As can be additionally appreciated fromFIG. 18, the conveyor mechanism618is mounted upon a fixed framework632and is disposed immediately downstream from the discharge tunnel616so as to be capable of immediately receiving the plurality of individual temporary raised pavement markers (TRPMs), as serially discharged from the discharge tunnel616, and for conveying the same in the downstream direction624. More particularly, the conveyor mechanism618comprises a pair of endless loop conveyor belts634,636which are disposed within a vertical array such that the lower loop of the upper conveyor belt634operatively cooperates with the upper loop of the lower conveyor belt636so as to effectively define a bite therebetween within which the horizontally disposed long leg portions638of the individual temporary raised pavement markers (TRPMs)640are grippingly disposed, as best seen inFIG. 21, while the vertically disposed short leg portions642of the individual temporary raised pavement markers (TRPMs)640, having adhesive patches644fixedly mounted upon undersurface portions thereof, have their upper surface portions disposed in contact with a fixed guide or support rail646. In order to ensure the fact that the vertically disposed short leg portions642of the individual temporary raised pavement markers (TRPMs)640are in fact properly disposed in contact with the guide rail646so as to effectively be supported thereon during the downstream conveyance of the temporary raised pavement markers (TRPMs)640in the conveyance direction624, it is noted, as can best be appreciated fromFIG. 19, that the upstream end portions of the vertically arrayed endless loop conveyor belts634,636are effectively disposed within a common vertical plane, however, as can best be appreciated fromFIG. 25, the downstream end portions of the vertically arrayed endless loop conveyor belts634,636are effectively disposed within laterally offset vertical planes. Considered from a different point of view, the vertical plane, within which the lower endless loop conveyor belt636is disposed, is slightly skewed in the transverse direction with respect to the vertical plane within which the upper endless loop conveyor belt634is disposed. Accordingly, a bias is effectively impressed upon each one of the temporary raised pavement markers (TRPMs)640, as they are conveyed in the downstream conveyance direction624, so as to force the vertically disposed short leg portions642of the temporary raised pavement markers (TRPMs)640into contact with, and maintain the vertically disposed short leg portions642of the temporary raised pavement markers (TRPMs)640in contact with, the guide rail646.

In order to provide motive drive power to both the upper and lower conveyor belts634,636, a motor drive system, as can best be appreciated fromFIGS. 20 and 21, is disclosed. More particularly, a servo drive motor648is fixedly mounted upon a platform650which comprises one component of a framework by means of which the entire conveyor mechanism or assembly618is movably mounted upon the fixed framework632, as will be described more fully hereinafter, and the drive motor648is seen to further comprise an output drive shaft652. The output drive shaft652is, in turn, drivably connected to an upper conveyor belt drive shaft654, through means of a drive coupler656, and the distal end of the upper conveyor belt drive shaft654has a first upper conveyor belt drive pulley658fixedly mounted thereon such that rotary drive can be transmitted directly from the drive motor648to the upper conveyor belt634which is disposed around the first upper conveyor belt drive pulley658. In a similar manner, an upper drive pulley660is also fixedly mounted upon the upper conveyor belt drive shaft654, while a lower, dual drive pulley662, as best seen inFIG. 25, is mounted within a pulley block664. The lower, dual drive pulley662is seen to comprise, in effect, first and second lower drive pulleys666,668, and a first endless drive pulley belt670is disposed within a vertical plane so as to be drivingly disposed around, and extend between, the upper drive pulley660and the first lower drive pulley666.

A second endless drive pulley belt672has a first end portion thereof drivingly disposed around the second lower drive pulley668, while a second opposite end portion thereof is drivingly disposed around a driven pulley674. The driven pulley674is mounted upon a driven shaft676which has one end thereof rotatably mounted within a pulley block678while the opposite end thereof is operatively engaged with a lower conveyor belt drive pulley680around which the lower conveyor belt636is disposed. As can be appreciated fromFIGS. 20 and 21, when the second drive pulley belt672has its opposite end portions disposed around the lower drive pulley668and the driven pulley674, the drive pulley belt672effectively crosses itself so as to have a substantially X-shaped configuration, and in this manner, the rotary drive direction of the upper conveyor belt drive pulley658is opposite that of the lower conveyor belt drive pulley680so as to achieve the simultaneous conveyance of the temporary raised pavement markers (TRPMs)640in the conveyance direction624. More particularly, as viewed, for example, inFIG. 21, the upper conveyor belt drive pulley658is being rotated in the counterclockwise direction such that the lower run of the upper conveyor belt634is moved in the conveyance direction624, while the lower conveyor belt drive pulley680is being rotated in the clockwise direction such that the upper run of the lower conveyor belt636is likewise moved in the conveyance direction624.

