Guardrail support, attachment, and positioning block

Abstract

A guardrail support, attachment and positioning block used to space guardrails from support posts is disclosed. The positioning or spacer block is a generally rectangular block having corded-out cavities to reduce weight and tabs or projections for cooperatively engaging the sides and top of a support post as well as the edges of the guardrail during roadway safety barrier system installation. Webbing within one or more of the cavities may be used for additional structural support. To optimize the strength to weight characteristics of the spacer block, the spacer block may be formed by low-pressure injection molding. The spacer block may also be formed from virgin and/or recycled plastic material and/or include virgin or recycled rubber material, such as that obtained from the regrind of used tires, and/or another elastomeric materials from other sources.

What is claimed is:  
     
         1 . A spacer block for attaching a guardrail to a support post, comprising: 
 a pair of side-walls having respective first and second ends;    a top panel disposed proximate the first end of the side-walls;    a bottom panel disposed proximate the second end of the side-walls;    the top panel, bottom panel and side panels forming a generally rectangular block having respective first and second faces;    at least one mounting bore traveling between the first and second face of the block;    an engagement mechanism operably coupled proximate the top panel, the engagement mechanism operable to engage the block with the support post; and    a resting mechanism operably coupled proximate the bottom panel, the resting mechanism operable to support a guardrail during assembly.    
     
     
         2 . The spacer block of  claim 1  further comprising: 
 a medial wall disposed between the side-walls, the medial wall positioned generally perpendicular to the side-walls and generally parallel to the top and bottom panels;  
 the medial wall, top panel and side-walls forming a first cavity; and  
 the medial wall, bottom panel and side-walls forming second cavity.  
 
     
     
         3 . The spacer block of  claim 2  further comprising: 
 at least one mounting bore traveling through the medial wall from the first face of the spacer block to the second face of the spacer block; and  
 the mounting bore operable to align with at least one mounting aperture on the support post.  
 
     
     
         4 . The spacer block of  claim 2  further comprising a reinforcement structure disposed in at least one of the cavities.  
     
     
         5 . The spacer block of  claim 2  further comprising a webbing structure disposed within at least one of the cavities, the webbing structure operable to structurally reinforce the spacer block.  
     
     
         6 . The spacer block of  claim 1  further comprising: 
 first and second medial walls disposed generally perpendicular to the side-walls and generally parallel to the top and bottom panels;  
 the first medial wall, side-walls and top panel creating a first cavity;  
 the first medial wall, second medial wall and sidewalls forming a second cavity; and  
 the second medial wall, side-walls and bottom panel forming a third cavity.  
 
     
     
         7 . The spacer block of  claim 6  further comprising: 
 at least one mounting bore disposed in the first medial wall, the mounting bore traveling between the first and second faces of the spacer block; and  
 at least one mounting bore disposed in the second medial wall, the mounting bore traveling between the first and second faces of the spacer block.  
 
     
     
         8 . The spacer block of  claim 1  further comprising: 
 the engagement mechanism including a tab operably coupled to the top panel, the tab extending beyond the second face of the spacer block;  
 at least two spaced apart fingers operably coupled proximate a distal end of the tab, the fingers extending from a bottom surface of the tab and forming a gap between the fingers and the second face of the spacer block; and  
 the gap between the fingers operable to engage respective sides of a web on an I-beam support post and the gap between the fingers and the second face of the spacer block operable to engage respective sides of a flange on the I-beam support post.  
 
     
     
         9 . The spacer block of  claim 1  further comprising: 
 the resting mechanism including a tab disposed proximate the bottom panel, the tab extending from the first face of the spacer block; and  
 the tab operable to support a guardrail thereon during assembly of a roadway safety barrier system.  
 
     
     
         10 . The spacer block of  claim 1  further comprising an alignment mechanism operably coupled to at least one side-wall.  
     
     
         11 . The spacer block of  claim 1  further comprising the first face including a generally flat solid surface.  
     
     
         12 . The spacer block of  claim 1  further comprising the engagement mechanism slidably engaged with the top panel.  
     
