Modular driving warning rumble strips system and method

Abstract

The modular driving warning rumble strip system includes a plurality of first sign portions assembled together to form a first warning rumble strip subassembly having a fixed length, and a plurality of second sign portions assembled together to form a second warning rumble strip subassembly having a fixed length, the two subassemblies being joined together using a magnetic connector interface.

Description

[Technical field]

[0001] Warning or raised rumble strips are well known in the road industry, especially in highway applications, providing a noticeable noise and vibration when driving over them. They are usually used to warn drivers of impending hazards ahead, such as at toll booths, highway exits, sharp turns, etc. Permanent raised rumble strips are placed within the roadway surface to address the above-mentioned permanent hazards. In other situations, such as construction sites, vehicle accidents, checkpoints, and similar hazards, temporary raised rumble strips may be useful. U.S. Patent No. 7,736,087 to Mettler et al. discloses such a temporary raised rumble strip system, which is expressly incorporated herein by reference. Summary of the Invention

[0002] The invention described herein is a portable raised rumble strip or warning rumble strip system that has many advantages over prior art systems of this type, including the use of improved molding techniques and the ability to recycle low-cost rubber materials, significantly lowering the cost of the system, which of course provides significant environmental benefits over expensive polyurethane-type prior art products. Other advantages include easier assembly and disassembly, availability in a variety of colors, handles for easy transportation, stacking lugs for convenient installation of multiple modules, jigsaw style connections for maximum installation options, and longitudinal metal cables that can provide stability and extra weight.

[0003] The present invention further provides a modular road warning rumble strips system, comprising modular warning sign portions, each having a first end and a second end, a length extending between the first end and the second end, two opposing longitudinal sides, a width extending between the opposing longitudinal sides of the warning sign portion, a top and a bottom surface, and a thickness. Each of the first end and the second end includes at least one convex protrusion and at least one concave receiving base, and the at least one convex protrusion is arranged to join the at least one concave receiving base. Each convex protrusion is disposed along the width direction of the sign portion, which is aligned with the width direction of the concave receiving base at the opposite end of the sign portion. In this way, each convex protrusion at one end of two adjacent sign portions is joined to the concave receiving base aligned with the opposite end of the two adjacent sign portions, and the two sign portions are connected end to end in a flatly aligned manner.

[0004] Preferably, the marker portion defines a handle with an opening extending through the thickness of the marker portion, the opening extending equally through the top and bottom surfaces of the marker portion, and large enough to accommodate a gloved adult hand.

[0005] Each of the opposing longitudinal sides all includes a bevel, the top surface of the marking portion slopes downwardly to its outer edge, and the thickness of the edge of the marking portion is less than the thickness of the central portion of the marking portion. In one embodiment, the bevel slopes downwardly at an angle of about 15 degrees.

[0006] A convex protrusion at one end of a first sign portion is joined to a misaligned concave receiving base at an adjacent end of a second sign portion, such that the first sign portion is connectable to an adjacent sign portion in an offset manner. Once joined, the sign portions are joined in a flat, aligned manner, but each has an offset width. The length of the two connected sign portions is essentially exactly twice the length of one sign portion, but the width of the two connected sign portions is essentially wider than the width of one sign portion. In practice, the width of the two connected sign portions is at least about one-third wider than the width of one sign portion. In one particular embodiment, the width of one sign portion is about 12 inches, and the width of the two joined sign portions is about 5 inches wider than the width of one sign portion.

[0007] At least one stacking lug may be disposed on an upper surface of the marking portion, and a stacking groove may be disposed on a lower surface of the marking portion to receive a corresponding stacking lug in flush alignment.

[0008] The sign portion is typically manufactured in a rubber mold, and in some embodiments may be molded into a sandwich structure, including a top layer of colored vulcanized rubber, a bottom layer of colored vulcanized rubber, and a middle core layer of black vulcanized rubber.

[0009] Advantageously, the system further comprises a plurality of metal cables molded into and extending essentially along the entire length of the sign portion, one cable extending into each convex projection to provide support and rigidity and ensure a rigid joint with adjacent sign portions. Preferably, the cables are made of corrosion resistant steel, and the cables are connected together to form a cable mat. The cable mat is molded into the sign portion, the sign portion being manufactured in a rubber mold.

[0010] The present invention also provides a modular road warning rumble strips system, comprising a modular warning sign portion having a first end and a second end, a length extending between the first and second ends, two opposing long sides, a width extending between the opposing long sides, a top and bottom surface, and a thickness. Each of said first and second ends includes at least one convex projection and at least one concave receiving base, at least one of said convex projections being adapted to be joined to at least one of said concave receiving bases, and a plurality of sign portions are connected together in an end-to-end manner. Advantageously, a plurality of metal cables are molded into the molded rubber portion and extend along substantially its entire length, one of the metal cables extending into each of the convex projections. Preferably, the cables are made of corrosion resistant steel and are preferably connected together to form a cable mat. The cable mat is molded into the sign portion, and said sign portion is manufactured in a rubber mold.

[0011] A convex protrusion at one end of a first sign portion is joined into a misaligned concave receiving base at an adjacent end of a second sign portion such that adjacent sign portions of the sign portions are adjacent and joined in an offset manner, and then the corresponding sign portions are joined together in a flat-aligned manner, but with their respective offset widths. In this way, the length of the two joined sign portions is essentially twice the length of one sign portion, but the width of the two joined sign portions is essentially wider than the width of one sign portion. In practice, the width of the two connected sign portions is at least about one-third wider than the width of one sign portion. In one particular embodiment, the width of one sign portion is about 12 inches, and the width of the two joined sign portions is about 5 inches wider than the width of one sign portion.

[0012] In one variation of the present invention, there is provided a modular road warning rumble strips system comprising a modular warning sign portion having first and second ends, a length extending between the first and second ends, two opposing long sides, a width extending between the opposing long sides, a top and bottom surface, and a thickness. Each of said first and second ends includes at least one convex projection and at least one concave receiving base, at least one of said convex projections being arranged to join at least one of said concave receiving bases. The modular warning sign portion includes an upper rubber layer, a lower rubber layer, and a segmented metal plate, preferably comprising steel, disposed between the upper and lower rubber layers. The segmented metal plate includes a plurality of sections, the plurality of said sections being separated by slits including moveable hinges.

[0013] A handle is formed in the sign portion, the handle including an opening through the thickness of the sign portion, the opening being equally spaced on the top and bottom surfaces and large enough to accommodate an adult hand wearing a glove. Each of the opposing long sides includes a bevel, the top surface of the sign portion slopes downward to its outer edge, and the thickness of the edge of the sign portion is less than the thickness of the central portion of the sign portion. In a preferred embodiment, the bevel slopes downward at an angle of about 10 degrees. The slits containing the moveable hinges are filled with rubber. A plurality of metal welding plates are spaced along the length of each moveable hinge, each welding plate extending across the slit containing the moveable hinge.

[0014] A plurality of spaced holes are disposed in the all-metal plate and filled with rubber during the molding process. The rubber fills the plurality of holes to bond the upper layer of rubber to the lower layer of rubber. In one embodiment, each of the sign portions has one of the holes.