As may best be appreciated fromFIG. 17which discloses the entire apparatus or system610from an overall point of view, as the plurality of individual temporary raised pavement markers (TRPMs)640are conveyed in the downstream conveyance direction624, it is of course desired to effectively assemble or deposit the same upon a single or common release sheet or liner such that the assembly of individual temporary raised pavement markers (TRPMs)640, as disposed upon the single or common release sheet or liner can subsequently be formed into the collated and nested array of temporary raised pavement markers (TRPMs) for supply to the apparatus for dispensing and applying the temporary raised pavement markers (TRPMs) onto the pavement surface as disclosed within the aforenoted U.S. patent application Ser. No. 10/302,994 which was filed on Nov. 25, 2002 and which is entitled COLLATED ROAD MARKER ASSEMBLY, AND SYSTEM AND METHOD FOR AUTOMATICALLY APPLYING COLLATED ROAD MARKERS TO ROADWAY SURFACES. Accordingly, a pair of supply rolls682,684of the single or common release sheet or liner are disposed at the downstream end portion of the conveyor mechanism618, and it is appreciated that the supply rolls682,684are oriented in such a direction that the outfeed of the single or common release sheet or liner paper686is oriented in a direction which is substantially perpendicular to the infeed direction of the temporary raised pavement markers (TRPMs)640along the conveyance path624. The apparatus or system610is provided with a pair of release paper or release liner supply rolls682,684so as to render the same operationally redundant and thereby more efficient from a time-wise processing viewpoint, meaning, for example, that when one of the release paper supply rolls682,684becomes depleted, the leading end portion of the release sheet or release liner686disposed upon the new or fresh one of the release paper supply rolls682,684may be attached, such as, for example, by manual means, to the trailing end portion of the release sheet or release liner686disposed upon the depleted one of the release paper supply rolls682,684whereby the infeeding process or supply of the release sheet or release liner686toward the operational station, at which the individual temporary raised pavement markers (TRPMs)640are to be applied onto the single or common release sheet or liner686, may be rendered operationally continuous.

As is further disclosed within FIGS.18,22and23, in order to actually determine the depletion state of the supply of the release sheet or release liner686upon each one of the release paper supply rolls682,684, the release paper supply rolls682,684respectively have operatively associated therewith an optical sensor or monitor688,690, such as, for example, a suitable photodetector or the like. The sensors or monitors688,690are seen to be respectively fixedly mounted upon housings692,694upon which the release paper supply rolls682,684are rotatably mounted, and in turn, the housings692,694are both fixedly mounted upon upstanding columns696,698which are fixedly secured to the main framework632of the system or apparatus610. As can best be appreciated fromFIG. 22, each one of the housing692,694is seen to comprise a pair of oppositely disposed side walls700,702, and704,706, and it is seen that the sensors or monitors688,690are respectively mounted upon the side walls700,704, while side walls702,706are respectively provided with view ports708,710by means of which the optical sensors or monitors688,690can in fact view the diametrical extent of the amount of release paper or release liner disposed upon the release paper supply rolls682,684so as to effectively monitor when the supply of release paper or release liner disposed upon the release paper supply rolls682,684becomes depleted.

It is lastly noted, in connection with the mounting of the release paper supply rolls682,684upon their respective housings692,694, that each one of the release paper supply rolls682,684is respectively mounted upon a shaft712,714which is respectively rotatably mounted within suitable bearing blocks716,718, and720,722which are respectively mounted upon the side walls700,702, and704,706of the housings692,694. As can best be appreciated fromFIG. 23, the rotary shafts712,714, upon which the release paper supply rolls682,684are respectively mounted, are provided with a suitable braking mechanism so as to impart a predetermined resistance level with respect to the rotation of the shafts712,714, rotatably disposed within the bearing blocks716,718, and720,722, whereby as the release paper or release liner686is unreeled from the particular one of the particular one of the release paper supply rolls682,684that is currently being used, the release paper or release liner686will be able to be supplied to the operating station, at which the individual temporary raised pavement markers (TRPMs)640are deposited upon the release paper or release liner686in a manner which will be more fully described hereinafter, will in fact be supplied in a relatively taut state without excessive slack.

