Abstract:
A vertical panel system comprises a vertical panel having a panel with opposing first and second panel surfaces and a base edge. The system further comprises a base having a slot for engaging the base edge of the panel. An aperture is disposed in the panel in proximity to the base edge, which is of sufficient size to receive a foot of a user, for assisting in the engagement of the panel and the base. The base for the vertical panel system comprises a center zone fabricated of vulcanized rubber, and an outer zone fabricated of recycled rubber. The slot is disposed in the center zone. Thus, the combination solves a need to be environmentally responsible and cost effective by recycling rubber which would otherwise fill our landfills, yet provides increased durability by using virgin vulcanized rubber in the zone of the base which includes the engagement slot.

Description:
This application is a continuation of application Ser. No. 10/404,354, now allowed, which is a continuation of application Ser. No. 09/847,876, now U.S. Pat. No. 6,659,681, which is a continuation-in-part of application Ser. No. 09/247,217, filed on Feb. 10, 1999, and now U.S. Pat. No. 6,402,422. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to traffic safety devices and, more specifically, to vertical panel display systems. 
   2. Description of the Related Art 
   Highway signs are generally used for promoting the safe passage of motor vehicles and/or pedestrians by advising of, for example, approaching unsafe driving conditions. These highway signs are generally provided with various highway legends, and are generally configured to flex in response to prevailing winds and wind gusts created by motor vehicles and the like. 
   It is known in the art to use a vertical panel system as a highway sign. In a typical vertical panel system, a vertical panel is on a collapsible support so that it folds down when impacted by a vehicle. This mitigates damage to the panel and the vehicle. A common example is an A-frame design consisting of two sides which are hinged together at the top. Each side has a panel attached to it. For support, the A-frame design is weighed down by sandbags. Upon impact, the A-frame folds flat. This design, while simple to build, is relatively unpredictable and requires at least two components, the A-frame and a sandbag, and maybe more than one sandbag. 
   An improvement on this idea is disclosed in U.S. Pat. No. 4,792,258 to Goff entitled “Collapsible Warning Barricade Apparatus” (“Goff”), which is incorporated herein in its entirety. Goff discloses a vertical panel pivotally attached to a base. The panel was maintained in a vertical position, with the use of a compression spring device that exerted a force on an automatic locking means at the pivot point. The automatic locking means has multiple elements that are coordinated to maintain the panel in an upright position until impact. Unfortunately, the design as disclosed in Goff is complicated to build and requires many parts. 
   It is also a problem with vertical panel systems that when they are impacted, the systems are dragged with the vehicle. As the base or support of the system is attached to the panel, both the panel and the base are damaged. Further, as the vehicle is dragging both the panel and the base, the vehicle incurs increased damage than if the panel was being dragged alone. 
   The prior art discloses a vertical panel system with a breakaway safety feature such that the panel separates from the base when impacted. This system is available under the trade name WindBreakers from Trafcon Industries Inc, 81 Texaco Road, Mechanicsburg, Pa. 17055. The WindBreakers&#39; panel is attached to the rubber base via a breakaway pin that is inserted through the width of the panel. A disadvantage of the WindBreaker is that a replacement pin must be used to reattached the panel to the base as the original pin shears upon separation. Another disadvantage is that the WindBreaker panel flexes in the wind. An additional disadvantage is that the panel does not easily release to stack the bases and panels flat. 
   Another prior art system is disclosed in U.S. Pat. No. 5,670,954 to Junker. This system is similar to WindBreakers system discussed supra, in that a vertical panel  4  is secured to a base using a bolt and nut mechanical fastening combination. A disadvantage of this system is complexity. Additionally, the base securement is designed to be permanent, so there is no ability for the panel to break away from the base, short of the destruction of the system. 
