Roadside barrier

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/028,354 filed Dec. 24, 2001 which in turn is a continuation-in-part of U.S. patent application Ser. No. 09/811,712 filed Mar. 19, 2001, now U.S. Pat. No. 6,343,821, which in turn is a continuation of U.S. patent application Ser. No. 09/200,367 filed Nov. 23, 1998, now U.S. Pat. No. 6,203,079.

[0002] This application claims domestic priority of U.S. provisional patent application Ser. No. 60/066,486 filed Nov. 24, 1997 through the '354 application, the '712 application and the '367 application.

[0003] All patents and literature referenced herein in incorporated herein by reference as if the entire contents were reproduced and inserted at the reference point.

[0004] The present invention relates in general to roadside barriers such as crash cushions (sand-filled yellow barrels) and Bullnose Median Barriers as well as crash attenuators, and more particularly to damped crash attenuators that dissipate the energy of an object such as a vehicle impacting the barrier or crash attenuator. It also relates in some cases to attenuators which use the controlled deformation of metal to absorb energy and thus damp the motion of the attenuator. Still more particularly, the invention relates to attenuators enabling active control of the rate of energy dissipation thereof to better control the deceleration of vehicles impacting the attenuator having widely varying kinetic energy.

[0005] The present invention also relates to method for protecting fixed structures from damage caused by the impact of objects such as vehicles, for example, structures situated alongside highways.

[0006] Many commercial products exist and numerous patents have been issued directed to the design and construction of impact attenuators or barriers to control the deceleration of an errant vehicle as it approaches an obstruction or hazard on, or adjacent to, a highway. Several prior art patents will be discussed below. This invention is concerned primarily with roadside barriers although it is also concerned with impact attenuators that are mounted on the rear of a construction vehicle, commonly called truck-mounted attenuators (TMA), although it is not limited thereto. The invention also has applicability to more permanent attenuator installations such as those of the type used around fixed highway structures especially where space is limited.

[0007] A review of some patents and commercial literature of TMAs illustrates a wide variety of designs which appear to have evolved by trial and error with little attempt to optimize the design to handle a wide variety of impacting vehicle kinetic energies. Thus, such existing devices generally have a fixed force versus deflection function that provides the same resisting force to the impacting vehicle regardless of that vehicle's mass or velocity.

[0008] The primary purpose of a roadside barrier is to protect the occupants of a vehicle from injury caused by the impact of a vehicle with a roadside structure such as a bridge support, pole, tree or other such object. Prior art systems generally use sand-filled plastic barrels called crash cushions and various types or guard rails and median barriers. Although this is typically not the case with prior art roadside barriers, such barriers should capture the errant vehicle and bring it safely to a stop. Additionally, it is desirable for the roadside barrier to be low cost, reusable after an impact, easily transported, light weight, easily shipped, easily stored, etc. No roadside barrier on the market today satisfactorily meets all of these requirements. Therefore, there is a dire need for such a roadside barrier, which is the subject of this invention.

[0009] The primary purpose of a TMA is to protect construction personnel from death or injury caused by a vehicle which mistakenly or accidentally intrudes into a construction zone. Secondarily, the TMA is designed to minimize the death and injury to the occupants of the errant vehicle. Ideally, the TMA should capture the impacting vehicle preventing it from being diverted either into adjacent traffic or off the road where it might impact a roadside structure such as a utility pole. Preferably, the TMA should even decelerate the vehicle at an acceptable level, such as 15 Gs, regardless of the mass or velocity of the impacting vehicle. Additionally, it is desirable for the TMA to be low cost, reusable after an impact, easily transported, light weight, easily shipped, easily stored, etc. No TMA on the market today satisfactorily meets all of these requirements. Therefore, there is a dire need for such a TMA that is the subject of this invention.

[0010] It is clear from the patents and commercial literature that many mechanisms exist for absorbing energy of an impacting vehicle into a TMA or roadside barrier. These include a variety of structures that depend on the bending of metal or plastic, devices that utilize water, foam rubber, plastic etc. in a variety of energy absorption modes. Frequently, the energy dissipated by the system is part of the structure of the device. In fact, the prior art inventions have frequently confused the functions of structure and energy absorption. The instant invention therefore centers on the separation of these two functions of supporting structure and energy dissipation and optimizing these functions separately.

[0011] The basic problem to be solved by a TMA design is to capture an impacting vehicle and preferably to decelerate it at an approximate constant value that is relatively independent of the velocity and mass of the impacting vehicle. It is also desirable for the impactor to be resetable and that it can be easily collapsed for transportation, shipping, storage etc. It is noteworthy that none of the TMAs on the market today are reusable and therefore invariably require replacement after an impact.

[0012] Review of the Prior Art:

[0013] U.S. Pat. No. 3,674,115 to Young et al. describes a liquid filled shock absorber comprised of many tubes each with a fixed orifice. On impact of a vehicle into the shock absorber, the fluid is forced to flow through the orifices which provides the energy dissipation. Since the orifices are fixed, the system will not adjust to vehicle impacts of varying kinetic energy to provide a constant deceleration. Also, since the device is substantially composed of such cylinders, it is heavy if used as a TMA. It is designed, therefore, for use in fixed installations.

[0014] U.S. Pat. No. 4,190,275 to Mileti describes a light weight reusable TMA which is self restoring and thus immediately available to receive an additional impact. The impact attenuator is constructed from a plurality of expanded plastic sheets sandwiched between plywood stiffeners. The expanded plastic sheets form air filled cells. The energy dissipation mechanism is not disclosed but it appears that the energy is stored as compressed gas within the cells rather than dissipated. Thus, there is a substantial force at the end of the crash to cause the impacting vehicle to change its direction and rebound at a substantial velocity off of the TMA thus substantially increasing the velocity change of the vehicle above the initial vehicle impact velocity. This increases the severity of the crash and thus the potential for injury to the construction crew and the vehicle occupants. There is no provision in this patent to adjust the force on the impacting vehicle so that substantially the same deceleration is achieved for vehicles of different kinetic energy. This has the effect of substantially increasing the length required of the device in order to handle both light and heavy impacting vehicles at high velocities. The first part of the TMA must be designed to decelerate a light, high speed vehicle at a safe level. This same force is then all that is available for the heavy vehicle which is then decelerated at a much lower level during the initial part of the crush and then at a higher level later.

[0015] U.S. Pat. No. 4,635,981 to Friton describes an attenuator including a series of chambers made from sheet metal with some of the chambers containing crushable plastic foam, which, along with the plastic deformation of the sheet metal, dissipates the kinetic energy of the impacting vehicle. The system is not reusable and does not adjust to impacting vehicles having different kinetic energies.

[0016] U.S. Pat. No. 4,674,911 to Gertz describes a crash cushion which uses the compression of air to act as a spring to provide an ever increasing force acting against the impacting vehicle. This system is reusable but does not adjust to impacting vehicles having different kinetic energies. By having the function of an ever increasing force with displacement, it is particularly inefficient in decelerating a vehicle where a constant force is desired.

[0017] U.S. Pat. No. 4,711,481 to Krage et al. describes an attenuator that uses the crushing or plastic deformation of sheet metal to provide the energy dissipation. This system is not reusable and does not adjust to impacting vehicles having different kinetic energies. By having the function on an ever increasing force with displacement, it is particularly inefficient in decelerating a vehicle where a constant force is desired.

[0018] U.S. Pat. No. 5,052,732 to Oplet et al. describes an attenuator which uses a plurality of layers of fibrous hexagonal elongate cells which provides energy absorption during crushing. It suffers from the same defects at Krage et al. (U.S. Pat. No. 4,711,481).