[0015] A plurality of the above-mentioned modular warning sign sections are connected together in an end-to-end manner by mating corresponding protrusions in the convex projections and concave receiving portions to form the required road raised rumble strips.

[0016] On the other hand, the present invention describes a method for manufacturing a modular road warning rumble strip, which includes the following steps: preferably, a laser cutter is used to cut a grid of slits in the metal plate in the longitudinal and transverse directions to form a plurality of portions separated and defined by the slits, and a plurality of holes are formed in the surface of the segmented plate to produce a segmented metal plate, the holes being extended through the thickness of the metal plate; a first rubber layer is placed in a compression mold; the segmented metal plate is placed on the first rubber layer, and locating pins are extended through the holes in the metal plate, and then, in another step, a second rubber layer is placed on top of the metal plate; then, heat is applied to the mold, which liquefies the rubber layer by the heat, causing the rubber to flow through the holes formed in the segmented metal plate and into the slits in the metal plate; after the molding process is completed, the fully formed modular road warning rumble strip is removed from the mold.

[0017] The present invention also provides a road warning rumble strip system comprising a plurality of sign segments assembled together to form a warning rumble strip assembly having a certain length, each of the sign segments being spaced apart from adjacent sign segments along the length of the warning rumble strip, the sign segments being assembled together along a rope that is arranged along the length of the warning rumble strip assembly, a plurality of spacers being arranged along the rope along the length of the warning rumble strip assembly, each spacer being arranged between two adjacent sign segments to maintain a distance between the two adjacent sign segments, each spacer being provided with a hollow structure, the size of the hollow structure being arranged as a surrounding rope, which may be tubular, and made of a corrosion-resistant material.

[0018] Each of the sign portions all have an opening therethrough, which is used to accommodate a rope. In an exemplary embodiment, each of the sign portions further has a second opening therethrough, which is also used to accommodate a rope. The rope exits one opening in the most distal sign portion at a first end of the warning rumble strips assembly, extends in an arc toward the second opening in the most distal sign portion, and enters the second opening to form a handle ring at the first end. In an exemplary embodiment, the rope further extends to and through the second opening in each of the sign portions, exits the second opening in the most distal sign portion at a second end of the warning rumble strips assembly, extends in an arc toward the other opening in the most distal sign portion at the second end of the warning rumble strips assembly, and enters the other opening to form a second handle ring at the second end of the warning rumble strips assembly.

[0019] Advantageously, the warning rumble strips assembly may comprise a first warning rumble strips subassembly and a second warning rumble strips subassembly connected together, each of which is a lightweight, maneuverable and easy to operate subassembly that is then placed on the road and connected together to further facilitate installation. In an exemplary embodiment, as shown in the example, the first and second warning rumble strips subassemblies are joined together by joining a first jigsaw member at an end of the first warning rumble strips subassembly and a second jigsaw member at an end of the second warning rumble strips subassembly. Each of the first and second jigsaw members together includes a straight edge and an opposing jigsaw edge, and the jigsaw edge of each of the first and second jigsaw members includes a series of protruding portions and recessed portions suitable for joining to the jigsaw edge of the other jigsaw member, and when the first and second jigsaw members are joined together by joining their respective jigsaw edges, they form a jigsaw part. In the illustrated embodiment, the first and second jigsaw members are substantially identical in structure.

[0020] Advantageously, some or all of the surface of each label portion is coated with a protective material such as urethane.

[0021] As another advantageous feature of the present invention, one or more of the plurality of marking portions may be dark in color and one or more of the plurality of marking portions may be light in color, and alternating portions of the plurality of marking portions may be formed of different materials, for example, some marking portions may be formed of steel and other marking portions may be formed of aluminum to provide the above-mentioned color contrast and to reduce the weight of the assembly.

[0022] The modular road warning rumble strip system of the present invention is further described, which comprises a plurality of sign sections, which are assembled together to form a warning rumble strip assembly having a certain length. One or more of the plurality of sign sections may be dark in color, and one or more of the plurality of sign sections may be light in color. The light and deep color sections may be assembled in an alternating manner, and may be made of different materials. For example, the deep color sections may be made of steel, and the light color sections may be made of aluminum.

[0023] The present invention further describes a modular road warning rumble strip system comprising a plurality of sign portions assembled together to form a warning rumble strip assembly having a certain length, the warning rumble strip assembly including a first warning rumble strip subassembly and a second warning rumble strip subassembly connected together, the first and second warning rumble strip subassemblies being joined together by joining a first jigsaw member at an end of the first warning rumble strip subassembly and a second jigsaw member at an end of the second warning rumble strip subassembly, each of the first and second jigsaw members together including a straight edge and an opposing jigsaw edge, the jigsaw edges of each of the first and second jigsaw members including a series of protruding portions and recessed portions adapted to join to the jigsaw edge of the other jigsaw member, the first and second jigsaw members forming a jigsaw portion when joined together by joining their respective jigsaw edges. In an exemplary embodiment, the first and second jigsaw members are substantially identical in structure. The present invention also provides a modular road warning rumble strip system, comprising: a plurality of first sign portions assembled together to form a first warning rumble strip subassembly having a fixed length, each of the plurality of first sign portions being spaced apart from adjacent sign portions of the plurality of first sign portions along a length of the first warning rumble strip subassembly, and a plurality of second sign portions assembled together to form a second warning rumble strip subassembly having a fixed length, each of the plurality of second sign portions being spaced apart from adjacent sign portions of the plurality of second sign portions along a length of the second warning rumble strip subassembly, and a plurality of second sign portions assembled together to form a second warning rumble strip subassembly having a fixed length, each of the plurality of second sign portions being spaced apart from adjacent sign portions of the plurality of second sign portions along a length of the second warning rumble strip subassembly, and a plurality of second sign portions being spaced apart from adjacent sign portions of the plurality of second sign portions along a length of the second warning rumble strip subassembly.

[0024] The first warning rumble strip subassembly has a first jigsaw member including a joining edge at a first end thereof, and the second warning rumble strip subassembly has a second jigsaw member including a joining edge at a first end thereof, the first joining edge and the second joining edge are arranged to join with each other to form a flat connection with the first jigsaw member and the second jigsaw member to form a jigsaw portion connected at a selected location, and then the first warning rumble strip subassembly and the second warning rumble strip subassembly are connected together to form a warning rumble strip assembly at a selected location. In the described arrangement, the joined jigsaw portions may be separate from each of the first warning rumble strip subassembly and the second warning rumble strip subassembly.

[0025] Advantageously, each of the first and second joining edges includes a magnetic surface that is adapted to join to a corresponding magnetic surface on the other of the first and second joining edges to provide a rigid joining of two sub-assembly members.

[0026] At least one magnetic connector is disposed within the at least one hole, and one end of the at least one magnetic connector is exposed at an opening of the at least one hole. In an exemplary embodiment, the first and second mating edges both have a plurality of the at least one hole and a corresponding plurality of the at least one magnetic connector, with one magnetic connector disposed in each of the plurality of magnetic connectors. The exposed end of each magnetic connector is essentially flush with the mating edge with the corresponding hole of the magnetic connector.