It is noted that only the braking mechanism724, operatively associated with the rotary shaft714of the release paper supply roll684, is visible inFIG. 23, and therefore, while the description of the braking mechanism will accordingly be confined to the braking mechanism724operatively associated with the rotary shaft714of the release paper supply roll684, it is to be understood that the braking mechanism, not visible, but operatively associated with the rotary shaft712of the release paper supply roll682, will comprise similar structure as that of the braking mechanism724. As seen inFIG. 23, the braking mechanism724is provided with an arcuately configured internal braking block member726which is adapted to operatively engage the outer peripheral surface of the rotary shaft714, and a control knob728, which is adjustably mounted within a cap member730of the housing694, is operatively connected to the braking mechanism724through means of a shaft732. In this manner, upon rotation of the control knob728, respectively in the clockwise and counterclockwise directions, the braking mechanism724, and in particular, the braking block member726thereof, can be positionally adjusted so as to either be closer to or further away from the outer peripheral surface of the rotary shaft714whereby the level of the braking force as impressed upon the rotary shaft714can be desirably adjusted.

Having described the mechanisms and operative implements for achieving the serial downstream conveyance of the plurality of individual temporary raised pavement markers (TRPMs)640toward the station at which the plurality of individual temporary raised pavement markers (TRPMs)640will be individually deposited and adhered upon the single, common release sheet or release paper686, the additional mechanisms and operative implements for achieving the deposition and adherence of the plurality of individual temporary raised pavement markers (TRPMs)640onto the single, common release sheet or release paper686will now be described. With reference therefore being made toFIGS. 20,24, and26, a release paper guide plate734, having a substantially inverted L-shaped configuration, is fixedly mounted upon an upper part of the main apparatus or system framework632so as to be within the vicinity of the downstream end of the conveyor mechanism or system618. In this manner, as can best be appreciated fromFIGS. 20 and 24, the release paper or release liner686can be unrolled from release paper supply roll682, conducted over the upper horizontally disposed guide surface736of the guide plate734, and conducted downwardly along the vertically disposed guide surface738of the guide plate734. It is to be noted that the vertically disposed guide surface738thus constitutes the upstream end of an assembly flow path AFP along which the assembly, comprising the serially arranged temporary raised pavement markers (TRPMs)640, as disposed upon the common release paper or release sheet686, will be conducted so as to ultimately achieve the collation and nested arrangement of the temporary raised pavement markers (TRPMs)640upon the common release sheet686, as will be more fully disclosed hereinafter.

As can best be appreciated fromFIG. 21, the longitudinal extent of the upper conveyor drive system, comprising, for example, the upper conveyor belt634and the upper conveyor belt drive pulley658, is greater than the longitudinal extent of the lower conveyor drive system, comprising, for example, the lower conveyor belt636and the lower conveyor belt drive pulley680. More particularly, the lower conveyor belt drive pulley680is located at a position which is substantially upstream from the position at which the upper conveyor belt drive pulley658is located, whereby the downstream end of the lower conveyor belt system terminates at a position which is upstream of the downstream end of the upper conveyor belt system, as considered along the temporary raised pavement marker (TRPM) conveyance path624. The reason for this relative disposition of the various operative components comprising the upper and lower conveyor belt systems is to ultimately enable the temporary raised pavement markers (TRPMs) to be transferred from their entrapped positions between the upper and lower conveyor belts634,636, onto the common release sheet or release liner686, and to transport or convey the common release sheet or release liner686, having the plurality of serially arranged temporary raised pavement markers (TRPMs)640fixedly adhered thereon, to a downstream collating mechanism by means of which the assembly, comprising the serially arranged temporary raised pavement markers (TRPMs)640, and the common release paper or release sheet686, will be collated and nested as has heretofore been described in connection with the first embodiment apparatus or system210of the present invention and as disclosed within FIG.16.

