Patent Publication Number: US-11377804-B2

Title: Highway sound barrier system

Description:
FIELD OF THE INVENTION 
     This invention relates to noise abatement systems and more particularly to highway noise barriers used to reduce noise from vehicle traffic. 
     BACKGROUND 
     Throughout the world, highway systems are commonly used by the population for commercial and personal transportation. In North America, and indeed throughout the world, these highway noise barriers are utilized to reduce unwanted truck and automobile noise from reaching residential areas. 
     Current wall designs used for noise abatement have not evolved much in the last 70 years. Typically, these high noise barriers are made of concrete or concrete mixtures but are also sometimes made of steel, wood or other masonry products. The problem in using these materials is that they are expensive, often hard to use, time consuming to install and not entirely effective in reducing noise in a highway environment. Moreover, the manufacturing of the materials has a negative impact on the environment. Accordingly, revolutionary and more sustainable solutions are needed to address current issues with highway barriers used to provide noise abatement. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention 
         FIG. 1  illustrates a foam wall assembly used in the highway sound barrier system showing multiple possible rotations according to an embodiment of the invention. 
         FIG. 2A  illustrates an example of a “fan assembly” at a 0-degree rotation showing the angular capabilities of the invention 
         FIG. 2B  illustrates an example of a “fan assembly” at a 5-degree rotation showing the angular capabilities of the invention 
         FIG. 2C  illustrates an example of a “fan assembly” at a 7.5-degree rotation showing another angular capability of the invention 
         FIG. 2D  illustrates an example of a “fan assembly” at a 10-degree rotation showing another angular capability of the invention 
         FIG. 3 ,  FIG. 3A  and  FIG. 3B  illustrate a 3-tier wall assembly and a single foam panel with the coating shown in the transparent view shown in  FIG. 3B . 
         FIGS. 4A, 4B, 4C, and 4D  are end views of the panel shown in  FIG. 3  illustrating possible types of panel connections. 
         FIG. 5 ,  FIG. 5A  and  FIG. 5B  illustrate elevated views showing possible male and female spine connections used in a foam assembly. 
         FIG. 5A  and  FIG. 5B  are magnified views of the spline connections shown in  FIG. 5 . 
         FIG. 6 ,  FIG. 6A , illustrate details of an upright member assembly as used in the invention. 
         FIG. 7 ,  FIG. 7A  and  FIG. 7B  illustrate details of a support bracket that may be used in lieu of footings under the cross-members. 
         FIG. 8A ,  FIG. 8B  and  FIG. 8C  illustrate alternative embodiment of the invention showing various footing designs that may be used under the cross-members and the support bracket shown in  FIG. 7 . 
         FIG. 9 ,  FIG. 9A  and  FIG. 9B  illustrate details of the tension reinforcement anchor assembly according to various embodiments of the invention. 
         FIG. 10A ,  FIG. 10B  and  FIG. 10C  illustrate the tension reinforcement anchor assembly with various large angle configurations. 
         FIG. 11A ,  FIG. 11B ,  FIG. 11C ,  FIG. 11D , and  FIG. 11E  illustrate details of the tension reinforcement anchor assembly. 
         FIG. 12 ,  FIG. 12A  and  FIG. 12B  illustrate magnified views of the tension reinforcement anchor assembly. 
         FIG. 13A   FIG. 13B  and  FIG. 13C  illustrate the top with various large angle configurations. 
         FIG. 14A ,  FIG. 14B  and  FIG. 14C  illustrate various versions of the constructed wall assembly that may be used depending on terrain conditions. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Before describing in detail embodiments that are in accordance with the present invention, it should be observed that the embodiments reside primarily in combinations of method steps and apparatus components related to a highway sound barrier system. Accordingly, the apparatus components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. 
     In this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element 
       FIG. 1  illustrates a highway sound barrier system  100  consisting of an upright member  101  where one cross-member  103   a ,  103   b ,  103   c ,  103   d  is shown in various angled orientations. More specifically, the cross-member is shown in a 0-degree, 5-degree, 7.5-degree, and 10-degree rotated position respectively. Those skilled in the art will recognize that any degree rotation of the cross-member from 0-degree to +/−10-degree is possible allowing for an infinite number of angular rotations allowing the system to conform to design requirements. 