[0027] Preferably, each of the plurality of magnetic connectors is entirely composed of a magnetic material and is cylindrical in shape, and at least one magnetic connector is permanently secured in the at least one hole by an adhesive.

[0028] The present invention also provides a modular road warning rumble strip system comprising a plurality of sign sections assembled together to form a warning rumble strip assembly having a length, each of the plurality of sign sections being spaced apart from adjacent sign sections along the length of the warning rumble strip, the sign sections being assembled together with a rope disposed along the length of the warning strip assembly. Advantageously, each sign section includes a lower surface, the lower surface of at least one sign section having a recessed groove suitable for receiving a layer of protective material.

[0029] As shown in the figure, the modular road warning rumble strips system further comprises a step formed on the groove edge, the height of the step being higher than the height of the bottom of the groove of at least one of the sign portions. The protective material preferably comprises a polyurethane layer.

[0030] In an exemplary embodiment, the polyurethane layer extends from the groove beneath the lower surface of the at least one sign portion and is thicker than the depth of the groove. In one embodiment, the polyurethane layer has a thickness of about 0.1 inches and the groove has a depth of about 0.05 inches. The step height is about 0.1 inches.

[0031] In some embodiments, the groove extends along the entire length of the at least one marking portion, and in other embodiments, the groove does not extend along the entire length of the at least one marking portion, and in one subsequent situation, the full thickness of the at least one marking portion is present at each end of the groove.

[0032] At least the following points will become apparent from the following specification and drawings. [Brief description of the drawings]

[0033] [Figure 1] 1 is an isometric view of a modular warning sign portion of a structure in accordance with an exemplary embodiment of the present invention; FIG. [Diagram 2]Similar to the view in FIG. 1, the internal structure of the sign portion is revealed by showing hidden lines. [Diagram 3] FIG. 3 is an oblique view similar to that of FIGS. 1 and 2, showing a steel cable mat forming part of a warning sign portion according to the invention, separated from the sign portion to be molded; [Figure 4] 2 is a top view of the modular warning sign portion of FIG. 1 according to the present invention; FIG. [Diagram 5] Similar to the top view of FIG. 4 of the modular warning sign portion shown in FIG. 2, the hidden lines are clearly visible. [Figure 6] FIG. 5 is a side view showing the warning sign portion of FIGS. 1 and 4. [Figure 7] FIG. 5 is an end view of the warning sign portion of FIGS. 1 and 4. [Figure 8] 1 shows three modular warning sign sections according to the present invention connected together in an end-to-end manner. [Figure 9] 8, another exemplary option is shown in which modular warning sign portions according to the present invention are connected together in a shifted fashion. [Figure 10] 1 illustrates another exemplary embodiment of a modular warning sign portion according to the present invention, where the sandwich style construction allows the sign portion to have a variety of colors. [Figure 11] 1 shows another view of a modular warning sign portion of the present invention having a sandwich construction. [Figure 12] 1 shows yet another view of a modular warning sign portion of the present invention having a sandwich construction. [Figure 13] 1 shows yet another view of a modular warning sign portion of the present invention having a sandwich construction. [Figure 14] FIG. 13 is a top view of another exemplary variation of a modular warning sign portion according to the present invention. [Figure 15] 15 shows a top view of a metal plate, preferably steel, used to provide internal support for the modular warning sign portion of FIG. 14. [Figure 16] FIG. 16 is an end view of the metal plate of FIG. [Figure 17] FIG. 17 is a detailed view showing part A in FIG. [Figure 18] FIG. 18 is an oblique view of a metal plate similar to those of FIGS. 15 to 17. [Figure 19] 16 shows a top view of the embodiment shown in FIG. 15 with the metal plate visible to clearly show the construction of the warning sign subassembly. [Figure 20] 15-19 illustrate the assembly of three modular warning sign sections, with the three sign sections connected in an end-to-end fashion similar to FIG. [Figure 21] 11 is an isometric view of a modular warning sign subassembly according to another exemplary embodiment in accordance with the principles of the present invention; FIG. [Figure 22] 22 is an oblique view showing a central portion of the warning sign subassembly shown in FIG. 21. [Figure 23] 22 is an oblique view of one of the ends of the warning sign subassembly shown in FIG. 21. [Figure 24] FIG. 24 is an isometric view of a warning sign portion of an assembly end of an embodiment similar to that of FIGS. 21-23, but having other unique features. [Diagram 25] 25 is a schematic cross-sectional view showing the warning sign portion shown in FIG. 24. [Figure 26] FIG. 26 is an isometric view of a warning rumble strips assembly for use in constructing any of a plurality of warning sign segments as shown in accompanying drawings 21 to 25. [Figure 27] 1 shows a warning rumble strips system assembled from a plurality of joinable partial warning sign subassemblies. [Figure 28] 1 shows a warning rumble strips system assembled from a plurality of joinable partial warning sign subassemblies. [Figure 29] 1 shows a warning rumble strips system assembled from a plurality of joinable partial warning sign subassemblies. [Diagram 30] FIG. 13 is an oblique view showing another exemplary modification of the warning rumble strip assembly according to the present invention. [Diagram 31] FIG. 13 is an oblique view showing another exemplary modification of the warning rumble strip assembly according to the present invention. [Diagram 32] 32 is an oblique view showing a partial enlargement of the assembly member shown in FIG. 31. FIG. [Diagram 33] FIG. 11 is a top view showing another modified example of the warning rumble strip assembly according to the present invention. [Diagram 34] 1 is a perspective view of several alternative embodiments of the warning rumble strip assemblies discussed above. [Diagram 35] 35 shows another view of the warning rumble strips assembly shown in FIG. 34. [Diagram 36] 1 illustrates a top-tilt view of a modified version of two jigsaw members according to the principles of the present invention, the two jigsaw members being suitable for joining together to connect two warning rumble strip subassemblies together to form a warning rumble strip assembly; [Figure 37] FIG. 37 is an isometric view of the end of the improved jigsaw member shown in FIG. 36. [Figure 38] 36 and 37 show an end view of one of the modified jigsaw members, which shows the jigsaw member being provided with a recessed groove for receiving a polyurethane layer. [Figure 39] 13 shows an end view of two further modified jigsaw members, illustrating the use of magnetic connectors to ensure a rigid connection of the jigsaw members. [Diagram 40] FIG. 31 is a top view showing the further modified jigsaw members of FIG. 30 joined together. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Referring now more particularly to the drawings, and referring to Figures 1-6, there is shown one exemplary embodiment of a modular warning sign segment 10 or traffic control bump 10 having a first end 12 and a second end 14. Each end has a convex projection 16 and a concave receiving base 18 adapted to connect adjacent opposing ends of similar sign segments 10 together to form the required warning rumble strips arrangement. In the exemplary embodiment, the sign segment 10 is constructed of rubber. Preferably, the rubber is recycled rubber. Typically, the material forming the sign segment is black in color, although other colors may be used, such as orange and white, and various variations are possible, such as the use of yellow segments along each long side. A handle 20 is formed in the sign segment for convenient transportation. Preferably, the handle 20 is large enough to accommodate a gloved hand. If desired, but not required, stacking lugs 22 are formed above each end to correspond to concave recesses (not shown) on the underside of the sign segment 10. Also, of course, the location of the stacking lugs along the top surface of the sign portion 10 and the corresponding concave recesses along the bottom surface can be varied as needed. Each longitudinal side of the sign portion 10 includes a downwardly angled portion 24 that is thinner in cross section compared to the overall thickness of the central portion of the sign portion to aid in traversal of the sign portion. The bi-directional bevel feature negates problems in orienting the sign portion to the roadway. In the illustrated embodiment, the bevel 24 is angled at an angle of about 10-15 degrees, although the angle can be modified if needed. Advantageously, the jigsaw end of each portion can be a handle if needed.