   Still another prior art system is disclosed in U.S. Pat. No. 5,484,225 to Warner. This patent discloses a vertical panel system wherein a vertical panel is secured to a base without the use of mechanical fasteners, by means of a friction/compression fit. However, although this approach is an improvement over the systems discussed supra, it still has a number of problems. For example, to effect the panel/base attachment, the bottom edge of the panel is merely inserted into a slot in the base. There is no structure to prevent the vertical panel from rocking from side to side, and the engagement between the panel and base is subject to wear of the interior surface of the base slot over time, until at a particular point in time the friction/compression fit will be inadequate to properly support the panel. Additionally, there is no structure to assist a user in inserting the panel into the slot. 
   Therefore, it is desirable to have a vertical panel system which is collapsible upon impact, the panel is separable from the base during impact, is easily stacked, and made from relatively few parts. It is also desirable to have a panel that can be reattached to the base without replacing parts. It is also desirable to have the panel surface protected from scratches and mars while it is being hit or dragged. It is also desirable to have a panel that does not flex from the wind force. 
   SUMMARY OF THE INVENTION 
   The present invention provides an advantageous improved vertical panel system, which comprises a vertical panel having a panel with opposing first and second panel surfaces and a base edge. The system further comprises a base having a slot for engaging the base edge of the panel. Advantageously, an aperture is disposed in the panel in proximity to the base edge, which is of sufficient size to receive a foot of a user, for assisting in the engagement of the panel and the base. 
   In another aspect of the invention, there is provided a base for a vertical panel system, which comprises a center zone fabricated of vulcanized rubber, and an outer zone fabricated of recycled rubber. A slot is disposed in the center zone for receiving a base end of a vertical panel in engagement therewith. This arrangement solves a need to be environmentally responsible and cost effective by recycling rubber which would otherwise fill our landfills, yet provides great durability by using virgin vulcanized rubber in the zone of the base which includes the engagement slot. 
   In still another aspect of the invention, there is disclosed a method of assembling a vertical panel system comprised of a vertical panel having a base end and an aperture sufficiently large to accommodate a user&#39;s foot disposed adjacent to the base end. A base comprising a part of the system for ballasting the vertical panel has a slot for receiving the vertical panel base end. The inventive method comprises the steps of positioning the vertical panel over the base, so that the base end is in proximity to and just above the slot. Then, a user&#39;s foot is placed through the aperture, whereupon the user presses downwardly with his or her foot to apply downward force on the vertical panel, so that the base end of the vertical panel is inserted into and becomes engaged with the slot. This innovative method avoids the problem of using one&#39;s arms to press down from the top of the vertical panel, which can be a tiring and difficult job. 
   The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawing. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows an exploded perspective view of a vertical panel system with one panel according to an embodiment of the invention; 
       FIGS. 2 and 3  are perspective and plan views, respectively, showing details of assembly of the vertical panel system of  FIG. 1 ; 
       FIG. 4  shows an exploded perspective view of a dual vertical panel system according to an alternative embodiment of the invention; 
       FIG. 5  is a plan view showing details of the engagement portion of the vertical panel system of  FIG. 4 ; 
       FIGS. 6 and 7  are plan views showing details and positioning of reflective portions of Type I and Type II barricades, respectively; 
       FIG. 8  is a plan view of another alternative embodiment of the present invention; 
       FIG. 9  is a perspective view of the base portion of the vertical panel system illustrated in  FIG. 8 ; 
       FIG. 10  is a perspective view of the vertical panel portion of the system of  FIG. 8 ; 
       FIG. 11  is a view similar to  FIG. 10  showing the application of reflective material to a front panel of the vertical panel portion; and 
       FIG. 12  is a view similar to  FIG. 10  illustrating an alternative embodiment wherein a sign panel is attached to the vertical panel portion. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now to the figures, wherein like reference numerals refer to like elements throughout the figures, and referring specifically to  FIG. 1 , a vertical panel system  10  according to an embodiment of the invention comprises a vertical panel  12  and a base  14 . When a tab  16  extending from a lower end of the vertical panel  12  is inserted into a slot  46  in the base  14 , the assembled vertical panel system  10  resembles an inverted T with the base  14  being the cross member. The vertical panel system  10  is designed to remain standing in wind and gusts from bypassing vehicles while being able to separate into the panel  12  and base  14  upon impact. Because the vertical panel system  10  is able to separate, the damage to the impacting vehicle and the system is mitigated. 