       FIG. 2A ,  FIG. 2B ,  FIG. 2C , and  FIG. 2D  are top views illustrating various examples of the barrier system set at in a range 0 to 10-degree rotation showing the angular capabilities of the invention.  FIG. 2A  shows cross member  201   a  set at 0-degrees in relation to upright member  203 .  FIG. 2B  shows cross-member  201   b  set at 5-degrees in relation to upright member  203 .  FIG. 2C  shows cross-member  201 C set at 7.5-degrees in relation to the upright member  203 . Finally,  FIG. 2D  shows cross member  201   d  set at 10-degrees in relation to the upright member  203 . 
       FIG. 3 ,  FIG. 3A  and  FIG. 3B  illustrate a 3-tier wall assembly having a single foam panel with the coating shown in a transparent view as seen in  FIG. 3 .  FIG. 3A  illustrates a magnified view of area IIIA shown in  FIG. 3 .  FIG. 3B  shows a magnified view shown as area IIIB shown in  FIG. 3A . As seen in both  FIG. 3  and  FIG. 3A , the unique shape allows the cross-members to nest into each other forming a strong bond. The required overall length of each cross-member is determined by particular design requirements with typical lengths ranging from 1 to 12 feet or more. More specifically, the horizontal cross-member panel  300  includes an inner core  301  and outer core  302  having a tongue end  303  that inserts into a groove end  304  on the upright member  305 . The tongue end  303  has a convex surface forming a radius that is typically centered on the core while the groove end  304  is the reverse having a matching concave surface sized to fit with one another. The use of tongue and groove type arrangement allows the cross-member panel  300  to be used as an adjustable wall assembly. 
     As described herein, the interior core  301  is comprised of expanded or extruded polystyrene foam with the required density as per design criteria. The outer core  302  typically is spec&#39;d as needed to coat the foam inner core  301  and provides additional sound attenuation and durability. The outer core  302  is typically comprised of a strong and durable single or multi-part polyurea type compound with a thickness as required by design. This compound minimizes damage and deterioration under exposure to moisture, ultraviolet radiation, ozone, and other harsh environmental conditions. 
     Those skilled in the art will further recognize that each cross-member may be set with or without a sealant or adhesive between them as required by design and or Federal and State building codes. Since the attachment point on the horizontal mating surfaces between each cross-member consists of a “tongue and groove” type feature, this prevents lateral movement and hinders sound transmission between them. Although shown as a sloped surface, the tongue and groove design may be a radiused, square, rectangle, pyramid, shaped or doweled as determined by design. 
       FIG. 4A  illustrates a perspective view of the stacked foam cross member panels  400   a / 400   b  as used in embodiments of the invention.  FIG. 4B  is a magnified perspective view of a male spine  401  mated with a female spine  403  used to stack foam panels.  FIG. 4C  is an end view of the foam panel.  FIG. 4D  is a magnified end view showing the male  405  and female spline  407  as used in the foam panel. As noted herein, the end shape of the cross-member  400  is designed with a radius, allowing a plus/minus i.e., +/−10-degree rotation of various cross-member assemblies to accommodate design needs in the field. 
       FIG. 5 ,  FIG. 5A  and  FIG. 5B  illustrate elevated views showing male and female spine connections used in a foam panel  500 . More specifically,  FIG. 5A  and  FIG. 5B  are magnified views of the top and bottom sections respectively shown in  FIG. 5 .  FIG. 5A  shows the contour of the top section  501 .  FIG. 5B  shows the contour of the bottom section  502 . 
       FIG. 6  illustrates a transparent view showing a upright member assembly used with various embodiments of the invention.  FIG. 6A  illustrates an upright member assembly  600   a  where the upright support  601  extends through the upright member  603 . The upright member  603  uses an in-ground support member  605  having a base plate  606  for providing additional support under the cross members. The tension reinforcement anchor assembly  602  is shown sleaved into the upright support  601 . A top cap  607  is fitted at the top of the upright member  603 . 