[0035] In one particular embodiment, the total thickness of each sign segment is about 1.5 inches, and the length of each sign segment 10 is about 46 to 46 1 / 2 inches. In some embodiments, the width of each sign segment is about 12 inches, and in other embodiments, about 13 inches. Other embodiments may employ varying thicknesses, such as about 1 inch or about 0.75 inches. The weight of each sign segment ranges between about 24 to 40 pounds. As shown in Figures 8 and 9, three sign segments 10 are connected together to form a warning rumble strip that covers a typical roadway width of about 11 to 12 inches. The sizes discussed throughout this application are representative and are dictated by the particular application, and variations in size are possible and may be necessary.

[0036] 10-13 show a unique alternative sandwich construction of the marking portion 10 of the present invention, allowing the marking portion 10 to be formed in a wide variety of colors. The marking portion 10 is manufactured as a sandwich. As shown in FIG. 11, a thin layer 25a of colored vulcanizable rubber is placed in a mold, and then a second layer 25b of conveniently black vulcanizable rubber is placed over the first layer. Then, a third thin layer 25c of colored vulcanizable rubber is placed on top of the second black layer 25b. The sandwich is then pressed and vulcanized to form the final finished part. Visually, the final finished part has the appearance of a solid color part, except for the parting line 26 shown in FIG. 12, for example. The advantage of such a method is that the cost of manufacturing the part is very low, since the black core rubber is very inexpensive. Because the core rubber is located within the protective case of the colored outer layer, no UV resistance or other expensive additives are required.

[0037] As mentioned above, Fig. 8 and Fig. 9 show two exemplary methods for developing modular warning sign parts 10 and forming raised rumble strips or warning strips assembly parts 28 or 30, respectively. In the example of Fig. 8, the assembly part 28 is only three sign parts 10 connected end-to-end using corresponding convex projections 16 and concave receiving bases 18, respectively, where the convex projections 16 at the ends of the sign parts 10 are inserted into the corresponding concave receiving bases at the opposite ends of the adjacent sign parts 10, and the concave receiving bases 18 are open so that the convex projections 16 are joined into the corresponding concave receiving bases 18 in a manner that they are connected together like puzzle pieces. Thus, as shown in the figure, a flush joint is formed for the sign part ends. Meanwhile, Fig. 9 illustrates the multifunctionality of the system according to the present invention, where the sign parts 10 are also designed to be all offset and joined in any offset direction, which is suitable for all the convex projections 16 to be all flush and joined to all the concave receiving bases. Such versatility of the socket 18 allows for the creation of a large number of warning rumble strip assemblies with different orientations, thus maximizing the functionality of the system of the present invention. As shown in FIG. 9, the offset connections between adjacent sign sections 10 allow the warning rumble strip assembly 30 to have a total width of approximately 22 inches in the illustrated embodiment, rather than the width of the warning rumble strip assembly 28, which is limited to the width of one sign section 10, which in the illustrated embodiment is approximately 12 inches. In other words, when connected in the offset manner shown, each sign section 10 is offset approximately 5 inches relative to its neighbors. However, the total length of the assembly is the same as the assembly 28 of FIG. 8, which in one exemplary embodiment is approximately 11 inches or 2.5 inches.

[0038] The sign portion 10 of the present invention is simply constructed of molded rubber, preferably recycled rubber, or a sandwich construction (see Figs. 10-13). One particularly advantageous embodiment of the present invention is shown in Figs. 2, 3 and 5. Applicant has found it particularly beneficial to have the molded sign portion 10 include a plurality of metal cables 32 extending longitudinally within the sign portion. As shown in Fig. 3, the cables 32 are formed into a cable mat 34, preferably formed of corrosion resistant steel cables 32, although the cable material can vary based on the application. The cable mat 34 is integrally molded with a molded rubber sign portion 36, for example of vulcanized rubber, to form the sign portion 10 shown in Fig. 2.

[0039] It should be noted that, as shown in the figures, some of the cables 32a forming the cable mat 34 have extended lengths that extend into the convex projections 16 on either end of the sign portion 10 once the cable mat 34 is molded into the rubber mat 36.

[0040] Advantageously, the steel cables 32, 32a extending along the length of the sign segments 10 increase the weight of each sign segment 10, which allows the sign segments to be manufactured using less rubber, thus saving cost and volume. More importantly, the action of the cables substantially stiffens and strengthens the convex projections 16, significantly improving the connection between adjacent sign segments 10 and enhancing the beveled surfaces 24 on each side of the sign segments.

[0041] Reference is now made to Figures 14-19, which show a variation of a modular warning sign portion 10 constructed in accordance with the principles of the present invention. These figures are to be combined and like parts are designated with like part numbers from Figures 1-13. In this embodiment, cables 32, 32a are not used, but rather a single segmented metal plate 38 (see Figures 15-19) is used to reinforce the rubber sign portion 10. In one particular embodiment, the metal plate 38, preferably made of steel, adds a ballast weight of about 32 pounds. With about 12 pounds of rubber surrounding the steel plate, the total weight of the entire assembly 10 is about 44 pounds. Of course, as dictated by the application, the size and weight of the aforementioned parts can be varied within the scope of the system of the present invention.

[0042] As shown in FIG. 15, the segmented metal plate 38 is formed of multiple sections or ballast blocks 40 separated from one another by hinges 42, and in one embodiment, is approximately 9 inches wide. In one embodiment, each ballast block 40 is approximately 4 inches long and approximately 3 inches wide. The hinges 42 include slits or slits formed along the longitudinal and transverse directions of a grid in the surface of the metal plate 38, and are preferably cut by a laser, although other suitable cutting methods may be used. In some embodiments, the width of the slits or hinges 42 ranges between 0.005 and 1 / 16 inches. The metal plate 38 has two longitudinal edges 44. In some embodiments, the slits 42 extend completely through the thickness of the plate 38, but do not include multiple metal welded plates extending from one section 40 to the other across the width of the slits 42, which are spaced apart along the length of a particular slit 42, and which may have a reduced thickness or the full thickness of the metal plate 38. In other embodiments, the slits 42 may extend through only a partial thickness of the plate 38. The depth of the slits must allow adjacent sections or ballast blocks 38 to bend and curve relative to one another.