   The vertical panel  12  is comprised of a panel  20  with opposing panel first and second surfaces  22  (only one panel surface shown). The panel  20  has a base edge  24  proximate to the base  14  and from which the tab  16  extends. The panel  20  also has a top edge  26  that opposes the base edge  24 . Two opposing side edges  28  of the vertical panel  12  extend between top edge  26  and the base edge  24 . 
   In the illustrated embodiment of the invention, the edges  24 ,  26 , and  28  are raised above the panel surfaces, so that the first and second panel surfaces  22  are recessed into the panel  20 . Because the edges  24 ,  26 , and  28  are raised, the edges get scraped during normal usage and wear and tear, rather than the panel surfaces  22  or anything on the panel surfaces. Examples of causes of scraping includes the system  10  being struck or the panel  20  skidding across the ground. The panel surfaces  22  may be reflective, either by having reflective material, such as sheeting, disposed thereon or the panel surfaces comprise reflective material. The panel surfaces  22  may have other indicia thereon. Whether it is reflective material or other indica on the panel surfaces, it is protected by the raised edges  24 ,  26 , and  28 . 
   In a preferred embodiment of the invention, the raised edges  24 ,  26 , and  28  protrude in a direction normal to the panel surfaces  22 . In other embodiments of the invention, the raised edges  24 ,  26 , and  28  may extend above the panel surfaces in a direction other than normal to the panel surfaces. In some instances, it may be advantageous for only a portion of the edges  24 ,  26 , and  28  to be raised, or the edges  24 ,  26 , and  28  may be raised above only one of the panel surfaces. The edges  24 ,  26 , and  28  may be integral to the panel  20  or may be a separate but attached component of the panel  20 . 
   In the illustrated embodiment of the invention, the vertical panel  20  is rectangular. Other embodiments of the invention may have vertical panels of other shapes. In the preferred embodiment of the invention, the vertical panel  12  is comprised of double wall blow molded plastic. Other embodiments of the invention may have a vertical panel comprised of other materials. 
   The tab  16  extends from a base edge  24  of the panel  20  and terminates at a tab bottom edge  30 . The tab  16  comprises two opposing side surfaces  32  (only one side surface is shown) that extend between two opposing side edges  34 . Each of the tab side surfaces  32  have two tab grooves  36  extending from the tab bottom edge  30  and towards the panel base edge  24 . In the preferred and shown embodiment of the invention, the tab bottom edge  30  is parallel to the panel base edge  24  and the tab grooves  36  extend perpendicularly to the bottom edge and the base edge. Other embodiments of the invention may have other relationships between edges  24  and  30  and the tab grooves  36 . The tab bottom edge  30  extends a length  31  that is shorter than the width  50  of the panel  20 . 
   In other embodiments of the invention, only one of the tab surfaces  32  may have tab grooves  36 . In other embodiments of the invention, there may be more or fewer than two tab grooves  36  on a tab side surface  32 . In the illustrated embodiment of the invention, the tab grooves  36  have a generally U-shaped profile (see  FIG. 2 ). Other embodiments of the invention may have tab grooves with other suitable profiles. In the illustrated embodiment of the invention, the tab  16  and the panel  20  reside in generally the same plane. In other embodiments of the invention, the tab  16  may be oriented at a different angle to the panel  20 , such as a plane extending through the tab side edges  34  defines a plane that is normal to the panel  20 . In the illustrated embodiment of the invention, the panel  20  has one tab  16 . Other embodiments of the invention may have more than one tab. In the illustrated embodiment of the invention, the tab  16  is of a rectangular cube shape. Other embodiments of the invention may have tabs of other shapes. In the illustrated embodiment of the invention, the tab  16  is integral to the panel  20 . Other embodiments of the invention may have the tab  16  separably attached to the panel  20 . 