[0019] U.S. Pat. No. 5,101,927 (Murtuza) describes an automatic brake actuation device including a feeler which extends forward of a vehicle and detects objects that the vehicle is about to strike. Upon detecting an object, the device actuates the brakes of the vehicle to bring the vehicle to rest. Also, upon impact with the object, the feeler is retracted without applying any force against such retraction. One stated object of the Murtuza invention is to provide an improved automatic brake actuation system wherein the extendable detector is retracted upon impacting an object. More particularly, in the embodiment shown in FIGS. 13 and 14, the device includes a support member 112 mounted to the vehicle and a feeler cylinder 114 having a piston 118 therein. Movement of the piston 118 controls expansion and retraction of a parallel-bar expanding feeler 130. Movement of the piston is obtained by forcing fluid into a retracting portion 128 of the cylinder 114 while fluid is vented from the extending portion 126 and vice versa. This is achieved by providing fluid controls to act as extending means or devices and retracting means or devices for supplying fluid under pressure to the feeler cylinder.

[0020] U.S. Pat. No. 5,192,157 to Laturner describes a fixed installation vehicle crash barrier that attempts to make use of a more efficient method of deforming metal to absorb energy. It also suffers from the same limitations as Krage et al. (U.S. Pat. 4,711,481).

[0021] U.S. Pat. No. 5,199,755 to Gertz describes a TMA that also uses the bending of metal as the main energy absorption mechanism and thus has the same limitations as Krage et al. (U.S. Pat. 4,711,481).

[0022] U.S. Pat. No. 5,403,112 to Carney describes a TMA where part of the structure is a scissors mechanism. The bending of metal is the energy absorption mechanism and thus has the same limitations as Krage et al. (U.S. Pat. 4,711,481).

[0023] U.S. Pat. No. 5,642,792 to June describes a TMA using large drum shaped plastic cylinders to provide an energy absorption system. The system is not reusable and does not adjust to the kinetic energy of the impacting vehicle.

[0024] U.S. Pat. No. 6,189,941 to Nohr, although not a TMA, describes a novel collapsing tube energy absorbing mechanism that is applicable to the invention disclosed herein for those cases where the variable damping feature is sacrificed for a lower cost system. This patent is incorporated by reference herein in its entirety and its teachings are particularly relevant to the invention disclosed herein.

[0025] Accordingly, none of the prior art patents mentioned above discloses a TMA having the sought after properties and thus, a critical need exists for such a device. A central issue is that since prior art TMAs are not optimally designed, they must be made very long in order to handle both low and high mass vehicles at high speed. This makes the devices expensive, difficult to maneuver and less than optimum as a life saving device.

[0026] In addition to the above there are several papers that explore the field results of various roadside barrier designs, see for example the paper In-service Performance Evaluation of the Bullnose Median Barrier in the State of Iowa, presented at the Transportation Research Board 80^th Annual Meeting, Jan. 7-11, 2001. The conclusions of that paper state:

[0027] An in-service performance evaluation of bullnose median treatments in a portion of Iowa was performed. This involved collecting information about bullnose collisions from field investigations, police reports and maintenance records. These sources of information indicated that the bullnose installations in the data collection area were usually installed consistent with Iowa DOT policy and represent good quality installations. While the dataset for this study was small (42 police and maintenance-reported cases and 38 unreported events) an examination of the characteristics of the collisions suggests that impacts at and near the nose often result in unacceptable penetrations or overrides. These collisions are not frequent, but when they occur they are often severe. Collisions at the nose resulted in serious or fatal injuries in one-third of the police-reported cases. While the bullnose does not appear to be particularly effective in nose and near-nose collisions it is unclear whether any other median treatment would result in better performance. These data suggest that there is a need to develop median treatments that prevent vehicles from penetrating the system and contributing to injuries of vehicle occupants.

[0028] In addition to the above, there are numerous examples in the literature of small vehicles underriding guard rail structures and other vehicles, those with a high center of gravity, overriding the structures and in many cases the structure causes the high center of gravity vehicle to flip or roll over, which can cause serious injuries to the occupants. Similarly oblique impacts can result in a deflection of the vehicle back onto traffic since the guard rail dose not move.

[0029] It is an object of the present invention to provide a new and improved roadside barrier that eliminates vehicle underride and override.

[0030] It is another object of this invention to provide a roadside barrier that does not accentuate the tendency of a vehicle to rollover.

[0031] It is a further object of this invention to provide a roadside barrier and method for stopping a vehicle after impact into a roadside barrier that gradually decelerates the errant vehicle and brings it to a safe stop.

[0032] Another object of this invention is to provide for an instant signal to be sent to the police or other authorities whenever a roadside barrier is struck.

[0033] A further object of this invention is to provide a roadside barrier that is reusable and can be reinstalled with the minimum cost.

[0034] Other objects of disclosed inventions include:

[0035] to provide a new and improved crash attenuator for mounting on a truck or a stationary structure;

[0036] to provide a new and improved crash attenuator for mounting on a truck of stationary structure which is reusable;

[0037] to provide a new and improved crash attenuator for mounting on a truck or a stationary structure which adjusts to the kinetic energy of a vehicle impacting into the same;

[0038] to provide a new and improved crash attenuator for mounting on a truck or a stationary structure which is efficient in decelerating a vehicle impacting into the attenuator where a constant deceleration is desired;

[0039] to provide a new and improved crash attenuator for mounting on a truck or a stationary structure that separates the functions of the supporting structure and the energy dissipation and optimizes these functions separately;

[0040] to provide a new and improved crash attenuator for mounting on a truck or a stationary structure which enables active control of the rate of energy dissipation in order to better control the deceleration of vehicles impacting the attenuator having widely varying kinetic energy;

[0041] to provide a new and improved crash attenuator for mounting on a truck or a stationary structure which is low cost, reusable after an impact, easily transported, light weight, easily shipped and easily stored; and

[0042] to provide a particularly low cost passive attenuator which does not require sensing and adjustment of the damping during the crash event.

[0043] In other to achieve some of the objects above and other objects, roadside barriers in accordance with this invention generally have a member or assembly having a T-shaped cross section with the horizontal portion of the T resting on the ground. When impacted by a vehicle, the tires of the vehicle rest on the horizontal portion of the T and the vertical portion is impacted by the front bumper. The momentum of the vehicle starts the barrier sliding and because of the weight of the vehicle, a minimum 1 G deceleration results. The coefficient of friction between the barrier and the road can be increased by various protrusions or projections that are under the surface, e.g., under the surface of the horizontal portion, and cause a plowing of the earth as the barrier slides. Since the barrier has mass, there is also an immediate deceleration of the vehicle caused by the need to accelerate the barrier mass.

[0044] If the mass of the barrier is 25% of that of the vehicle, then an approximate 25% reduction of the vehicle velocity occurs immediately. The mass of the barrier can be controlled by adding sand to the opposite side of the barrier from the vehicle-impacting side. For single barrier installations, additional sand bags can be placed in the path of the barrier so that it continues to increase in mass as it slides and thus continues to decelerate the errant vehicle.

[0045] For multiple barrier installations, the various barriers can be joined together by hinges or other linkages such that as the vehicle continues on its path it drags more and more barriers with it and thereby the barrier installation captures the errant vehicle and slows it to a stop as the vehicle pulls more and more barriers along.

[0046] As such, one embodiment of a barrier for placement along a road comprises a plurality of barrier sections coupled to one another, each comprising a horizontal portion, a vertical portion extending upward from the horizontal portion and a front plate coupled to the vertical portion and adapted to receive an impact from a moving object. The vertical portion extends upward from a middle region of the horizontal portion to provide the horizontal portion with a front part at least partially below the front plate and a rear part. The vehicle would be situated on the front part when impacting the front plate. To this end, the horizontal potion should extend to a location in front of the front plate. A mass, such as gravel or sand, can be placed on the rear part of the horizontal portion, either loose or in a barrel or box.

[0047] The barrier section is preferably designed to provide an increased drag once moved from its installation position. This is accomplished for example by forming downwardly-extending protrusions on the lower, ground-engaging surface of the horizontal portion and which are adapted to penetrate the ground below the barrier section.