     Thus, in  FIG. 6A , the upright support  601  extends through a hole in the upright member  603  into the center of a self-supporting ledge  606 . The upright member  603 , can be formed of a post or pole of any shape, and can be hollow or solid such that the diameter and shape is determined by the design. Those skilled in the art will recognize that the upright member  603  has a post and/or panel-type form factor where its interior core uses expanded or extruded polystyrene foam. The upright member  603  may consist of one solid piece or multiple pieces of foam that are bonded together to form a post. At the core of the upright member assembly  600 , a hole is used having a round or square shape as required, to allow an upright support  601  in the form of a structural pole to be inserted to full or partial height as required. As noted herein, the upright member  601  such as a pole can be connected to a second pole and/or footing that is cemented into the ground. 
     The overall height is also determined during design and will depend on wall height. In other embodiments, the upright member  601  may consist of multiple stacked poles or can be one contiguous section. In use, these poles can be assembled on top of the bottom-most pole that is cemented into the ground. An optional support ledge can be used if desired in order to support the weight of the cross-members without the need for special footings or foundations. The support ledge can be made from ferrous, non-ferrous, or molded plastic materials as required. 
       FIG. 7 ,  FIG. 7A  and  FIG. 7B  illustrate a support bracket assembly  700  that is located below ground level  701  and is typically positioned within a round bored concrete pier footing  703 . An upright member assembly  700  includes a support pole or pipe  705  holding the assembly securely below ground level. An above ground upright support  704  is used to extend into the upright member  702 . The below ground pipe  705  is attached to and extends a self-supporting ledge  707 . The self-supporting ledge  707  may be used in lieu of any footings under the horizontal member  708 . 
       FIG. 8A ,  FIG. 8B  and  FIG. 8C  illustrate various footing designs that may be used under the cross-members and the support bracket shown in  FIG. 7 .  FIG. 8A  is a sectional view illustrating a pea rock trench foundation.  FIG. 8B  is an elevated view illustrating a poured concrete trench foundation. Finally,  FIG. 8C  is an elevated view illustrating a poured concrete pier foundation which is a preferred embodiment of the invention. By nature of these designs, the cross-members, like that shown in  FIG. 7 , may be sitting on top of a self-supporting ledge  707  and require no special footing and/or foundation requirements. Those skilled in the art will recognize that there are multiple options for foundations if design requirements dictate that they are needed. 
       FIG. 9  illustrates a tension reinforcement anchor assembly as used in the invention.  FIG. 9A  and  FIG. 9B  illustrate magnified views of the tension reinforcement anchor assembly sleaved into the top of an upright support member. More specifically,  FIG. 9A  illustrates a tension reinforcement anchor bar  902  sleaved into the top an upright support member  901 . The anchor bar  902  typically extends substantially orthogonally from the support member  901 . A top cap  905  and upright assembly member  907  are illustrated transparently for ease in viewing. The anchor bar inserted sleeve  903  provides a convenient connector point for attaching a cable  904  on each end of the anchor bar  902 . The cable  904  is attached within an aperture configured within the end of the anchor bar  902  that continues to allow for the +/− 10-degree rotation between the support bracket and the wall assembly. 
     In use, the anchor bar  902  is used to form a tension reinforcement anchor assembly. The tension reinforcement anchor assembly includes a spring-loaded pin that is engaged with a slotted pin hole  906  in the upright support member  901 . When installed, the spring-loaded pin prohibits the tension reinforcement anchor assembly from sliding out of the upright support member. When under tension, the cable  904  enhances stability of the wall assembly and prevents excessive horizontal or vertical movement of the wall assembly. This makes for a far more rigid wall installation while still allowing for the +/− 10-degree rotation between the support bracket and the wall assembly. Further,  FIG. 9B  illustrates a detailed view of the self-locking pin assembly  908 . The self-locking pin assembly  908  secures the tension reinforcement anchor assembly  911  to the upright support member. In this view, the top cap  910 , upright assembly member  909  and the tension reinforcement anchor assembly are shown transparently. The opposing spring-loaded pin assembly will self-engage for securing the tension reinforcement anchor assembly into the upright support member  909  but still allow for quick and easy removal of the tension reinforcement anchor assembly if required. 