   The base  14  has a top surface  40 , a major axis  42  extending along the length of the base and a minor axis  44  extending along the width of the base. At the intersection of the axes  42  and  44  is a slot  46 . The slot  46  extends from the top surface  40  and into the base  14 . The slot  46  complements the tab  16  and the tab grooves  36 . The fit of the slot  46  with the tab  16  may be loose, snug, or it may be an interference fit. An interference fit of the slot  46  and the tab  16  may be suitable for embodiments of the invention in which the base is made of an elastomeric material, such as rubber. The slot  46  may extend through the base  14  or terminate in the base. 
   To assemble the vertical panel system  10 , the tab  16  is inserted into the slot  46 . In the illustrated embodiment of the invention, the vertical panel  12  is oriented along the minor axis  44 . Other embodiments of the invention may have the vertical panel oriented in other directions. 
   In the illustrated embodiment of the invention, the base  14  has a length  48  that is long enough to inhibit the vertical panel system  10  from tumbling in the direction of the major axis  42  when wind or gusts catches the vertical panel  20 . The panel base edge  24  extends a width  50  that is substantially equal to a width  52  of the base  14 . 
   Referring now to  FIGS. 2 and 3 , the tab  16  is shown partially and fully inserted into the slot  46 , respectively. The complementing slot  46  is shown with projections  47  extending into the grooves  36  in  FIG. 3 . It is clearly shown in  FIG. 3  that the width  50  of the panel  20  is approximately the same of the width  52  of the base  14 . Further, when the tab  16  is fully inserted into the slot  46 , the base edge  24  of the panel  20  is in contact with the upper surface  40  of the base  14  across the width  52  of the upper surface. This contact provides a stable fitting of the panel vertical panel  12  and the base  14  that resists the tab  16  from coming out of the slot  46  through repeated lateral movements of the vertical panel  12  in the direction of the minor axis  44 . 
   A significant advantage of the present invention over the prior art is that this “button” or “tongue and groove” engagement between the tab grooves  36  and the base projections  47  is a vast improvement over the mere friction/compression fit disclosed in the prior art, such as in the Warner &#39;225 patent discussed supra. The advantages include increased durability, because wear and tear to the interface over time does not as severely affect the positive interface between the projections and grooves as it does a mere friction/compression fit, and improved stability, or, more specifically, the ability to resist rocking of the panel to the left or right side because of wind gusts due to passing traffic. 
   The base  14  is made of rubber in a preferred embodiment of the invention. The rubber base  14  provides ballast for the system  10  to inhibit tipping or moving the system while in use. Other embodiments of the invention may use any suitable ballasting type device as a base, such as a hollow plastic container filled with sand or another ballast or a frame that is secured in place with sand bags. 
   Referring now to  FIG. 4 , a dual paneled vertical panel system  100  has a vertical panel  112  with a lower panel  120  and an upper panel  121  that is mounted in a base  114 . In the illustrated embodiment, the panels  120  and  121  generally define a plane. Other embodiments of the invention may have the panels  120  and  121  at a different orientation relative to one another or to the ground. 
   The panels  120  and  121  preferably have raised edges  123 . A base edge  124  of the lower panel  120  is located distal to a top edge  127  of the upper panel  121 . A top edge  126  of the lower panel is located proximate to a base edge  125  of the upper panel  121 . A support member  102  extends between the lower panel top edge  126  and the upper panel base edge  125 . The support member  102  may be unitary with the two panels  120  and  121  or may be separably attached to the panels. Other embodiments of the invention may have different arrangements for the support member, including a plurality of support members or a support member that supports the two panels other than extending between the edges  125  and  126 . In a preferred embodiment the support member  102  is integrally molded (such as by injection molding) with the panels  120 ,  121 . 
   A tab  116  extends downwardly from the base edge  124  of the lower panel  120 . The tab  116  has tab grooves  136 , tab side edges  134 , and a bottom edge  130  much like the tab grooves  36 , tab side edges  34  and a bottom edge  30  of the vertical panel system  10 . Additionally, tab  116  has shoulder portions  135  that laterally extend from the tab side edges  134 . The shoulder portions  135  result in the tab  116  expanding to a width  150  ( FIG. 5 ) as it approaches the lower panel. In a preferred embodiment of the invention, the width  150  is approximately the same as the width  152  of the base  114 . 
