Reflective pavement marker

Abstract

A reflective pavement marker shell is provided having a top wall, a side wall extending from an end of the top wall, and reflective end walls extending from an other end of said top wall, wherein the shell forms an interior cavity. The shell is formed from a polyacrylate or a polycarbonate having a tensile strength of more than 10,000 psi and a flexural modulus of more than 450,000 psi. The shell also includes a reflective portion integral with the reflective end wall, a reflective coating covering the reflective portion and a bonding coating covering at least the reflective portion. The shell is integrated into a reflective pavement marker with inclusion of a filler material within the interior cavity of the shell.

1 . A reflective pavement marker shell comprising: 
 at least one side wall having a reflective portion, and forming an interior cavity, said reflective portion having an inner surface partially defining said cavity, said shell formed of a polymer selected from the group consisting of polyacrylate and polycarbonate, said polymer having a tensile strength of greater than 10,000 pounds per square inch and a flexural modulus of greater than 450,000 pounds per square inch.    
     
     
         2 . The shell of  claim 1  wherein said polymer has an optical transmittance greater than 85%.  
     
     
         3 . The shell of  claim 1  wherein said polymer is a polyacrylate.  
     
     
         4 . The shell of  claim 1  wherein said polymer is methyl methacrylate.  
     
     
         5 . The shell of  claim 1  wherein said polymer is a copolymer of ethyl acrylate and methyl methacrylate.  
     
     
         6 . The shell of  claim 1  wherein said shell includes a top wall and side wall that are integral and formed as one piece.  
     
     
         7 . A reflective pavement marker shell comprising: 
 at least one side wall having a reflective portion, and forming an interior cavity, and said reflective portion and said shell at least one side wall are integral and formed as one piece, said shell formed of a polymer selected from the group consisting of polyacrylate and polycarbonate, said polymer having a tensile strength of greater than 10,000 pounds per square inch and a flexural modulus of greater than 450,000 pounds per square inch;    said reflective portion having a plurality of integrally formed cube—shaped members arranged in a grid pattern on an inner surface.    
     
     
         8 . The shell of  claim 7  wherein said polymer has an optical transmittance greater than 85%.  
     
     
         9 . The shell of  claim 7  wherein said polymer is a polyacrylate.  
     
     
         10 . The shell of  claim 7  wherein said polymer comprises methyl methacrylate.  
     
     
         11 . The shell of  claim 7  wherein said polymer is a copolymer of ethyl acrylate and methyl methacrylate.  
     
     
         12 . A method of forming a reflective pavement marker, said method comprising: 
 forming a shell having at least one reflective portion with an inner surface wherein the shell forms an interior cavity, said shell formed of a polymer selected from the group consisting of polyacrylate and polycarbonate, said polymer having a tensile strength of greater than 10,000 pounds per square inch and a flexural modulus of greater than 450,000 pounds per square inch;    coating said inner surface with a metal material;    covering at least said metal material with a bonding compound; and    filling the cavity of the shell with a filler material.