Continuing further, then, and with reference being made to FIGS.20,21,25, and26, a support plate740, having a substantially L-shaped configuration as viewed in FIG.25and as best seen inFIG. 21, is provided for reciprocal movement between an extended state, as disclosed within FIGS.20,21, and25, and a retracted state as disclosed within FIG.26. More particularly, as can best be seen inFIG. 21, the substantially L-shaped support plate740comprises a horizontally disposed support leg742, and a vertically disposed mounting leg744. The vertically oriented mounting leg744is fixedly secured to a mounting plate or mounting block746, and it is further seen that the mounting plate or mounting block746is fixedly secured upon the free or distal ends of a pair of laterally spaced guide rods748as well as upon the free or distal end of a centrally located piston rod750. The three rods748,750,748are operatively associated with a cylinder mechanism752, which may be, for example, a pneumatic cylinder, whereupon actuation of the cylinder mechanism752either in its extension or retraction modes, the support plate740will be moved between its extended position, as disclosed within FIGS.20,21, and25, and its retracted position as disclosed within FIG.26. When the support plate740is disposed at its extended position, as may best be appreciated fromFIGS. 20,21, and25, the horizontally disposed support leg742is disposed at an elevational level which substantially corresponds to the elevational level at which the upper run or loop portion of the lower conveyor belt636is disposed. In this manner, the upper run or loop portion of the lower conveyor belt636can effectively transfer each temporary raised pavement marker (TRPM)640onto the horizontally disposed support leg742of the support plate740.

Subsequently, as can best be appreciated fromFIGS. 21 and 25, in lieu of the long leg portion638of each temporary raised pavement marker (TRPM)640being entrapped between the lower run or loop portion of the upper conveyor belt634and the upper run or loop portion of the lower conveyor belt636, the long leg portion638of each temporary raised pavement marker (TRPM)640is now entrapped between the lower run or loop portion of the upper conveyor belt634and the upper surface portion of the horizontally disposed support leg742of the support plate740. Accordingly, this particular one of the temporary raised pavement markers (TRPMs)640is now ready to be deposited onto and adhered to the common release sheet or release liner686. In order to therefore deposit and adhere each one of the temporary raised pavement markers (TRPMs)640onto the common release sheet or release liner686, a placement or application piston-cylinder assembly, comprising a cylinder housing754, as best seen inFIG. 24, and a piston assembly, comprising a piston rod756and an application plate758, as best seen inFIGS. 25 and 27, is disposed at an elevational level which is just below that of the vertically disposed guide surface738of the guide plate734so as to be within the vicinity of the horizontally disposed support leg742of the support plate740when the support plate740is disposed at its extended position.

In this manner, the application plate758is also located at an elevational level which substantially corresponds to that of the vertically disposed short leg portion642of the temporary raised pavement marker (TRPM)640which is entrapped between the lower run or loop portion of the upper conveyor belt634and the upper surface portion of the horizontally disposed support leg742of the support plate740. The piston assembly, comprising the piston rod756and the application plate758, can of course be actuated for movement between an extended position as illustrated withinFIG. 25, at which position the application plate758moves beyond, or to the left of, the plane within which the release sheet or release paper686is normally disposed as a result of being conveyed downwardly along the vertically disposed guide surface738of the guide plate734, and a retracted position, not illustrated, at which position the application plate758will be disposed to the right of the plane within which the release sheet or release paper686is normally disposed as a result of being conveyed downwardly along the vertically disposed guide surface738of the guide plate734.

Accordingly, it can be readily appreciated that when the piston rod756is moved from its retracted position to its extended position, the application plate758will engage the release sheet or release paper686and force the same into contact with the adhesive patch644disposed upon the vertically disposed short leg portion642of the temporary raised pavement marker (TRPM)640which is entrapped between the lower run or loop portion of the upper conveyor belt634and the upper surface portion of the horizontally disposed support leg742of the support plate740. Consequently, that particular temporary raised pavement marker (TRPM)640is now deposited and adhered upon the common release sheet or release paper686. In order to permit successive ones of the plurality of temporary raised pavement markers (TRPMs)640to be deposited and adhered onto the common release sheet or release paper686, the piston rod750is retracted into the cylinder housing752so as to correspondingly move the support plate740to its retracted position as illustrated within FIG.26. This operation will permit the common release sheet or release paper686, and the temporary raised pavement marker (TRPM)640just deposited thereon, to be indexably moved downwardly along the vertically disposed guide surface738of the guide plate734. Subsequently, the piston rod750is again extended with respect to the cylinder housing752so as to correspondingly move the support plate740to its extended position as illustrated withinFIG. 20in preparation for receiving a successive one of the temporary raised pavement markers (TRPMs)640which is now in fact conveyed onto the support plate740as a result of the conveyor mechanism618likewise being indexably moved along the conveyance direction624.