   Referring now to  FIG. 5  as well, only a lower portion  117  of the tab  116  is inserted in a slot  146  of the base  114  when the system  100  is assembled. The tab lower portion  117  extends between the tab bottom edge  130  to the shoulders  135 .  FIG. 5  more clearly shows that the width  150  of the tab  116  is approximately the same as the width  152  of the base  114 . This results in the shoulder  135  making contact with the base upper surface  140  across the width  152  of the base  114 . The contact provides a very stable assembled system  100  as previously described in connection with the base edge  24  making contact with the base  14 . 
   In an embodiment of the invention, panel surfaces are sized and positioned to conform to Type I or Type II barricade requirements. More specifically, the reflective sheeting requirements of the Type I or Type II barricades are mounted to appropriately sized and positioned panel surfaces in a vertical panel system that embodies the invention. 
   Referring now to  FIG. 6 , the size and positioning of a reflective portion  200  of a Type I barricade is shown relative to the ground  202 . The reflective portion  200  has white stripes  204  that alternate with orange strips  206 . The stripes  204  and  206  are oriented at a right-facing 45 degree angle and have a width  208  of six inches. Other reflective portions of Type I barricades may have the stripes  204  and  206  oriented in a left-facing manner. The portion  200  preferably has a height  210  of 8 to 12 inches and a length  212  of at least 2 feet. The top  214  of the portion  200  is at least 3 feet above the ground  202 . 
   Referring now to  FIG. 7 , the size and positioning of an upper reflective portion  220  and a lower reflective portion  221  of a Type II barricade is shown relative to the ground  202 . The stripes  204  and  206 , the stripe width  208 , the stripe orientation, the height  210  and the length  212  of each reflective portion  220  and  221  is the same as for the reflective portion  200 . The portion  221  is positioned below the portion  220 . The top edge  214  of the upper portion  220  is preferably greater than 3 feet from the ground  202 . 
   In illustrated embodiments of the invention, the vertical panel has a contact surface that makes contact with the upper surface of the base. In the embodiment of the invention  10  shown in  FIG. 1 , the contact surface is the portion of the base edge  24  that extends beyond the tab  16 . In the embodiment of the invention  100  shown in  FIG. 4 , the contact surfaces are the shoulders  135  of the tab  116 . In preferred embodiments of the invention, the contact surface has an overall length that is approximately equal to the width of the base at the point of contact. The matching of the vertical panel contact surface length and the base width results in a laterally stable vertical panel system without having a vertical panel with excess material and the resulting higher manufacturing costs. Other, less preferred embodiments of the invention may have a vertical panel contact surface that does not extend across the width of the base. Additionally, other, less preferred embodiments of the invention may have portions of the contact surface extend beyond the width of the base. 
   Now with reference to  FIGS. 9-11 , a modified and preferably preferred embodiment of the invention is illustrated. In this embodiment, a vertical panel system  310  comprises a vertical panel  312  which is securable to a base  314  and includes a panel portion  322 . As in prior embodiments, the vertical panel  312  is preferably blow molded of plastic, though any known fabrication techniques may be employed. As in the prior embodiments, as well, the panel portion  322  (preferably, opposing panel portions) is recessed relative to the raised edges of the vertical panel, to protect from incidental damage any reflective sheeting  360  (see  FIG. 11 ) which may be disposed on the panel portion surface  322 . 
   As shown in the  FIGS. 9-11  embodiment, the top end  326  of the vertical panel  312  comprises a flange  362  having a pair of handle apertures  364 , for easy carrying of the vertical panel  312 , and a center mounting hole  366  for ready attachment of accessories. Such accessories may include a barricade light  368 , as shown in  FIG. 8 , which is secured to the vertical panel  312  by means of mechanical fasteners attached to the mounting hole  366 , and to a similar hole (not shown) in the light. The attachment mechanism is well known in the traffic safety product art for securing barricade lights to a variety of traffic safety products, typically barricades and traffic delineators. Other accessories might include a panel sign  370 , as shown in  FIG. 12 , which may be attached to the vertical panel  312  by means of mechanical fasteners  372  and  374 , wherein fastener  372  is secured to the mounting hole  366  and fastener  374  is secured to a second mounting hole extending through the vertical panel surface  322 . The sign  370  may have any desired message displayed thereon, and may preferably be comprised of a corrugated semi-rigid material, or any other suitable rigid or semi-rigid material. In one preferred embodiment, the sign  370  is 36 inches square, although other dimensions may be suitable as well. 