[0048] A cooperating linking mechanism for linking adjacent barrier sections together can be provided. In one embodiment, an energy absorbing expandable metal joint is used.

[0049] In another embodiment, the barrier section comprises a horizontal portion, a vertical portion extending upward from the horizontal portion, a front plate coupled to a forward side of the vertical portion and adapted to receive an impact from a moving object and a drag increasing mechanism for increasing the drag of the barrier section during rearward movement. The drag increasing mechanism may be projections or protrusions formed on the lower surface of the horizontal portion. Each protrusion may have a flat rearward face to thereby cause the horizontal portion to resist movement in the rearward direction.

[0050] Another embodiment of a barrier section for use in a road barrier comprises a horizontal portion, a vertical portion extending upward from the horizontal portion, a front plate coupled to the vertical portion and adapted to receive an impact from a moving object and a sensor system for sensing impact into the front plate and transmitting information about the impact to a remote location. The sensor system may include a motion sensor, a camera, a chemical sensor and/or a temperature sensor.

[0051] The invention will be described with reference to the accompanying non-limiting drawings wherein:

[0052] FIG. 1 shows a first embodiment of a crash attenuator in accordance with the invention in its contracted condition;

[0053] FIG. 2 shows an enlarged view of the first embodiment of the crash attenuator in accordance with the invention in its contracted condition;

[0054] FIG. 3 shows the first embodiment of the crash attenuator in accordance with the invention in its expanded condition;

[0055] FIG. 4 shows another view of the first embodiment of the crash attenuator in accordance with the invention in its expanded condition;

[0056] FIG. 5 shows a second embodiment of a crash attenuator in accordance with the invention in its expanded condition;

[0057] FIG. 6 shows the airbag used in the second embodiment of the crash attenuator in accordance with the invention;

[0058] FIG. 7 shows a modified embodiment of the crash attenuator in accordance with the invention having an accordian design for the airbag;

[0059] FIG. 8 shows an enlarged view of a third embodiment of a crash attenuator in accordance with the invention, using a metal deformation energy absorption system, in its contracted state;

[0060] FIG. 9 shows the third embodiment of the crash attenuator in accordance with the invention in its expanded condition;

[0061] FIG. 10 shows a detail of the detachable die system to permit the collapse of the mechanism of the third embodiment for transportation and storage;

[0062] FIGS. 11 and 11A show a prior art bullnose roadside median barrier installation;

[0063] FIG. 12 shows a bullnose median barrier installation in accordance with the invention;

[0064] FIGS. 13A, 13B and 13C show several possible cross sections of the median barrier of FIG. 12;

[0065] FIG. 14 shows a detail of the linking system whereby an errant vehicle is captured by a linked barrier in accordance with the invention and brought to a stop;

[0066] FIGS. 15, 15A and 15B illustrate an alternate design employing an energy absorbing expandable metal joint between the sections of the barrier; and

[0067] FIG. 16 illustrates the use of a sensor that communicates with the police via a satellite when an impact occurs.

[0068] Referring to the accompanying drawings wherein like reference numerals refer to the same or similar elements, FIGS. 1-4 show a first embodiment of a crash attenuator in accordance with the invention denoted generally as 10. The crash attenuator 10 is mounted to a vehicle such as a truck 12, most often so that it faces rearward of the truck 12. As such, it will protect the truck 12 from damage resulting from a vehicular impact from the rear of the truck 12. The crash attenuator 10 is secured to the truck 12 by conventional mounting means, e.g., bolts, screws, welding, clamps.

[0069] The typical size of the crash attenuator 10 when mounted to a standard size truck is about eight feet wide, fifteen feet long and two and one half feet high in the expanded condition. The crash attenuator 10 is preferably designed so that the center of pressure is about 23 inches off ground.

[0070] The crash attenuator 10 includes a rigid frame 14 comprising a pair of spaced apart, parallel beams 16 extending substantially perpendicular to the rear of the truck 12, a cross beam 18 for connecting the beams 16 to provide stability thereto and a rigid support beam structure 20 arranged at a rearward end of the beams 16 and connected thereto. Beams 16 are connected to a suitable surface of the truck 12. A diagonal beam 22 is arranged at each side of the frame 14 (only one of which is shown) and is connected to the beam structure 20 to provide stability for the same. The beam structure 20 comprises an upper horizontal beam 24, a lower horizontal beam 26 parallel to the upper horizontal beam 24 and spaced therefrom and three spaced apart, parallel vertical beams 28 connecting the upper and lower horizontal beams 24,26. A substantially rigid plate 30 is connected to one or more of the beams 24,26,28 and serves as a connecting surface to which ends of the beams 16 and 22 are attached. The connections between the beams and plates, which are preferably made of a metal material, may be in any suitable manner, e.g., by welds, screws, etc.

[0071] FIGS. 1 and 2 show the crash attenuator 10 in its compressed or contracted condition or position that is also the storage and transport position and is as small as 25% of the length of the crash attenuator in its expanded condition or position. Generally, the length of the crash attenuator 10 in its contracted state can be 50% or less of the length in its expanded state. To enable the expansion or extension of the crash attenuator 10, the crash attenuator 10 includes a movable displacement structure such as a scissors mechanism 32 which comprises a plurality of elongate members 34a-34h on each side of the crash attenuator 10 (FIG. 3). Elongate members 34 are substantially rigid and have a rectangular body section and projecting links 36 at each end. Member 34a is connected via its link 36 at its upper end to a link 38 which in turn is connected to a link 40 fixedly mounted on the upper horizontal beam 24 of the beam structure 20.

[0072] The connection between the links 36,38,40 is designed so that each link is rotatable relative to each of the links connected therewith, e.g., through a pin 42 extending through each pair of connected links and defining a pivot axis. As such, link 36 and thus member 34a can rotate relative to link 38 and link 38 is also rotatable relative to link 40 so that as a result, the lower end of member 34a is swingable outward away from the beam structure 20 by virtue of the rotation of the link 36 at the upper end of member 34a relative to the link 38 which in turn is rotatable relative to the link 40. In a similar manner, member 34b is movably coupled to the lower horizontal beam 26 via links 36a, 38a, 40a so that the upper end of member 34b is swingable outward away from the beam structure 20. A pin 44 is arranged at the center point of the members 34a, 34b to connect the same while enabling rotation of both members 34a, 34b, i.e., both members are rotatable about the axis defined by the pin 44.

[0073] Member 34c is connected to member 34a via the links 36 at the lower end of each member whereby a pin 45 extends through the links to enable rotation of both members 34a, 34c about the axis defined by the pin. Member 34e is connected to member 34c via the links 36 at the upper end of each member whereby a pin extends through the links to enable rotation of both members 34c, 34e about the axis defined by the pin. Member 34e is connected to member 34g via the links 36 at the lower end of each member whereby a pin extends through the links to enable rotation of both members 34e, 34g about the axis defined by the pin.

[0074] Member 34b is connected to member 34d via the links 36 at the upper end of each member whereby a pin extends through the links to enable rotation of both members 34b, 34d about the axis defined by the pin. Member 34f is connected to member 34d via the links 36 at the lower end of each member whereby a pin extends through the links to enable rotation of both members 34d, 34f about the axis defined by the pin. Member 34h is connected to member 34f via the links 36 at the upper end of each member whereby a pin extends through the links to enable rotation of both members 34f, 34h about the axis defined by the pin.

[0075] Overall, by means of the links 36 and pins connecting adjoining links 36, the scissors mechanism 32 is movable between the contracted position shown in FIGS. 1 and 2 and the expanded position shown in FIGS. 3 and 4. The scissors mechanism 32 should be sufficiently rigid and sturdy to maintain a bumper 70 arranged at the end of the scissors mechanism 32 at a desired level from the ground without excessive sag. Note that in general permanently lubricated journal bearings are used at each rotation joint which is the convention in the art. Naturally, other types of bearings such as ball or roller bearings can also be used.