[0043] In one particular embodiment, there are 28 ballast blocks 40, although of course that number can vary within the scope of the present invention. As shown in Figures 15, 18 and 19, the grid of moveable hinges 42 and the longitudinal edges 44 of the metal plates 38 collectively define 28 ballast blocks 40. Each inner ballast block 40 is defined by moveable hinges 42 on four of its sides, and each outer ballast block 40 is defined by moveable hinges 42 on three of its sides and the outer edge 44 of the metal plate on the remaining side.

[0044] The movable hinge 42 provides ideal field performance characteristics, including close axial and transverse spacing and controlled flexibility throughout the warning sign portion 10. Such flexibility allows the sign portion 10 to easily conform to any unknown irregular surface, as is commonly encountered when using the sign portion 10 on uneven, recessed, or elevated road surfaces.

[0045] Metal plate 38 having individually formed ballast blocks or sections 40 has the flexibility to separate axially or laterally, one ballast block from another adjacent ballast block, or groups of ballast blocks from adjacent groups of ballast blocks, while retaining their specific spacing as manufactured and specific relationship to one another as molded.

[0046] Using known manufacturing techniques, each ballast block or section 40 is drilled or otherwise formed with a hole 46 (see Figures 15, 18 and 19). A similar additional hole or holes 46 may be formed in the central section 48 of the metal plate 38. One such hole 46 is shown in Figure 15, and three holes 46 are shown in the central section 48 of Figures 18 and 19. Any one of the above arrangements and any other quantities of such holes 46 are all within the scope of the present invention. Holes 46 are also shown at the ends 16 and 18, respectively. It is not necessary to have one hole 46 in each section 40, or in the central section 48, or at each end 16, 18, but the entire surface of the metal plate 38 should have a sufficient number of holes 46 to provide the functionality of the holes 46 as described below. In one embodiment, each hole 46 is 3 / 4 inch in diameter, but may be sized as needed to suit application and preference, as long as it maintains its functionality. A handle hole 20 is further formed in central region 48 to ensure that the completed sign portion includes a handle 20. Metal plate 38 further includes a convex projection 16 formed at a first end and a concave receiving base 18 formed at a second end to ensure that the completed molded sign subassembly 10 includes these features.

[0047] Combining the embodiments shown in Figures 14-20, we now describe a method for compression molding and manufacturing modular warning sign parts according to the present invention. First, a plate or layer of vulcanized rubber is placed on top of the mold (the part is molded upside down) and penetrated with three locating pins that protrude through the top surface of the vulcanized rubber layer. The three locating pins are used to position and precisely locate a sectioned metal plate 38 in the open mold, with the locating pins located on top of the initial rubber layer and extending through the locating pin holes 51 in the metal plate 38. Once the partial ballast plate 38 is positioned on the three locating pins that protrude through the rubber plate or layer placed in the mold, the mold is ready for the final step before molding.

[0048] A second block of vulcanized rubber is placed on three support pins in the mold on top of the first block of rubber plate and partial steel plate 38, in preparation for closing the mold, with partial steel plate 38 sandwiched in the middle of the product to be molded and positioned between the two rubber layers. In one particular embodiment, steel plate 38 is approximately 5 / 16 inch thick and each of the two rubber layers is approximately 1 / 4 inch thick, although these sizes are intended to allow for some degree of variation based on design.

[0049] When the mold is closed and the rubber is heated in the preheating press, the vulcanized rubber in both rubber layers all turn into a viscous fluid. Under the enormous pressure of the press molding machine, the molten rubber flows into the holes 46 formed in the metal plate 38. This process actually forms a rubber bolt, which is stretched through each hole between the upper and lower rubber layers. The rubber layers and metal plates are all connected together, which defines the structure of the final assembly and ensures the stability and position of each layer in the three layers relative to each other.

[0050] The free-flowing rubber is squeezed out and cut through 1 / 16 inch wide laser cut spaces or hinges 42 between the ballast blocks 40 (where the slits 42 extend through the entire thickness of the plate 38) to form one vulcanized rubber hinge 42.

[0051] 19 shows a partially completed warning sign portion 10 and, for purposes of illustration, the top layer of rubber has been removed to conveniently show how metal plate 38 sits within assembly member 10. In this manner, the figure shows lower rubber layer 50 and metal plate 38 seated within layer 50. The previously mentioned rubber bolts fill each of the holes 46 and secure the rubber layer and metal plate together.

[0052] 14 and 20 show a complete molded warning sign part 10 according to the present invention. In these figures, an upper rubber layer 52 is shown, and a metal plate 38 is sandwiched between itself and the lower rubber layer 38. The upper surface of the upper rubber layer 52 is essentially smooth, which can prevent injuries to motorcycle riders and other motorcycles running on rumble strips, and only a molded engine bump 54 is selectively disposed on the upper surface. If information such as company name, contact information, model number information, etc. is to be molded therein, an information block 56 is provided. As shown in FIG. 20, any number of warning sign parts 10 can be connected in an end-to-end manner by fixing the convex protrusion 16 of one sign part 10 into the concave receiving base 18 of the adjacent part 10. As shown in the figures, each sign part 10 is provided with only one convex protrusion 16 and concave receiving base 18, respectively, but other connecting structures can be adopted, such as the connecting structures shown in FIG. 1 to FIG. 13, especially when adjacent sign parts 10 are to be connected in an offset manner (see FIG. 9).

[0053] The present invention meets the following important objectives: 1) The modular warning sign portion 10 is heavy enough to be held in place with minimal movement as vehicles pass, but is too heavy for one person to lift, place, and handle. 2) As shown in Figures 8, 9 and 20, when each sign section 10 is assembled together, the rigidity must be sufficiently high, particularly at the joints where they are connected, so that they do not come apart when a vehicle passes through them. 3) The sign sections 10, whether single or assembled, must all have sufficient flexibility to accommodate changes and uneven road surfaces. The flexibility must preferably be closely connected to the static weight and closely linked to the flexibility of nearby neighbors in the axial and lateral directions. 4) The sign portion 10 is about 12-14 inches wide, has very smooth approaching and separating sloped portions 24, each sloped portion being about 1.5-2.5 inches wide, and has lead and exit angles of up to 15 degrees, preferably 10 degrees. The point is that in the embodiment of Figures 14-20, the metal plate 38 does not extend into the sloped portions 24 of the sign portion 10, to improve the positioning of the sign portion 10, provide elasticity for driving thereover, and ensure the sign portion's adaptability to conform to the road surface. 5) Each sign segment has a maximum height of approximately 3 / 4 inch and a length of approximately 4 inches. 6) With particular reference to the embodiment shown in FIGS. 14-20, the use of a small laser slit or moveable hinge 42 to separate the spacer plates has significant advantages, increasing manufacturing efficiency and accuracy since one plate is placed in the mold instead of multiple separate plates.