       FIG. 10A ,  FIG. 10B  and  FIG. 10C  illustrate views of the tension reinforcement anchor assembly with various large angle configurations. In these illustrations, the tension reinforcement anchor assembly is inlayed into various large angle upright and adjacent horizontal cross section assemblies with the top caps removed. More specifically,  FIG. 10C  illustrates a tension reinforcement anchor assembly inlayed into an upright and adjacent horizontal cross section assemblies with a 15-degree horizontal angle between them without the top cap.  FIG. 16B  illustrates a tension reinforcement anchor assembly inlayed into an upright and adjacent horizontal cross section assemblies with a 45-degree horizontal angle between them without the top cap.  FIG. 10A  illustrates a tension reinforcement anchor assembly inlayed into an upright and adjacent horizontal cross section assemblies with a 90-degree horizontal angle between them without the top cap. These illustrations are provided as examples of alternative angles and should not be considered exclusive to other angles or configurations. Additionally, the tension reinforcement anchor assembly can be constructed with a vertical angle to accommodate a change in elevation between consecutive upright assemblies. Regardless of the primary support bracket angle the interface will still allow for +/− 10-degree rotation between the support bracket and the wall assembly. 
       FIG. 11A ,  FIG. 11B ,  FIG. 11C ,  FIG. 11D , and  FIG. 11E  illustrate details of the tension reinforcement anchor assembly with an adjustable tensioner as used in the invention.  FIG. 11A  shows an elevation view of the complete tensioner assembly between two adjacent upright assemblies with a horizontal cross member in-between and the upright assembly and horizontal cross member top caps removed. The tensioner assembly ensures each horizontal cross member assembly remains seated in-between the two upright assemblies and provides a continuous structural connection along the length of the wall system to resist lateral forces such as wind loads.  FIG. 11B  illustrates a plan view of the complete tensioner assembly between two adjacent upright assemblies with a horizontal cross member in between and the upright assembly and horizontal cross member top caps removed.  FIG. 11C  and  FIG. 11E  illustrate magnified plan views of the two tension reinforcement anchors sleeved into the upright assembly with the top cap removed.  FIG. 11D  illustrates a magnified plan view of the horizontal cross member with the cable tensioner with the top cap removed. The cable tensioner provides on-site adjustment of the cable tension. Additionally,  FIG. 11D  shows the recessed track in the top of the horizontal cross member where the tension cable and tensioner reside. Furthermore, the cable tension can be accessed post installation, allowing for adjustment to the horizontal cross member assembly system as required while in service. 
       FIG. 12A  illustrates a magnified view of the tension reinforcement anchor assembly sleeved into the upright assembly as it interfaces with an adjacent horizontal cross member assembly with the upright assembly member and top cap shown transparently.  FIG. 12B  illustrates the tension reinforcement anchor set into the recessed track of the bottom of the top cap in an inverted view. The recessed track in the bottom of top cap and the adjacent horizontal cross member top cap is also shown with the end of the track flared, allowing for +/−10-degree rotation between the support bracket and the horizontal cross member assembly. 
       FIG. 13A ,  FIG. 13B , and  FIG. 13C  illustrate various large angle upright assembly top cap configurations.  FIG. 13C  illustrates the 15-degree angle upright assembly top cap.  FIG. 13B  illustrates the 45-degree angle upright assembly top cap.  FIG. 13A  illustrates the 90-degree angle upright assembly top cap. These illustrations are provided as examples of alternative angles and should not be considered exclusive to other angles or configurations. Regardless of the primary upright assembly angle the interface will still allow for +/− 10-degree rotation between the support bracket and the horizontal cross member assembly. 
       FIG. 14A ,  FIG. 14B  and  FIG. 14C  illustrate various versions of the constructed horizontal cross member assembly that are be used depending on terrain conditions at the installation location. More specifically,  FIG. 14A  shows an assembly that is used with sloped and/or hilly terrain.  FIG. 14B  shows an assembly used with flat terrain. Finally,  FIG. 14C  shows an assembly used where there a transition from flat to sloped terrain. 
     Those skilled in the art will also recognize that the objectives of this invention are to substantially reduce material construction cost, reduce shipping, handling, and installation costs. Moreover, its attributes are focused on how the wall itself is constructed e.g., an expanded or extruded polystyrene core coated with a durable shell, how the wall is assembled viz. using multiple interlocking wall panels and its use of an upright member assembly and the type of support bracket/footer. Further the wall assembly has the ability to be adjusted angularly because of the joint connection between the wall panel ends and the main upright member assembly. Further, the foam sound barrier as described herein reduces on-site installation costs and substantially reduces long-term maintenance costs and utilizes 100% recyclable materials. 
     In the foregoing specification, specific embodiments of the present invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. 
     Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.