It is noted, as was the case with the first embodiment of the apparatus or system210of the present invention, that all of the cyclic, indexable movements of the various operative components of the second embodiment of the apparatus or system610of the present invention are under the control of a programmable logic controller (PLC)760which is schematically illustrated within FIG.27. Accordingly, it is to be appreciated that the programmable logic controller (PLC)760will in fact control the indexable movement of the common release sheet or release paper686from the supply rolls682,684, as well as the indexable movement of the assembly, comprising the common release liner686and the plurality of temporary raised pavement markers (TRPMs)640as deposited and adhered upon the common release sheet or release liner686, along the assembly flow path AFP. Still further, the programmable logic controller (PLC)760will of course operatively coordinate such movements with the indexable conveyance or movement of the plurality of individual temporary raised pavement markers (TRPMs)640along the conveyance path624prior to the operative mating of the plurality of temporary raised pavement markers (TRPMs)640with the common release sheet or release liner686so as to in fact achieve the desired deposition and adherence of the plurality of temporary raised pavement markers (TRPMs)640onto the common release sheet or release liner686. In order to therefore achieve the indexably controlled drive of the release sheet or release liner686, both to and beyond the station or location at which the release sheet or release liner686is effectively mated with the plurality of individual temporary raised pavement markers (TRPMs)640being conveyed along the conveyance path624, a drive system, as illustrated withinFIG. 27, is provided.

More particularly, it is seen that the release sheet or release paper drive system comprises a drive motor762which is operatively connected to a set of laterally spaced drive pulleys764,764through means of an output drive shaft766of the drive motor762upon which the drive pulleys764are mounted. The output drive shaft766has its opposite ends rotatably mounted within a pair of bearing members768,768which are respectively mounted within a pair of bearing blocks770,770, and the drive pulleys764,764are respectively operatively connected to a pair of laterally spaced driven pulleys772,772through means of a pair of pulley belts774,774. The driven pulleys772,772are mounted upon a driven shaft776, and the opposite ends of the driven shaft776are mounted within a pair of bearing members778,778which are respectively mounted within a pair of bearing blocks780,780. A pair of vertically oriented, laterally spaced guide plates782,782are mounted upon a portion of the main framework632such that the interior surface portions thereof are disposed in a substantially coplanar manner with respect to the external vertically disposed guide surface738of the guide plate734as can best be appreciated from FIG.25. In this manner, as the release sheet or release liner686is conveyed along the assembly flow path AFP, as defined upon the external guide surface738of the guide plate734, the release sheet or release liner686will also be interposed between the upper interior surface portions of the guide plates782,782and the external surfaces of the pulley belts774,774as disposed around the driven pulleys772,772, as well as being interposed between the lower interior surface portions of the guide plates782,782and the external surfaces of the pulley belts774,774as disposed around the drive pulleys764,764. In this manner, in accordance with the indexable drive movements imparted to the drive and driven pulleys764,764,772,772by means of the drive motor762, and in accordance with suitable control signals issued by means of the programmable logic controller (PLC)760, the release sheet or release liner686, having the plurality of temporary raised pavement markers (TRPMs)640disposed thereon, is indexably advanced in the downstream direction. It is noted that the lateral width dimension of the release sheet or liner686is greater than that of each one of the individual temporary raised pavement markers (TRPMs)640, and accordingly, the opposite edge regions of the release sheet or liner686are actually caught or entrapped within the bite regions defined between the pulley belts774,774and the guide plates782,782, while the temporary raised pavement markers (TRPMs)640are disposed between the laterally spaced guide plates782,782so as to effectively pass through such region in a non-obstructing manner.

As can further be seen inFIGS. 27 and 28, as the assembly, comprising the release sheet or release liner686and the plurality of temporary raised pavement markers (TRPMs)640disposed thereon, passes beyond the lower edge portions of the guide plates782,782, the assembly will be conveying transferred onto an upstream, arcuately configured chute member784which, in turn, conducts or conveys the assembly of temporary raised pavement markers (TRPMs)640, as disposed upon the single, common release sheet or release liner686to a conveying mechanism786. It will also be noted that the conveying mechanism786is substantially identical to the conveying mechanism as disclosed withinFIGS. 13-15in connection with the first embodiment apparatus or system210of the present invention, and accordingly, a detailed description of the conveying mechanism786will be omitted for brevity purposes. It is still further noted that in addition to the conveying mechanism786, a collating system, similar to the collating container498as also utilized within the first embodiment apparatus or system210of the present invention, is adapted to be utilized in conjunction with the conveying mechanism786of the second embodiment apparatus or system610of the present invention whereby, again, the collated and nested array of temporary raised pavement markers (TRPMs)640, similar to the array of temporary raised pavement markers (TRPMs)428as disclosed withinFIG. 16, can also be achieved.