[0054] Another exemplary embodiment of the present invention is shown in Figures 21-23. In this embodiment, the raised rumble strip or warning rumble strip assembly 28 includes two opposing linear sign sections 58 with a jigsaw section 60 sandwiched between the two linear sign sections 58, the jigsaw section 60 including two connected jigsaw members 62. In some embodiments, the linear sign sections 58 and the jigsaw members 62 are made of steel, for example, pressure cast steel or other suitable metal, and include tapered surfaces 64, 66 on the leading and trailing edges of each section, respectively. A urethane sheet or other suitable material may be bonded to the bottom surface of each linear sign section 58 and the jigsaw members 62. As shown, a layer of anti-skid, anti-corrosive coating is applied to the top and sides. In the exemplary embodiment, each linear sign section 58 and the jigsaw members 62 are all powder coated with a flat textured decorative surface. A urethane sheet is adhered vertically to the underside of the linear marking portion 58 and the jigsaw member 62. Alternatively, the linear marking portion / jigsaw member may be dipped in urethane or injection molded to form a urethane surface.

[0055] After each jigsaw member 62 is joined together, a jigsaw part 60 is formed, which has a straight edge 68 and a jigsaw edge 70. The jigsaw edge has a series of protrusions 72 and grooves 74, which are specially designed to be tightly connected with the corresponding grooves and protrusions on the edge of the adjacent jigsaw member and ensure that they are immovable. As a special advantage, the jigsaw end or jigsaw edge 70 is designed to be bidirectionally usable. In other words, they are not commonly used for left and right sides. Thus, as shown in FIG. 21, the two jigsaw members 62 to be joined have the same structure but in opposite directions.

[0056] Although the rumble strip assembly 28 is shown with two interconnected jigsaw members 62 (the two jigsaw members facing in opposite directions) to form a jigsaw section 60, and two linear marker sections 58 are connected to the left and right edges of the jigsaw section 60, the system of the present invention is fully flexible to any combination of linear marker sections and jigsaw section assemblies as shown in Figures 21-23. For example, separate linear marker sections 58 may be attached to the left and right ends of the rumble strip assembly 28, or separate jigsaw sections 60 may be secured to one or two edges of the rumble strip assembly 28. In some cases, it may be desirable to simply secure multiple linear marker sections together, and in other circumstances, it may be desirable to secure multiple jigsaw sections 60 together. Any such combination is possible, as determined by design parameters and application needs. The separate linear marker sections and jigsaw members 58, 62 may be moved into position by a tension rod and magnet system, or other suitable method. Manual assembly may also be an option.

[0057] As shown in Figure 21, ropes 76 are used to connect and assemble the various linear sign sections 58 and jigsaw sections 60 and secure them together. The ropes 76 may include cables, wire ropes, etc., and may be formed of steel, such as braided steel, or other suitable materials. The ropes 76 are extended through openings 78, which may include holes or narrow slots formed in each linear sign section 58 and jigsaw member 62. If narrow slots 78 are used rather than holes, the ropes may be advantageously welded into the narrow slots to hold them in place.

[0058] Figures 24 and 25 show a variation of the linear marking portion 58 shown in Figures 21-23, and the features of the linear marking portion 58 of Figures 24-25 may be applied to the jigsaw member 62 of Figures 21-23. In particular, each linear marking portion 58 and jigsaw member 62 is provided with a through hole 80. As shown, one such through hole 80 is provided in a central region of the portion, and other such through holes 80 may be provided at the leading edge 64 and trailing edge 66 of the portion, respectively. As shown, each through hole 80 has a wide flared mouth portion 82 adjacent the top surface of the portion.

[0059] One purpose of the through holes 80 is as a locking system in situations where the manufacturing process involves casting the aforementioned polyurethane coating layer in place around the linear marker portion 58 and the jigsaw member 62. Using such a method, in situations where the urethane is cast in place, the urethane flows through the through holes 80 and the carbamate becomes secured to the rod or portion.

[0060] 26 to 29 show an example of a warning rumble strip assembly 28 assembled based on the above-mentioned principle, in which a number of sign sections 58 are fixed together by a length of rope 76 including a stainless steel cable. As shown in FIG. 27, in a typical rumble strip assembly, the length is sufficient to stretch across the roadway. As shown in the figure, about 30 sign sections with a total weight of about 180 pounds are connected together. It should be noted that the rope 76 is stretched to surround and pass through the two openings 78 of each section, so that the sign sections 58 are strung together when the sections are assembled together. As shown in the figure, the rope 76 between the sign sections 58 is provided with a spacer 84. The spacer comprises a tube with a sufficient diameter to be assembled to the rope 76, and ensures the function of maintaining the distance between the sign sections 58, which can be clearly seen from FIG. 26 to FIG. Such spacer tubes 84 preferably comprise a corrosion resistant material having sufficient wall thickness to ensure sufficient strength to hoist the rumble strip assembly 28 without twisting the ropes 76. The spacers 84 may be constructed, for example, from copper or stainless steel.

[0061] 26-29. A technique for assembling the warning rumble strip assembly 28 includes assembling subassemblies 86 (see FIG. 28), which are a portion of the size of the warning rumble strip assembly 28, and then assembling a plurality of subassemblies 86 together to create a complete warning rumble strip assembly 28. Specifically, as described above, a complete warning rumble strip assembly 28 may weigh 180-210 pounds with 30 or more sign sections 58. In some cases, it may be undesirable for a user to transport a 180 pound rumble strip assembly 28 from a truck to a roadway installation site, and it may be desirable to transport the lighter subassemblies 86 to the installation site location and then secure the subassemblies 86 together to create a complete rumble strip assembly at the installation site. A subassembly of any desired size (e.g., 15 sign segments 58) is assembled on a suitable length of rope 76 with spacers 84 between the sign segments 58. This effectively forms a half rumble strip 86, 5 or 6 inches long and weighing about 104 pounds, that is suitable for crossing approximately half the roadway. The half rumble strip 86 crosses the roadway at the location where it is placed. In this arrangement, the last sign segment in the half rumble strip has a jigsaw member 62 with the jigsaw edge 70 exposed at the end of the half rumble strip. The end of the rope 76 is welded into the opening 78 of the jigsaw member 62 at the end of the half rumble strip. Set screws may be placed at the top and bottom of the segments. The other half rumble strip is then connected to the first half rumble strip in an end-to-end manner at the road site by fastening the end jigsaw member 62 of the other half rumble strip to the end jigsaw member 62 of the first half rumble strip and joining their respective jigsaw edges together, so that the two subassemblies 86 are connected together to form one complete rumble strip assembly 28 that covers the entire roadway.

[0062] Thus, taken together, the subassemblies 86 are joined together to form a complete rumble strip assembly 28 on the roadway. The ropes 76 form rings 88 on either end of each subassembly 86, such that each end of the completed rumble strip assembly 28 has a rope ring 88. As shown, the rope rings 88 aid in positioning the subassembly / assembly.

[0063] In the illustrated embodiment, each rumble strip subassembly 86 is 5.5 inches long and has a jigsaw member 62 on one end and a rope handle 88 on the other end. As shown, two subassemblies 86 are connected together by connecting corresponding jigsaw members 62 to form an 11 inch long rumble strip assembly 28 that spans the roadway.

[0064] In the exemplary embodiment described above, the jigsaw members 62 are the same regardless of how they are oriented. As noted above, there are no designated "left-hand" or "right-hand" members. The jigsaw connections are located in the middle of the rumble strip assembly 28 so that the connections are as far away from where the vehicle tires pass. In this particular assembly, again as described above, each subassembly 86 weighs 104 pounds, thus creating a rumble strip assembly 28 that weighs approximately 208 pounds, although these weights will vary based on material and size scale. In this example, the ropes 76 connecting the assembly members are corrosion / salt resistant grade 3 / 8" wire rope.