[0076] Bumper 70 as shown in FIG. 1 is a flat plate. In FIGS. 2-5, the bumper 70 is shown as a rather, large bumper, additional details of the construction of which are provided below.

[0077] In the embodiment shown in FIGS. 1-4, a support structure is included for supporting a hydraulic system which facilitates the expansion and contraction of the attenuator 10 and also enables the controlled contraction of the attenuator after a crash to enable the attenuator to be responsive to the kinetic energy of the impacting vehicle, i.e., provide a variable resistive or energy dissipation force depending on the mass and velocity of the impacting vehicle.

[0078] To this end, pin 44 is formed integral with or connected to a transverse rod 46 that extends from one side of the crash attenuator 10 to the other side. At the other side of the crash attenuator 10, the rod 46 is connected to or formed integral with the pin connecting the corresponding members 34a, 34b at that side. A pin 48 is also arranged at the center point of the members 34c, 34d to connect the same while enabling rotation of both members 34c, 34d, i.e., both members are rotatable about the axis defined by the pin 48. Pin 48 is formed integral with or connected to a transverse rod 50 that extends from one side of the crash attenuator 10 to the other side.

[0079] At the other side of the crash attenuator 10, the rod 50 is connected to or formed integral with the pin connecting the corresponding members 34c, 34d at that side. A pin 52 is also arranged at the center point of the members 34e, 34f to connect the same while enabling rotation of both members 34e, 34f, i.e., both members are rotatable about the axis defined by the pin 52. Pin 52 is formed integral with or connected to a transverse rod 54 that extends from one side of the crash attenuator 10 to the other side. At the other side of the crash attenuator 10, the rod 54 is connected to or formed integral with the pin connecting the corresponding members 34e, 34f at that side. Similarly, a pin 56 is arranged at the center point of the members 34g, 34h to connect the same while enabling rotation of both members 34g, 34h, i.e., both members are rotatable about the axis defined by the pin 56. Pin 56 is formed integral with or connected to a transverse rod 58 that extends from one side of the crash attenuator 10 to the other side. At the other side of the crash attenuator 10, the rod 58 is connected to or formed integral with the pin connecting the corresponding members 34g, 34h at that side.

[0080] Rods 46,50,54,58 thus constitute a support structure for the energy dissipation system described below. Other support arrangements are of course encompassed within the invention without deviating from the scope and spirit thereof Rods 46,50,54,58 are shown as being elongate and substantially cylindrical. However, it is pointed out that the rods 46,50,54,58 may be any shape whatsoever and further, that not all of the rods are required, i.e., it is possible to dispense with one or more of the rods connecting the pins on opposite sides of the crash attenuator 10. Also, each of the transverse rods may be formed integral with the associated pins.

[0081] In the embodiment shown in FIGS. 1-4, the energy dissipation system is a hydraulic actuating mechanism 100 arranged in connection with the scissors mechanism 32 and which serves to expand and contract the same. Hydraulic actuating mechanism 100 is designed to provide an energy dissipation force to dissipate at least some, if not all, of the energy of the vehicle impacting the bumper by controlling the contraction or compression of the scissors mechanism 32, i.e., the movement of the scissors mechanism 32 from its expanded condition shown in FIGS. 1 and 2 toward its contracted condition shown in FIGS. 3 and 4. The energy dissipation force is ideally adjustable and determined, e.g., based on the kinetic energy of the impacting vehicle.

[0082] To mount the hydraulic actuating mechanism 100, at each side of the crash attenuator 10, a mounting plate 61 is attached to the transverse rod 46 and a mounting plate 63 is attached to transverse rod 58. Mounting plates 61,63 may be formed with a projecting part having an aperture designed to receive the respective rod 46,58. A pair of actuators 60 are coupled to the mounting plate 61 and via rigid mounting links 65 to transverse rod 50. Similarly, a pair of actuators 64 are coupled to mounting plate 63 and via rigid mounting links 67 to transverse rod 54. Mounting links 65,67 include an aperture designed to receive the respective transverse rod 50,54.

[0083] Each actuator 60,64 includes a cylinder having a hollow interior, a piston rod which is movable within the interior of the cylinder and means for passing a fluid into the hollow interior into a space between a head of the piston rod and an end of the cylinder so as to cause the piston to move outward from the cylinder when the fluid is passed into the space and to move back into the cylinder when the fluid is removed from the space. The construction of the cylinders is conventional. Actuators 60 each have a piston rod 62 that is connected to the mounting plate 61, whereas the cylinder itself is connected to mounting links 65. In a like manner, actuators 64 each have a piston rod 66 which is connected to the mounting plate 63, whereas the cylinder itself is connected to mounting links 67.

[0084] The actuators 60,64 are positioned so as not to interfere with the transverse rods 46,50,54,58 when the scissors mechanism 32 is in its contracted position. Thus, as shown in FIGS. 3 and 4, the actuators 60,64 are situated above and below the transverse rods 46,50,54,58 that are essentially in the same horizontal plane. Also, by virtue of the connections of the cylinders of the actuators 60,64 to the transverse rods 50,54 and the connection of the piston rods 62,66 to the mounting plates 61,63, which are connected to the transverse rods 46,58, the transverse rods 54,58 are movable relative to each other upon actuation of the actuators 64 and the transverse rods 46,50 are movable relative to each other upon actuation of the actuators 60.

[0085] In operation, the piston rods 62,66 start out housed within the respective cylinder 60,64 as shown in FIGS. 1 and 2. Thereafter, when it is desired to expand the scissors mechanism 32, a hydraulic medium is directed into the actuators 60,64 to force the respective piston rod 62,66 out of the interior of the cylinder. In this manner, the transverse rods 46,50,54,58 are moved apart from one another which causes the members 34a-34h to be forced into the expanded position shown in FIGS. 3 and 4 in view of the connection between the transverse rods 46,50,54,58 and the members 34a-34h via the pins connecting the center regions of crossing members.

[0086] Note that the hydraulic hoses and reservoirs have not been shown in the drawings in order to permit the concepts to be more easily understood.

[0087] Although a scissors mechanism has been illustrated for the supporting structure in the above-described embodiment, other linkage designs would also work for some applications without deviating from the scope and spirit of the invention. Thus, instead of the scissors mechanism described above, other collapsible structures composed of a plurality of members arranged to provide the collapsible structure with a contracted position and an expanded position may be used. Such structures could include members linked and articulated to one another. One such design uses a bifold door type structure, using hinged vertical frames, and another is based on 4-bar linkages. Although a vertical scissors structure has been illustrated employing two such structures, in some applications as many as four or more such mechanisms are used. Similarly, although the scissors are shown lying in a vertical plane, they can be combined with scissors mechanisms that are on top and bottom of the device, or, alternately, only horizontal scissors mechanisms are used with appropriate vertical bracing. Even with the illustrated design, many types of cross bracing can be added as needed.

[0088] A variety of added supporting structures or apparatus could be used including wheels and cables. The system may even be designed to deflect downward when impacted so as to obtain some support from the ground. This would also add a certain amount of lateral stability to the system.

[0089] The crash attenuator 10 also comprises a bumper 70 mounted via links 72 to the upper link 36 of members 34g and via links 74 to the lower link 36 of members 34h. Bumper 70 is made from a material that can provide a low level of energy absorption for low speed impacts, such as polyurethane foam. The extreme rear end of the bumper 70 may include reflectors 76. Bumper 70 may also be made of fibrous hexagonal elongate cells, or a series of chambers made from sheet material, or any other known construction for providing energy absorption.