With reference lastly being made toFIGS. 29 and 30, a last feature characteristic of the second embodiment of the apparatus or system610of the present invention resides in the fact that the conveyor mechanism618, the drive motor648therefor, the support plate assembly740,752, and the platform650upon which the drive motor648and the cylinder housing752are mounted, are mounted upon a framework which is slidably mounted upon the fixed framework632such that the upstream end portion of the conveyor mechanism618can be alternatively and selectively disposed at an extended position, as illustrated withinFIG. 29, at which the upstream end portion of the conveyor mechanism618will be disposed immediately adjacent to the output end of the extrusion discharge tunnel616, and a retracted position as illustrated withinFIG. 30, at which the upstream end portion of the conveyor mechanism618will be disposed at a position which is located a short distance away from the output end of the extrusion discharge tunnel616. In this manner, when the various noted components of the system610are disposed at the extended position such that the upstream end portion of the conveyor mechanism618is disposed immediately adjacent to the output end of the extrusion discharge tunnel616, then the plurality of individual temporary raised pavement markers (TRPMs)640can be processed further so as to collate and nest the same in order to achieve a collated array of temporary raised pavement markers (TRPMs) similar to that disclosed withinFIG. 16, whereas when the various noted components of the system610are disposed at the retracted position such that the upstream end portion of the conveyor mechanism618is disposed at a position which is located a short distance away from the output end of the extrusion discharge tunnel616, then the plurality of individual temporary raised pavement markers (TRPMs)640can simply be collected, for example, within a suitable container or the like so as to be used independently or individually, as opposed to being collated and nested.

In order to achieve such slidable mounting of the noted system components upon the fixed framework632, it is noted, for example, as can best be appreciated from FIG.18, that the upstream end portion of the conveyor mechanism618is fixedly mounted upon a first slide block788, and that the first slide block788is slidably mounted upon a first slide guide790which is fixedly mounted upon the fixed framework632. In addition, as may best be appreciated fromFIG. 20, the support platform792, upon which the pulley block678is fixedly mounted, is integrally formed atop a second slide block794, and the second slide block794is slidably mounted upon a second slide guide796which is also fixedly mounted upon the fixed framework632. Still yet further, and in a similar manner, the support platform650, upon which the cylinder mechanism752is fixedly mounted, is integrally formed atop a third slide block798, and the third slide block798is slidably mounted upon a third slide guide800which is also fixedly mounted upon the fixed framework632.

Continuing further, a piston-cylinder assembly, comprising a cylinder housing802and a piston rod804, is provided for moving the previously noted components with respect to the fixed framework632. More particularly, the free or distal end of the piston rod804is fixedly attached to a mounting bracket806of the fixed framework632, while the cylinder housing802is fixedly attached to the undersurface portion of the support platform650. Accordingly, when the piston-cylinder assembly802,804is activated whereby the piston rod804is effectively extended with respect to the cylinder housing802, since the free or distal end of the piston rod804is fixedly attached to the mounting bracket806of the fixed framework632, the cylinder housing802is caused to move relative to the piston rod804. Consequently, support platform650, support platform792, and the conveyor mechanism618are moved relative to the fixed framework632from the extended position, as illustrated withinFIG. 29, to the retracted position as illustrated within FIG.30.

Thus, it may be seen that in accordance with the principles and teachings of the present invention, there has been provided two embodiments of apparatus or systems for forming a serial array of temporary raised pavement markers (TRPMs), disposed upon a single, common release sheet or release liner, into a collated and nested array of the temporary raised pavement markers (TRPMs) such that the collated and nested array of temporary raised pavement markers (TRPMs) can be supplied to apparatus for dispensing and applying the temporary raised pavement markers (TRPMs) onto pavement surfaces. More particularly, in accordance with the first embodiment of the apparatus or system of the present invention, the plurality of temporary raised pavement markers (TRPMs) are formed from a single temporary raised pavement marker (TRPM) extrusion, the temporary raised pavement markers (TRPMs) are mounted upon the single, common release sheet or release liner which has a plurality of adhesive patches previously disposed thereon, and the assembly, comprising the plurality of temporary raised pavement markers (TRPMs) and the common release sheet or release liner, are formed into a collated and nested array, whereas in accordance with the second embodiment of the apparatus or system of the present invention, a plurality of pre-formed temporary raised pavement markers (TRPMs), having adhesive patches already disposed thereon, are serially deposited and adhered onto a single, common release sheet or release liner, and the assembly, comprising the plurality of temporary raised pavement markers (TRPMs) and the common release sheet or release liner, are formed into a collated and nested array.