[0065] The underside of each sign segment 58 and jigsaw member 62 is 1 / 8" thick urethane which, in one particular example, is adhered to a steel strip with a special two-part adhesive. Spacers 84 are made of thick wall stainless steel.

[0066] Another exemplary embodiment of the present invention is shown in Figure 30. It is similar to the embodiment shown in Figures 21-23 and 26-29. Figure 30 shows a warning rumble strips subassembly 86, with the same parts as in all the embodiments shown in Figures 21-23 and 26-29 being labeled with the same reference numerals. The only substantial difference between this embodiment and the previous embodiment is that the subassembly 86 of this embodiment is comprised of sign portions 58 and jigsaw members 62, with alternating adjacent sign portions 58 and jigsaw members 62 having different colors, alternating between dark and light colors (see figure). In the illustrated embodiment, the light colored sign portions 58 and jigsaw members 62 are comprised of colored aluminum, and the dark colored sign portions 58 and jigsaw members 62 are comprised of colored steel. The point is that, other than the color contrast between adjacent sign portions 58 and jigsaw members 62, the lightweight aluminum portions make the weight of the subassembly 86 even lighter than the subassembly of the previous embodiment. For example, in the illustrated embodiment, the subassembly 86 weighs approximately 80 pounds, instead of 104 pounds, which results in a total weight of the rumble strip assembly 28 of approximately 160 pounds, instead of approximately 204 pounds. Of course, this lighter weight makes the rumble strip assembly 28 easier to manipulate. Advantageously, the alternating contrasting colors of the marker portions 58 and jigsaw members 62 greatly enhance the visibility of the rumble strip assembly 28 to approaching motorists. On darker asphalt, the lighter marker portions 58 and jigsaw members 62 are particularly visible, while on lighter concrete, the darker marker portions 58 and jigsaw members 62 are particularly visible.

[0067] Another exemplary embodiment of the present invention is shown in Figures 31-32. It is similar to the embodiment shown in Figure 30. The only substantial difference between Figures 31-32 and Figure 30 is that the rope handle 76 shown in Figure 30 is omitted in Figures 31-32, which is advantageously fixed to one manufactured handle portion at each end of the subassembly member 86. The handle portion 90 and the handle portion 92 are manufactured with a narrow handle member 94 for connecting the two ends 95 of the handle portions 90, 92, and the narrow handle member 94 defines one handle space 96, which is large enough to accommodate a gloved hand of a user. The handle member 94 in the handle portion 90 has an outer straight edge, while the handle member 94 in the handle portion 92 has an outer jigsaw edge 70, which adjoins the subassembly member 86 to one adjacent subassembly member.

[0068] FIG. 33 shows an embodiment very similar to FIGS. 31 and 32, in which lighter colored marking portion 58 has information engraved thereon.

[0069] 34-35 show an example of connecting multiple subassemblies 86 using the jigsaw edge 70 of the handle portion 92. Compared to the previous embodiment shown in FIG. 31-32, two differences should be noted. First, in these embodiments, the subassemblies 86 are shorter, less than 4 inches in length, rather than the 5.5-6 inches or so of the previous embodiment. By shortening the length of each subassembly, the weight of said subassembly is reduced to about 50 pounds or less, making the raised rumble strips assemblies manufactured herein easier to operate, install, and remove by a small team of two people. Instead of connecting two sign sections together to cover a typical roadway, three of these short subassemblies 86 are connected together to cover the roadway. The jigsaw connection system is thus simple, reliable, and not likely to be displaced by passing vehicles, so these are not an issue. The jigsaw connectors 70 at each end of each subassembly 86 greatly simplify the connection process.

[0070] 34-35, a second difference with this embodiment is the inclusion of two adjacent handle portions, such as handle portion 90 adjacent handle portion 92 shown in FIG 35. As can be seen, such an arrangement increases the size of the handle opening 96, making it easier to manage the subassembly 86.

[0071] Yet another alternative embodiment of the present invention is shown in Figures 36-38. The objective of this particular embodiment is to maximize the height of the mating surfaces 70 of the two jigsaw sections 62, which are adapted to be mated together as discussed in the preamble of this application. A design limitation is that the roadway standards for the warning rumble strips disclosed herein limit the total height of the completed warning rumble strips. As an example, American codes limit the finished height of warning rumble strips to 0.75 inches. This means that the overall height of the sign portion cannot be increased simply by increasing the mating height of the mating surfaces 70, since the height of the sign portion may already be at the maximum allowable height.

[0072] As mentioned above, the bottom surface of each sign portion 58, 62 of the warning rumble strips assembly is preferably provided with a protective layer made of a durable material such as polyurethane. Although advantageous, such a layer is simply adhered to the bottom surface of each sign portion, thereby increasing the overall height of the warning rumble strips assembly, and therefore, the height of each sign portion must be reduced in order to keep the overall height of the system within regulatory limits. Such a reduction in height requires a reduction in the height of the mating surface 70, which in some circumstances may reduce the bond strength of the contacts formed.

[0073] Thus, in the disclosed embodiments, it may be advantageous to provide a recess or recess 98 on the bottom or ground-interfacing side of the marker portion 62 or additionally the marker portion 58. The recess or recess 98 is intended to receive a layer of protective material 100, such as polyurethane, so that the total thickness of the protective material does not increase the overall thickness of the marker portion.

[0074] 36 to 38, in this embodiment, steps 102 are formed at the edges of the grooves 98, and the height of the sign parts adjacent to the jigsaw edges 70 is increased to its full value in a ladder-like manner, allowing the height of the joint edges 70 to be closer to the maximum allowable height of the warning strips system, improving the joint of the sign parts, which on the one hand increases the joint area of ​​the jigsaw joint, and at the same time further maintains the height of the polyurethane anti-slip pad material.

[0075] As shown in FIG. 38, polyurethane layer 100 is higher than the height of steps 102 so that when the sign portion is placed on the ground, polyurethane layer 100 faces down and contacts the ground.

[0076] In the exemplary embodiment, the height of the step 102 may be approximately 0.1 inches, which in this example increases the joint height from 0.625 inches to 0.725 inches, a 16% increase. The depth of the recess or groove 98 may be approximately 0.05 inches, and the height of the polyurethane layer 100 may be approximately 0.1 inches, with the polyurethane layer protruding approximately 0.50 inches above the top of the groove 98.

[0077] The groove 98 disclosed in this embodiment employed by one or more of the sign portions 58, 62 is within the scope of the present invention. All of the above discussed sizes and materials may be varied. If desired, this embodiment may be incorporated into other embodiments disclosed herein. Although the illustrated embodiment shows the groove 98 extending along the entire length of the sign portion 62 (and 58, by extension), it is within the scope of the present invention to shorten the groove 98 to only a portion of the length of the sign portion. Each end of the sign portion has a full thickness section member to protect the ends of the polyurethane layer 100 that are pulled over the ground when the sign portion is deployed and retracted.