     
         13 . The spacer block of  claim 1  further comprising the engagement mechanism removably engaged with the top panel.  
     
     
         14 . The spacer block of  claim 1  further comprising the bottom panel including a notch disposed proximate the second face of the spacer block, the notch operable to allow stacking of the spacer blocks.  
     
     
         15 . The spacer block of  claim 1  wherein the spacer block includes at least one polymer.  
     
     
         16 . The spacer block of  claim 1  wherein the spacer block is formed using an injection molding process.  
     
     
         17 . The spacer block of  claim 1  wherein the spacer block is formed, at least in part, using a structural foam.  
     
     
         18 . A method of manufacturing a spacer block for attaching a guardrail to a support post, comprising: 
 forming a block having respective first and second sides, respective first and second faces, a top and a bottom;    forming a first aperture through the block, the first aperture disposed generally perpendicular to the respective faces and generally parallel to the respective sides, top and bottom; and    positioning an engagement mechanism on the block proximate the top and second face, the engagement mechanism operable to retain the block proximate a mounting position during assembly of a roadway safety barrier system.    
     
     
         19 . The method of  claim 18  further comprising positioning a support mechanism on the block proximate the bottom and first face, the support mechanism operable to support the guardrail during roadway safety barrier system assembly.  
     
     
         20 . The method of  claim 18  further comprising forming the second face of the block such that the second face and the support post may be maintained in generally flush engagement.  
     
     
         21 . The method of  claim 18  further comprising creating at least two cavities in the second face of the block.  
     
     
         22 . The method of  claim 21  wherein the cavities are formed by positioning at least one medial wall generally parallel to the top and bottom of the block and generally perpendicular to the respective sides and faces of the block.  
     
     
         23 . The method of  claim 22  further comprising: 
 forming at least one aperture through each medial wall, the apertures traveling generally parallel to the top, bottom and respective side and generally perpendicular to the respective faces; and  
 the apertures operable to receive an attachment mechanism therethrough such that the guardrail may be coupled to the support post.  
 
     
     
         24 . The method of  claim 21  further comprising forming a reinforcement structure in at least one of the cavities.  
     
     
         25 . The method of  claim 21  further comprising forming a webbed reinforcement structure within each of the cavities.  
     
     
         26 . The method of  claim 18  further comprising forming at least one alignment mechanism on the block, the alignment mechanism operable to engage a portion of the support post such that the first aperture through the block is aligned proximate a corresponding aperture on the support post.  
     
     
         27 . The method of  claim 18  further comprising forming a second aperture through the block, the second aperture disposed generally perpendicular to the respective faces, generally parallel to the respective sides, top and bottom and spaced from the first aperture with respect to the top and bottom such that the block may be used to attach a thrie-beam guardrail to the support post.  
     
     
         28 . The method of  claim 18  further comprising incorporating at least one artificially created material into the formation of the block.  
     
     
         29 . A guardrail support assembly comprising: 
 a support post operable to support at least a portion of a guardrail; and    a spacer block operable to maintain the guardrail a distance from the support post, the spacer block including a top tab operable to engage the support post and maintain the spacer block in position and a mounting bore operable to receive an attachment mechanism such that the guardrail may be coupled to the spacer block and the support post.    
     
     
         30 . The guardrail support assembly of  claim 29  further comprising the spacer block having a generally rectangular shape and at least two cavities disposed therein, the cavities separated by a medial wall.  
     
     
         31 . The guardrail support assembly of  claim 30  further comprising the medial wall including at least one mounting bore disposed therein.  
     
     
         32 . The guardrail support assembly of  claim 30  further comprising a webbed reinforcement structure disposed in the two cavities.  
     
     
         33 . The guardrail support assembly of  claim 29  further comprising the spacer block having an alignment tab on respective sides thereof, the alignment tabs operable to orient the spacer block such that the mounting bore aligns with a mounting aperture on the support post.  
     
     
         34 . The guardrail support assembly of  claim 29  further comprising an I-beam support post, the I-beam support post including a web disposed between respective flanges.  
     