[0090] To provide the damping of the crash attenuator 10 during a crash, the hydraulic actuating mechanism 100 includes control means associated with the actuators 60,64 for controlling the release of fluid therefrom, the release of fluid from the actuators 60,64 determining the movement of the piston rod 62,66 back into the respective cylinder and thus the energy dissipation force effective to decelerate the vehicle. Initially, in the expanded condition, the actuators 60,64 include enough fluid to provide for the desired length of the attenuator 10, and thus in a crash, some of this fluid will be released. The hydraulic actuating mechanism 100 may comprise a valve having a variable opening or variable size orifice through which the fluid from the actuators 60,64 flows.

[0091] An electronic control module 80 is arranged at the rear of the bumper 70 to detect the deceleration of the vehicle and is coupled to control means for the valve. Accordingly, the orifice of the valve has an initial size that will result in a predetermined outflow of fluid from the actuators 60,64 and thus a predetermined energy dissipation force to the impacting vehicle. If the electronic control module 80 determines that the deceleration of the vehicle is too rapid or too slow, it adjusts the size of the orifice to obtain a desired deceleration rate of the vehicle. As such, by adjusting the size of the orifice, the attenuator 10 provides a substantially constant deceleration rate of all vehicles regardless of their mass and velocity. Alternately, once the mass and velocity of the impacting vehicle has been determined, the control module 80 can adjust the deceleration of the impacting vehicle so as to use up nearly all of the stroke of the TMA. In this manner, injury to the vehicle occupants, damage to the impacting vehicle and risk of airbag deployment is minimized especially for low velocity crashes.

[0092] FIG. 5 shows a pneumatic system 10 for providing an energy dissipation force for dissipating the energy from the impact of the vehicle into the attenuator 10A. The pneumatic system 110 comprises one or more inflatable airbags 112 defined by a material 114, and if a plurality of such compartments is provided, then the compartments may be fluidly separated from one another or coupled to one another. The scissors mechanism 100 is essentially the same as that described above with respect to FIGS. 1-4, except that the transverse rods 46,50,54,58 are not provided since it is not necessary to couple actuators to the same. Rather, the links 36 at the ends of each member 34a-34h are mounted to intermediate supports 116 and the material 114. Tethers 118 may also be provided to maintain a desired shape of the airbags 112.

[0093] The airbag 112 is closed and to this end, has a face at one end adjoining the plate 30 of the beam structure 20 connected to the truck 12 and a face at an opposite end connected to the bumper 70. A pneumatic device 120 is arranged on the frame 14 and has an outlet into the airbag 112. To initially expand the airbag 112, the pump is activated to direct air or another medium into the airbag 112. The outlet from the pneumatic device 120 has a variable size and the pneumatic device 120 is also designed to allow outflow of air from the airbag 112.

[0094] In a crash, the airbag 112 will experience a controlled deflation thereby providing a desired deceleration to a vehicle impacting the attenuator 10A regardless of that vehicle's mass and velocity. To this end, the electronic control module 80 is arranged on the rear of the bumper 70 and senses deceleration of the vehicle, as conveyed through the bumper 70. The outlet of the pneumatic device 120 has an initial size which allows air to be expelled from the airbag 112 reducing the pressure in the airbag 112 yet still enabling the airbag 112 to provide a energy dissipation force to the impacting vehicle and decelerate the same.

[0095] If the deceleration rate of the vehicle is too high or too low, i.e., beyond safe ranges, as detected by the electronic control module 80, then the electronic control module 80 causes an adjustment in the size of the outlet of the pneumatic device 120, i.e., increases or decreases the same. In this manner, the airbag will deflate at a controlled rate, or more appropriately maintain a specific pressure in order to decelerate the impacting vehicle at the desired rate.

[0096] The airbag 112 may be made with tethers 118 alone to provide its shape in its expanded condition, without any intermediate supports.

[0097] As shown in FIG. 7, the airbag 112 may be encased within an accordian like housing 122 which thus serves to provide the shape of the airbag 112. In this embodiment, the scissors mechanism 126 only comprises two expanding sections and a bumper 124 having a concave face for directing the vehicle into the center of the crash attenuator.

[0098] A third embodiment of the invention is shown in one form in FIGS. 8-10. The basic parts of the system are the same as in FIGS. 1-4 and thus are not renumbered here. Only those parts that are new and different are numbered. Further, to the extent possible, it is intended that the features of the other embodiments described herein can be incorporated into the embodiment described in FIGS. 8-10.

[0099] Referring now to FIG. 8, the attenuator is shown in the collapsed state following an impact at 200. An auxiliary hydraulic system including a hydraulic cylinder 250 is provided to expand and contract the scissors mechanism 32 instead of the plurality of hydraulic cylinders as shown in the embodiment of FIG. 2. This hydraulic system is left open after the attenuator 200 is opened and does not provide any resistance to the collapse of the scissors mechanism, i.e., fluid flows freely therethrough. Hydraulic cylinder 250, when supplied with high-pressure fluid, presses on support bar 252 and rod 254 and expands the attenuator 200.

[0100] The attenuator 200 is shown expanded in FIG. 9 where metal deformation energy absorption mechanisms comprising, for example, rods 262 and 266 and dual die assembly 260, replace the corresponding hydraulic cylinders 60,64 in the embodiment shown in FIG. 2. Upon the impact of an errant vehicle with the bumper 70, the attenuator 200 begins to collapse and rods 262 and 266 are forced through die 260. Die 260 causes the rods 262 and 266 to reduce their outside diameters and then energy is dissipated through the cold working of the rod material and the motion of the errant vehicle is opposed.

[0101] The amount of energy dissipated depends on the properties of the material of the rods 262,266 and the amount of reduction of the outside diameter of the rods, i.e., the difference between the diameter of the apertures in the die 260 through which the rods 262,266 are forced and the diameter of the rods. Although a fixed die diameter is illustrated, it can be easily seen by those skilled in the art that the die 260 can be designed in the form of a collet and the diameter reduction of the rods 262,266 controlled by the effective diameter of the collet which can in turn be controlled by a motor or other means, which may be based on the impact velocity of the object, the deceleration of the object or any of the other control variables discussed above. Thus, the amount of energy dissipation can be controlled in a similar manner as with the hydraulic and pneumatic systems described above.

[0102] FIG. 10 illustrates one assembly method for the die 260 that permits the die 260 to be disassembled to permit the collapse of the attenuator 200 for travel and storage. Naturally, more automatic methods are preferable and many such systems can be implemented by those skilled in the art. For the collet example discussed above, the collets would be opened up to the point where the rods 262,266 freely move through them. The die 260 can thus be made of two die parts 260a, 260b connected together by screws 261 with the option of removing the screws to open up the die 260. In most cases, the rods 262 and 266, and the other corresponding rods that are not numbered (the recitation of the two rods 262,266 being merely exemplary with the intention that the attenuator 200 can include any number of rods), would have a reduced diameter at the end to permit initial entry into the dies. End 263 of rod 266 is similarly reduced in diameter to permit insertion into a base 270.

[0103] The particular method illustrated for absorbing energy by deforming a metal rod is only one of many such systems. In some cases, a tube having a larger diameter is more appropriate in order to give greater stability from buckling. Alternately, the inverting tube design illustrated in U.S. Pat. No. 6,189,941 referenced above is an alternate viable approach. Similarly, the rod or tube need not be reduced in diameter but can be caused to change shape, i.e., the apertures in the die assembly 260 have a different shape than the cross-sectional shape of the rods 262,266, or even part of the material can be cut as the rod or tube passes through the die, these options being alternative energy absorbing mechanisms. Naturally, many other such mechanisms will now be obvious to those skilled in the art.

[0104] The prime advantage of this third approach is the cost of the attenuator is reduced at the expense of some additional complication in collapsing the attenuator. If the case where a fixed die is used, the entire cost of the electronics and control system is eliminated.