   Another significant improvement in the  FIG. 9  embodiment is the employment of a foot aperture  376 , molded or cut into a bottom portion of the vertical panel surface  322 , adjacent to the bottom edge  324  of the vertical panel  312 . This foot aperture has been found by the inventors to be a significant advantage when inserting the tab portion  316  into the slot  346  in the base  314  to assembly the vertical panel system  10 , in that it permits a user to merely place his or her foot conveniently into the aperture  376  and use downward force generated by the act of stepping down with the inserted foot to press the vertical panel  312  into the slot  346 . Without using the aperture  376 , which in preferred embodiments is approximately 3 inches high by 5 inches wide, the panel  312  must be pressed into the slot by pushing downwardly on the top edge of the panel  312  using the arms. As the insertion forces necessary to complete the assembly are quite high, this can be a tiring procedure. 
   In a particularly preferred embodiment, gussets  378  are molded in the vertical panel surface  322  adjacent to each side edge of the aperture  376 . These gussets comprise raised portions or ridges, relative to the remaining vertical panel surface  322 , which provide strength at the bend point. 
   Still another preferred feature is the employment of a plurality of stacking lugs  380  on each edge of the vertical panel  312 , for assisting in stacking a plurality of vertical panels  312  together. Protruding stacking lugs on one side of each of the vertical panels engage complementary recesses on opposing sides of adjacent stacked vertical panels to thereby engage the vertical panels to one another, thus decreasing slippage of the stacked vertical panels relative to one another. 
   With respect to  FIG. 9 , in particular, the base  314  is an improved version of the bases shown in previous embodiments, in that carrying handles  382  have been molded or cut into opposing edges thereof. The base  314  is preferably molded of recycled rubber, such as crumb rubber, in order to reduce costs and to be environmentally responsible. However, Applicants have found that the use of crumb rubber in the vicinity of the slot  346  is not ideal, because it is much more prone to wear and tear (erosion) over time, shortening greatly the useful life of the base because the erosion will ultimately be too great to permit a proper friction/compression fit between the base and tab  316 . Accordingly, Applicants have developed an innovative solution whereby a zone  384  of virgin vulcanized rubber is insert-molded into the crumb rubber base during the fabrication process. The slot  346  is then formed in the vulcanized rubber zone, providing reinforcement from wear and tear due to repeated panel separation. In presently preferred embodiments, the base  314  is fabricated in two weights—28 pounds and 43 pounds. 
   Still another innovative feature is the employment of four raised anti-rotational foot pads  386  ( FIG. 8 ) on the lower surface of the base  314 , to minimize movement from wind, or turbulence from passing vehicles. This is particularly important in the case of vertical panels, where it is important to maintain a zero degree orientation relative to passing traffic. Preferably, these feet  386  are molded into the extreme corners of the base, and may comprise in one preferred embodiment a size of three inches in diameter and ¼ inch in height. 
   The vertical panels illustrated in the drawings are merely representative of the various shapes, sizes, and configurations which fall within the scope of the claimed invention. For example, vertical panel systems may be offered in various sizes, such as 36 inch×8 inch, 24 inch×12 inch, 24 inch×8 inch, or 29½ inch×12 inch, and may be utilized in combination with different sized bases (such as the 28 and 43 pound bases which are presently preferred). Additionally, the reflective sheeting on the panel face may cover some or all of the available surface, depending upon application. As an alternative to the illustrated striped pattern, a vertical panel may accommodate a display sign, with a message for passing motorists. 
   Although presently preferred embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that many variations and/or modifications of the basic inventive concepts herein taught, which may appear to those skilled in the pertinent art, will still fall within the spirit and scope of the present invention, as defined in the appended claims.