[0078] Another exemplary embodiment of the present invention is shown in Figures 39-40. In some traffic conditions, especially when the road surface is installed with the type of warning rumble strips posted by the present application, especially the warning rumble strips subassembly 86 in the embodiment of Figures 21-38, if it is placed on an uneven or very rough road surface, the warning rumble strips subassembly 86 may be located at the midpoint joint on the road and the connection between adjacent jigsaw sections 62 may be separated from each other. If so, this problem can be solved by increasing the height of the joint edge 70 adjacent to the jigsaw section 62 in the embodiment shown in Figures 36-38, but the other method shown in Figures 39-40 may be used separately or in combination with the method shown in Figures 36-38. In this embodiment, each joint edge 70 is provided with a plurality of receiving holes, which are spaced apart from each other along the length of the sign section 62. As shown in Figure 39, a magnetic connector 104 is installed in each hole, one end of which is exposed. These holes are not specifically shown because the magnetic connector 104 is filled in them. In the illustrated embodiment, six spaced apart magnetic connectors 104 are positioned along each mating edge 70, although the specific number is not limited and the key is an appropriate number of magnetic connectors that securely adhere to adjacent sign portions 62.

[0079] In this embodiment, the magnetic connectors 104 and their receiving holes (not shown) are circular, but may be of other suitable shapes. The illustrated magnetic connectors are cylindrical and fixed in the aforementioned holes. They are designed to be permanently attached, and are not attached with loose fasteners or pins that may become loose and / or lost over time, and are preferably made of permanent magnetic material. A suitable type of adhesive may be used to secure the magnetic connectors. The magnetic connectors 104 are joined to each other by magnetic attraction, and form a solid connection, reinforcing the traditional connection of a jigsaw joint, while at the same time, the connection formed is not too strong (having some additional applied force) to prevent the correct assembly and removal of the joint. It should be noted that although the illustrated embodiment shows a single magnetic connector being attached to the corresponding receiving hole, it is within the scope of the present invention to achieve this result in other ways, such as gluing one magnetic strip along each corresponding joint edge, or simply fastening multiple thin magnetic connectors to the joint edges.

[0080] Although the present invention has been described above using the embodiments, the scope of the technology of the present invention is not limited to the scope described in the above embodiments. It is clear to those skilled in the art that various modifications and improvements can be made to the above embodiments. It is clear from the description of the claims that such modifications and improvements can also be included in the scope of the technology of the present invention.

Claims

1. a plurality of first sign portions assembled together to form a first warning rumble strip subassembly having a length, each of the plurality of first sign portions being spaced apart from adjacent sign portions of the plurality of first sign portions along a length of the first warning rumble strip subassembly, the plurality of first sign portions being disposed along the length of the first warning rumble strip subassembly; a plurality of second sign portions assembled together to form a second warning rumble strip subassembly having a fixed length, each of the plurality of second sign portions being spaced apart from adjacent sign portions of the plurality of second sign portions along the length of the second warning rumble strip subassembly, and a second rope being installed along the length of the second warning rumble strip subassembly, the first warning rumble strip subassembly has a first jigsaw member including a joining edge at a first end thereof, and the second warning rumble strip subassembly has a second jigsaw member including a joining edge at a first end thereof, the first joining edge and the second joining edge being arranged to join with each other to form a flat connection with the first jigsaw member and the second jigsaw member to form a jigsaw portion connected at a selected location, and then connecting the first warning rumble strip subassembly and the second warning rumble strip subassembly together to form a warning rumble strip assembly at a selected location, and the joined jigsaw portion is separated from each of the first warning rumble strip subassembly and the second warning rumble strip subassembly; each of the first and second joining edges includes a magnetic surface, the magnetic surface being adapted to join to a corresponding magnetic surface on the other of the first and second joining edges; Modular road warning rumble strips system.

2. 2. The modular road warning rumble strip system of claim 1, wherein the magnetic surfaces at the first and second mating edges include at least one magnetic connector, the at least one magnetic connector being disposed at each of the first and second mating edges, and the at least one magnetic connector at the first mating edge being adapted to mate with a corresponding at least one magnetic connector at the second mating edge.

3. 3. The modular road warning rumble strip system of claim 2, wherein the first mating edge and the second mating edge include at least one hole for receiving the at least one magnetic connector.

4. 4. The modular road warning rumble strip system of claim 3, wherein at least one of the magnetic connectors is installed in at least one of the holes, and an end of the at least one of the magnetic connectors is exposed at an opening of the at least one of the holes.

5. 5. The modular road warning rumble strip system according to claim 4, wherein the first joining edge and the second joining edge each have a plurality of at least one of the holes and a corresponding plurality of at least one of the magnetic connectors, and one of the magnetic connectors is installed in each of the plurality of holes.

6. 6. The modular road warning rumble strips system of claim 5, wherein an exposed end of each of the magnetic connectors is aligned essentially flush with an abutment edge of a corresponding one of the holes in the magnetic connector.

7. 6. The modular road warning rumble strips system of claim 5, wherein each of said plurality of magnetic connectors is constructed from a magnetic material.

8. 8. The modular road warning rumble strips system of claim 7, wherein each of the plurality of magnetic connectors has a cylindrical shape.

9. 5. The modular road warning rumble strip system of claim 4, wherein at least one said magnetic connector is permanently secured in at least one said hole.

10. 10. The modular road warning rumble strips system of claim 9, wherein the at least one magnetic connector is permanently secured in the at least one hole by an adhesive.

11. a plurality of sign portions assembled together to form a warning rumble strip assembly having a length; each of the plurality of sign portions is spaced apart from adjacent sign portions along a length of the warning rumble strip assembly; A plurality of said sign segments are assembled together with a rope extending along the length of said warning rumble strip assembly; Each of the sign portions includes a lower surface; a lower surface of at least one of the marking portions having a recess suitable for receiving a layer of protective material; Modular road warning rumble strips system.

12. 12. The modular road warning rumble strip system of claim 11, further comprising a step formed in an edge of the recess, the step having a height greater than a height of a bottom of the recess of at least one of the sign portions.

13. 12. The modular road warning rumble strip system of claim 11, wherein the protective material layer comprises a polyurethane layer.

14. 14. The modular road warning rumble strip system of claim 13, wherein the polyurethane layer extends from the recess in the underside of at least one of the sign portions.

15. 15. The modular road warning rumble strip system of claim 14, wherein the thickness of the polyurethane layer is greater than the depth of the recess.

16. 16. The modular road warning rumble strip system of claim 15, wherein the polyurethane layer has a thickness of about 0.1 inches and the recess has a depth of about 0.05 inches.

17. 13. The modular road warning rumble strip system of claim 12, wherein the step height is approximately 0.1 inches.

18. 12. The modular road warning rumble strip system of claim 11, wherein the recess extends along the entire length of at least one of the sign portions.

19. 12. The modular road warning rumble strip system of claim 11, wherein the recess does not extend along the entire length of at least one of the sign portions.

20. 20. The modular road warning rumble strip system of claim 19, wherein each end of the recess has a full thickness of at least one of the marker portions.

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