[0105] Energy Absorption

[0106] Although the hydraulic system shown in FIGS. 1-4 is preferred, the pneumatic system shown in FIGS. 5-7 has some advantages especially where space is not as limited. A large airbag that can be injected with additional gas just prior to an impact, possibly in response to the anticipatory sensing of a vehicle about to impact the attenuator, also partially solves the loss of space problem which occurs due to the compressibility of air during impact. Alternately, a sacrificial plastically deformable metal structure can be provided to compensate for the compression of the air during the initial stages of the impact. The design of such structures is known in the art but their use in this manner is unique.

[0107] Both the hydraulic and the pneumatic systems can be affected by the mass of the TMA structure. This may or may not be an advantage and in some cases it is desirable to add additional mass which must be accelerated by the impacting vehicle as part of the system. The crush characteristics of the impacting vehicle should also be taken into account in the design of the TMA The vehicle crush has the effect of giving a lower deceleration during the initial portion of the impact and a higher deceleration in the later portion when the vehicle is subjected to a constant force. This should be compensated for in the TMA algorithm since the sensing system 80 measures the deceleration of the front of the impacting vehicle rather than, as desired, its center of gravity.

[0108] Interception of Impacting Vehicle

[0109] Current TMAs make little provision for effecting the trajectory of the impacting vehicle. This is important since it is not desirable to deflect the vehicle off of the TMA if this can be avoided. Such a deflection could result in further accidents by allowing the impacting vehicle to leave the road and impact a tree, for example, or direct it into the path of oncoming traffic. When possible, therefore, the impacting vehicle should be captured by the TMA.

[0110] In accordance with the invention, means for guiding the path or trajectory of the object after impact into the bumper may be provided. For example, this can be done to some extent through the design of the TMA where the sides of the bumper 70 are made stiffer than the center. As shown in FIGS. 2-5, this is achieved by forming a recessed area 78 in the center region of the bumper 70 facing the impacting vehicle. In the alternative, in some cases it is desirable to provide wing-like structures, which extend laterally beyond the TMA, to further guide the vehicle into the center of the TMA.

[0111] Additionally, some local structure associated with the end of the TMA that is impacted can be designed to grab the impacting vehicle to prevent it from sliding off of the face of the TMA. One example of such a structure is shown in FIG. 7 wherein the bumper 124 is concave.

[0112] An alternate solution is to permit local plastic deformation of the face of the TMA so that it conforms to the surface of the impacting vehicle to oppose sliding of the vehicle off of the TMA face. This will result in some permanent damage to the TMA face. In this case, the face should be made as a replaceable part.

[0113] Electronics & Functional

[0114] The TMA is designed to provide a constant deceleration to any object that impacts it. This design deceleration is a particular value that is chosen to minimize injuries to vehicle occupants. A potential problem exists in that the deceleration must also be sufficient to trigger deployment of the airbags within the vehicle. This poses a problem since the airbag crash sensor algorithms are generally considered proprietary and therefore are unknown to the TMA designer. The TMA designer must be careful that an optimum design of one safety system does not defeat another safety system and thereby result in more injury than would otherwise occur.

[0115] Basically, if the TMA is designed to provide a constant deceleration of typically 15 Gs, for example, the force exerted onto the vehicle by the TMA should be proportional to the mass of the impacting vehicle regardless of its impacting velocity. Since the mass of possible impacting vehicles varies by a factor of three or more, the TMA must be capable of supplying forces having a similar variation in magnitude. This is accomplished by having sensors that are capable of sensing the deceleration of the impacting vehicle as described above. Sensor technologies which are capable of this function include mechanical seismic devices, radar, accelerometers, string potentiometers, laser optical ranging sensors (lidar), ultrasonic ranging sensors, and mechanical probes, among others.

[0116] Although the preferred embodiment uses sensors that sense the deceleration of the impacting vehicle, or the face of the TMA which is assumed to approximately represent the impacting vehicle, anticipatory sensing using a neural network derived algorithm can also be used beneficially. In all cases, in the instant invention the sensors provide information to the control module which adjusts the opening of the airbag valve or the hydraulic cylinder orifices (the flow restrictors) to adjust the force of the TMA face against the vehicle to achieve the desired constant deceleration.

[0117] It is believed that the invention disclosed herein is the first adaptive crash attenuator system. Namely, it is believed that it is the first system to vary the force of the impactor against the impacting vehicle in response to the vehicle deceleration. It is the first electronic system applied to impactors. It is also the first adjustable or adaptive impact attenuator system.

[0118] Restrictor

[0119] The restrictor which is used to control the flow of the fluid from the airbag(s) (pneumatic embodiment shown in FIGS. 5-7) or the fluid from the actuators 60,64 (hydraulic embodiment shown in FIGS. 1-4) is an important part of this invention. The size of the restrictor opening, along with the pressure within the chamber, determines the flow of the fluid out of the airbag(s) or hydraulic cylinders. This in turn determines the force that the TMA applies to the impacting vehicle and thus the deceleration of the impacting vehicle. The size of the restrictor opening is determined by an actuator and associated Electronic Control Unit (ECU) 80 that contains a microcomputer and associated algorithm.

[0120] In operation, accelerometers coupled to the ECU 80 first determine that the impact-receiving face of the TMA is being impacted as the face initially achieves the velocity of the impacting vehicle. The TMA's impact-receiving face, and the impacting vehicle, then begin decelerating at substantially the same rate, which deceleration is measured by the accelerometers or other types of sensors as described above.

[0121] The accelerometer or other sensor signal(s) is/are fed into the ECU, which determines the rate of deceleration of the face and vehicle. If this rate is above the predetermined value, the restrictor is opened allowing more fluid to flow out which reduces the pressure in the chamber (hydraulic cylinder or airbag) and thus reduces the resistive force of the TMA repelling or opposing the movement of the impacting vehicle. If the deceleration is too great, that fact is determined by the ECU and the restrictor opening is made smaller to reduce the outflow of fluid from the chamber in the hydraulic actuators 60,64 (FIGS. 1-4) or airbag(s) 112 (FIGS. 5-7). In this manner, the deceleration of the TMA face and thus the impacting vehicle is controlled to the prescribed, predetermined value.

[0122] The algorithm in the ECU includes corrections for the mass and thus the dynamics of the truck on which the TMA is mounted as well as, to the extent possible, for the crush of the impacting vehicle. In some implementations when multiple accelerometers or other sensors are present permitting a measurement of the rotation of the vehicles, that fact can also be taken into account in the algorithm and used to more accurately adjust the restrictors to attempt to reduce the vehicle rotation.

[0123] Pressurization (Pneumatic Case)

[0124] For the pneumatic case shown in FIGS. 5-7, the airbag(s) 112 is/are expanded when the truck arrives at the work site using a pump or other pneumatic pressurizing device 120 such as a vacuum cleaner type pump or a small turbine. If desired, the pump can increase the airbag pressure to a value above atmospheric pressure thereby reducing the compressibility effects described above.

[0125] Additionally, if an anticipatory crash sensor such as a radar or lidar system is used, or another sensor or sensor system (which may be based on pattern recognition techniques) which will detect the impending impact of a vehicle into the attenuator 10A, a pyrotechnic inflator can also be employed which will substantially increase the pressure in the airbag immediately prior to the impact in much the same manner as interior airbag inflators supply gas to a driver or passenger airbag during a crash. Instead of a pyrotechnic inflator, other available inflators can also be used. The pressure should be increased to about 15 psi, which may be achieved by using a pump, a compressor, a turbine or by heating the gas with an inflator after impact has been predicted by, for example, an anticipatory sensor, or after the impact has started (the impact has been detected).

[0126] Applications

[0127] The primary application for the TMA of this invention is for mounting onto movable platforms such as trucks to provide protection for highway work crews. Naturally, the teachings are also applicable to fixed installations especially where there is limited available space. This invention is the first smart crash attenuator which adjusts the restraining force automatically in response to the kinetic energy of the impacting vehicle or object.