     
         35 . The guardrail support assembly of  claim 34  further comprising: 
 the spacer block including a top tab extending beyond a rear face of the spacer block; and  
 the top tab including a bottom surface and at least two fingers extending from the bottom surface, the fingers creating a gap between the rear face of the spacer block and the fingers operable to engage one flange of the support post proximate the web and a gap between the two fingers operable to engage the web of the support post.  
 
     
     
         36 . The guardrail support assembly of  claim 29  further comprising the spacer block having a rest operable to support at least a portion of the guardrail in position for attachment.  
     
     
         37 . The guardrail support assembly of  claim 29  further comprising the spacer block including at least one polymer among its component materials.  
     
     
         38 . A method for assembling a roadway safety barrier system, the roadway safety barrier system including a plurality of spacer blocks, at least one guardrail segment and a plurality of support posts, comprising: 
 engaging a tab disposed on at least one spacer block with a support post such that the spacer block is retained in position proximate a mounting location;    aligning a first mounting bore on the spacer block with a corresponding aperture on the support post;    engaging at least a portion of one guardrail segment with a support mechanism disposed on the spacer block such that the guardrail segment may be retained in position proximate the mounting location;    aligning a corresponding aperture on the guardrail segment with the first mounting bore; and    coupling the guardrail segment and spacer block to the support post.    
     
     
         39 . The method of  claim 38  further comprising: 
 passing an attachment mechanism through first mounting bore, the corresponding aperture in the guardrail segment and the corresponding aperture in the support post; and  
 fixing the attachment mechanism in place.  
 
     
     
         40 . The method of  claim 38  further comprising positioning an alignment flange disposed on the spacer block proximate an edge of the support post such that the first mounting bore generally aligns with the corresponding aperture on the support post.  
     
     
         41 . The method of  claim 38  further comprising joining one end of a first guardrail segment to one end of a second guardrail segment.  
     
     
         42 . The method of  claim 38  further comprising: 
 aligning a second mounting bore on the spacer block with a corresponding aperture on the support post;  
 aligning a corresponding aperture on the guardrail segment with the second mounting bore; and  
 fixing an attachment mechanism passed through the second mounting bore and the corresponding apertures on the support post and guardrail segment in place.  
 
     
     
         43 . A roadway safety barrier system comprising: 
 a guardrail;    a support post operable to maintain at least a portion of the guardrail;    a spacer block operable to position the guardrail a distance from the support post;    the spacer block including at least one mounting mechanism therethrough, at least one guardrail rest, the guardrail rest operable to support at least a portion of the guardrail during assembly of the roadway safety barrier system and at least one positioning mechanism, the positioning mechanism operable to depend the spacer block from the support post during assembly of the roadway safety barrier system; and    an attachment mechanism disposed through a mounting aperture on the guardrail, the mounting bore and a mounting aperture on the support post, the attachment mechanism operable to maintain engagement between the guardrail, spacer block and support post.    
     
     
         44 . The roadway safety barrier system of  claim 43  further comprising an alignment mechanism disposed on the spacer block, the alignment mechanism operable to position the spacer block such that the mounting bore generally aligns with the mounting aperture on the support post.  
     
     
         45 . The roadway safety barrier system of  claim 44  further comprising: 
 the spacer block including a plurality of cavities in one face thereof, the cavities separated by a medial wall; and  
 each medial wall including at least one mounting bore.  
 
     
     
         46 . The roadway safety barrier system of  claim 45  further comprising a reinforcing structure disposed in one or more of the cavities.  
     
     
         47 . The roadway safety barrier system of  claim 43  further comprising an I-beam support post.  
     
     
         48 . The roadway safety barrier system of  claim 43  further comprising at least two mounting bores, the mounting bores positioned in the spacer block such that a thrie-beam guardrail may be coupled to the support post and spacer block.  
     
     
         49 . The roadway safety barrier system of  claim 43  wherein the spacer block is formed from at least one thermoplastic polymer.  
     
     
         50 . The roadway safety barrier system of  claim 43  wherein the spacer block is formed, at least in part, from a structural foam composition.