[0128] The application of such sensing systems to other safety barriers will now be possible and, thus, the invention disclosed here is not limited to crash attenuators. In particular, in many cases there is insufficient space to deploy even the attenuators described herein in their expanded state and thus anticipatory sensing, i.e., sensing an impending impact of a vehicle into the attenuator, coupled with pyrotechnic inflators may be used to permit an airbag crash attenuator to be deployed in anticipation of a crash to cushion an impacting vehicle. This is believed to be the first use of an airbag mounted on a fixed structure which inflates to cushion the impact of a vehicle. Alternatively, in the hydraulic embodiment shown in FIGS. 1-4, the hydraulic cylinders 60,64 may be actuated to extend the scissors mechanism upon a determination of an impending crash by an anticipatory sensor system.

[0129] Such a device will find wide application along with the development of smart highways where vehicles are automatically guided at high speeds. On such highways, a vehicle may suffer a catastrophic failure and go out of control. An anticipatory sensor with a deployable crash attenuator would then cushion the impact of the troubled vehicle. For the cases of anticipatory sensors, a neural network based algorithm such as disclosed in U.S. patent application Ser. No. 08/247,760 may be used.

[0130] Other Advantages

[0131] A key advantage of the attenuators of this invention is that they are for the most part collapsible to a length substantially shorter than their expanded or deployed length. In some cases, the collapsed length is less than about 25% of the expanded length. This permits the attenuator to be easily stored, shipped and transported to the work site. To decrease their length, current TMAs are rotated into a vertical position during transportation to the work site. This not only requires expensive hydraulic apparatus to be mounted onto the vehicle to provide the power to rotate the TMA to and from the vertical position but it also limits the length of the TMA and thus the degree of protection afforded by the device.

[0132] The attenuator of the present invention also has a relatively lighter weight than current attenuators of comparable capacity. This is a result of the structural optimization in the design of this invention.

[0133] Finally, providing the attenuator is impacted within its design capabilities, the device can be reused shortly after an impact.

[0134] Crash attenuators in accordance with this invention are first designed as a structural mechanism which is capable of supporting the loads arising from the impact of a vehicle and the resulting reaction loads arising from the truck inertial loading and the energy dissipation or damping device. The damping device is then designed which may be either one or more hydraulic cylinders, and/or one or more inflatable/deflatable airbags, and/or one or more controlled metal deformation mechanisms. This separates the structural function from the energy dissipation function and permits the optimization of each separately. In all three cases, a movable displacement structure is provided to enable movement of a bumper having an impact-receiving face toward and away from a frame connected to the truck or stationary structure.

[0135] The displacement structure may comprise a scissors mechanism that has an expanded condition in which the bumper is distant from the frame and a contracted condition in which the bumper is relatively close to the frame. Similar scissors mechanisms have found a successful application for cases of load lifting in industrial settings. The energy dissipation device is coupled to the scissors mechanism and can be either hydraulic, pneumatic, or based on the deformation of metal, although the hydraulic design is preferred for most applications.

[0136] When based on the deformation of metal, i.e., deformation energy absorption means are coupled to the displacement structure for dissipating at least some of the impact energy of the object received by the bumper which causes the displacement structure to be moved from the first position toward the second position and thereby reducing the velocity of the object. Such deformation energy absorption means may comprise at least one deformable member is deformed upon movement of the displacement structure from the first position toward the second position with such deformation causing dissipation of impact energy of the object received by the bumper. The deformable members may be in the form of solid rods, hollow tubes, with such rods or tubes having non-specific cross-sections, e.g., circular cross-section, oval cross-section, square cross-section, etc. The deformation energy absorption means may further comprise a die assembly having a respective aperture through which each deformable member is forced. Multiple die assemblies can be provided, e.g., one die assembly for each deformable member or one die assembly for each pair of deformable members.

[0137] To enable deformation of cylindrical members, the apertures may have a smaller diameter than the diameter of the respective member being forced therethrough. The diameter may be controlled to vary in order to thereby vary the dissipation force. A smaller diameter aperture will provide a greater dissipation force relative to a larger diameter aperture for the same diameter member, with both smaller and larger diameter aperture s being smaller than the diameter of the member. In addition to or instead of enabling deformation by providing a smaller diameter, the apertures can have a different shape than the rods, e.g., cylindrical rods with oval-shaped apertures.

[0138] If the members have a square or rectangular cross-section, then the apertures can also have a smaller square or rectangular cross-section, respectively, and optionally a different shape.

[0139] An expansion arrangement is provided to displace the displacement structure from the second position to the first position. To this end, a hydraulic cylinder may be positioned between the frame and a support rod connected to the die assembly. The hydraulic cylinder is arranged to freely allow movement of the displacement structure from the first position to the second position.

[0140] In a method for protecting a truck or fixed structure from damage resulting upon impact of a moving object with the truck or structure, a movable displacement structure is mounted to the truck or structure, the displacement structure having an expanded position and a contracted position, a bumper having an impact-receiving face adapted to receive the impact from the moving object is arranged on the displacement structure, and at least one deformable member is arranged in connection with the displacement structure and in a position in which it is caused to deform upon movement of the displacement structure from its expanded position to its contracted position. Such deformation is effective to dissipate at least some of the impact energy of the moving object and reduce the velocity of the moving object.

[0141] When members having a circular cross-section are used, a die assembly having a respective aperture having a smaller diameter than the diameter of the member is provided such that deformation of the member is caused by forcing the member into the respective aperture. The dissipation force is then controlled by varying the diameter of the respective aperture. Another die assembly can have apertures having a different shape than the shape of the members such that deformation of the members is caused by forcing the member into the respective aperture.

[0142] The properties of the member can also be selected appropriately to provide for a desired dissipation force.

[0143] When the deformation of metal is used herein, it must be understood that use of metal is not intended to limit the scope of the invention and other materials which exhibit similar properties as metal may also be used in the invention.

[0144] This approach was only partially implemented in U.S. Pat. No. 5,248,129 to Gertz wherein a scissors mechanism is coupled with energy absorbing elements and in U.S. Pat. No. 5,642,792 to June wherein a hinged support frame supports an energy absorbing rectangular box-like structure. A preferred design of a crash attenuator in accordance with the invention combines a scissors or other expandable structure containing a plurality of sections, preferably at least three or four sections, with hydraulic damping cylinders. In a second design of a crash attenuator in accordance with the invention, the scissors mechanism houses at least one inflatable airbag which may be in the form of an accordion structure with the various sections of the airbag internally tethered for shape retention. Other shape retention means may also be provided in connection with the airbag(s). In third design of a crash attenuator in accordance with the invention, a design similar to the hydraulic design is used with the hydraulic cylinders replaced with collapsing metal deformation energy dissipation devices.

[0145] An electronic control module may be incorporated onto the scissors mechanism in order to sense the motion of an impacting vehicle and control the opening of exhaust orifices associated with the hydraulic, the pneumatic energy dissipation device, or the metal deformation energy dissipation device in order to achieve a substantially constant deceleration of the vehicle regardless of the mass and velocity of the impacting vehicle. The cross section area of the airbag(s) will be made as large as possible in the pneumatic case in order to minimize the initial compression of the airbag(s) before maximum pressure is obtained. The motion sensing system may be ultrasonic, radar or lidar based, or preferably accelerometer based. An electronically controlled valve is used to control the flow of either the hydraulic fluid or other medium from hydraulic cylinders in the hydraulic case, or gas or other medium out of the airbag(s) for the pneumatic case, during impact. A motor controlled die can be used to perform a similar functions for the metal deformation design.

[0146] The system functions as follows. In the collapsed state, the TMA will occupy a space of typically approximately 25% of its expanded state making it easy to transport, store and ship. It could occupy any amount less than about 50% of its expanded state. This is facilitated by the use of a scissors mechanism comprises linked members articulated to one another. Upon arrival at the work site, a hydraulic pump in the hydraulic or metal deformation cases, or small vacuum cleaner type pump for the pneumatic case, can be activated to expand the TMA to its extended state where it is ready to receive an impact. The scissors mechanism will thus be expanded as the hydraulic pump is actuated to extend pistons associated therewith, the cylinder and piston of each hydraulic cylinder being connected to different parts of the scissors mechanism, or the airbag(s) is(are) inflated.

[0147] Bumpers at the end of the TMA, made from a material such as polyurethane foam, provide a low level of energy absorption for low speed impacts. At higher speeds, a deformable sub-bumper structure can be used to help channel the vehicle into the center of the TMA and capture it to prevent it from being deflected off of the TMA. In some cases, no compliant bumper is used and the bumper is a rigid metal plate.

[0148] Accelerometers can be located in the rear of the bumper structure to sense the deceleration of the bumper, and thus the deceleration of the impacting vehicle. These accelerometers can send signals to a control module, which then adjusts the valve or orifice openings to control the fluid outflow from the hydraulic cylinders or medium outflow from the airbag(s), or the opening of a die or other similar mechanism for the metal deformation case, and thereby vary the energy dissipation force provided by the energy dissipation device and as a result, the vehicle deceleration. In the hydraulic embodiment, the rate of fluid outflow will be reflected in the movement of the piston back into the cylinder. In this manner, the system will provide a large energy dissipation force when the impacting vehicle is a heavy vehicle and a lower energy dissipation force for light vehicles, thus approximately stopping both types of vehicles in the same distance for the same velocity of impact. This permits a more efficient utilization of the available crush space and thus minimizes the size of the TMA. A similar function can be provided in the metal deformation case.

[0149] Some loss of efficiency results from the initial compressibility of the gas in the airbag for the pneumatic case. However, calculations set forth in Appendix 1 show that this loss of efficiency is manageable without greatly increasing the length of the TMA if atmospheric pressure is used. To the extent that the airbag can be pressurized, this effect will become smaller. Other energy absorption mechanisms, such as those using the deformation of metal as discussed below, that provide a force in parallel at least during the compression stage can of course be added to help compensate for this compressibility effect.

[0150] Another concern of the pneumatic system is in the compliance of the airbag itself. Once again, calculations indicate that this should not be a significant problem if the airbag is properly designed. In some cases, an accordion design with simple tethering will prove to be insufficient and a design based on a self-shaping airbag design, as disclosed in U.S. Pat. No. 5,653,464 incorporated herein by reference, which solves the problem by properly shaping the airbag to cause it to naturally take on the desired shape.

[0151] Although the preferred design uses electronics to control the energy absorption system, such as the valve associated with the hydraulic cylinders or orifice opening(s) associated with the airbag(s), other variations include the use of a mechanical system to sense the acceleration and control the opening of the flow restrictors, i.e., the valve or orifice openings. This results in an all-mechanical system by eliminating the electronics. The all-mechanical system is particularly applicable for fixed installations in addition to truck mounted applications.

[0152] In one method for protecting a truck or fixed structure in accordance with the invention, a movable displacement structure is mounted to the truck or structure and has an expanded position and a contracted position. A bumper having an impact-receiving face adapted to receive an impact from an object in a crash is arranged on the displacement structure. The displacement structure is preferably stored and transported in its contracted condition and when readied for use, it is expanded to its expanded position. In use, impact of an object into the bumper which causes the displacement structure to be moved from the expanded position toward the contract position is sensed and at least some, if not all, of the impact energy of the object is dissipated by adjusting an energy dissipation force such that the object is brought to rest. In some preferred embodiments, the displacement structure may be expanded after the impact energy of the object is dissipated such that the crash attenuator is reusable.

[0153] It is possible to sense deceleration of the object after impact into the bumper and adjust the energy dissipation force based on the sensed deceleration of the object. The hydraulic, pneumatic and metal deformation systems described herein may be applied.

[0154] Roadside Barriers

[0155] What has been learned for TMAs can now be applied to the design of roadside barriers. First, a review of the literature shows that the normal guardrail design and the implementation of guardrails for bullnose median barrier designs, for example, results in many unnecessary injuries and fatalities (see for example the paper In-service Performance Evaluation of the Bullnose Median Barrier in the State of Iowa, presented at the Transportation Research Board 80^th Annual Meeting, Jan. 7-11, 2001 and quoted above).

[0156] FIGS. 11 and 11A show a prior art bullnose roadside median barrier installation such as reported in the Iowa study and FIG. 12 shows an improved bullnose median barrier installation in accordance with the invention (designated 298).

[0157] Note that there is no need to make a closed elliptical shield as is conventionally done and illustrated in both FIGS. 11 and 12, since a vehicle cannot approach the hazard through the area of the dead zone, as shown on FIG. 12, unless it is traveling in the wrong direction on the roadway. This can result in a substantially simpler installation by eliminating sections that cannot be impacted. The resulting installation can be as mush as about 40% smaller. The barrier 298 of FIG. 12 is not anchored to the ground with wooden or concrete posts and thus does not rely on the non-reproducible forces that such conventional structures produce. The barrier 298 shown in FIG. 12 does not tip over as do the conventional designs which thus allow the vehicle to override the barrier.

[0158] The embodiment shown in FIG. 12 is engineered to provide reproducible retarding forces to the crashing vehicle and to apply those forces at the most effective point and manner. The design relies on momentum changes to the vehicle in much the same manner as the sand-filled crash cushions are designed to do. However, instead of the sand mass being scattered as in the case of the sand barrels, it becomes part of the vehicle, i.e., is moved along with the vehicle, further aiding in its slowing down through the generation of increased friction forces with the ground. It thus makes much more efficient use of the sand mass.

[0159] FIGS. 13A, 13B and 13C show cross section details of the median barrier 298 of FIG. 12, with each section of the barrier 298 being designated generally as 300, and various methods of adding mass to the barrier. FIG. 13A illustrates a conventional barrier face with a typical guardrail front plate 302 and a wood backing 304. Backing 304 may be made of materials other than wood.

[0160] Studies made of TMAs with various facings have shown that such facings add only cost to the barrier and essentially no functionality. If the face can be designed to reduce the tendency of the vehicle to slide off of the face than perhaps there would be some value but if the center of gravity is not on a line perpendicular to the barrier face and passing through the vehicle bumper then it will rotate and slide off the barrier if there is room to do so. Therefore, a flat steel face is probably sufficient.

[0161] FIG. 13A uses a barrel 306 to hold the sand, gravel or other mass. The barrier section 300 also comprises a horizontal portion or flange 310 which may be made of steel, or another suitable rigid or non-rigid material, and optionally has protrusions 314 extending downward from the horizontal portion 310 into the ground to increase the drag by the earth upon movement of the barrier section in the direction fo the arrow. The length L of the front, left portion of the barrier section 300, i.e., that portion of the barrier section 300 extending in a forward direction relative to the vertical portion 308, can be about 2 meters. The protrusions 314 may be triangular-shaped and oriented with a flat surface perpendicular to the horizontal portion 310 at a rear to thereby increase the drag upon movement of the barrier section 300 in the direction of the arrow representing the impacting vehicle. The barrel 306 is positioned on a rear part of the horizontal member 310 behind the vertical portion 308.

[0162] The horizontal portion 310 of the barrier section 298 can be attached to the vertical portion 308 by welding and/or by reinforcing members shown as 316 in FIG. 13B. A composite or sandwich structure can also be used to reduce the cost of the barrier section 298. Such a sandwich can be made from steel and concrete or other appropriate materials.

[0163] The horizontal portion 310 can also be formed integral with the vertical portion 308 and the protrusions 314, or these components are be formed separately and attached to one another.

[0164] As shown in FIG. 13B, the barrier section 300 can accumulate mass (sand in this case) as it moves after impact by the vehicle and the rate of accumulation can be controlled by the distribution of gravel or sand on the ground in the path of the barrier section 300. Thus, one method for slowing and finally stopping movement of a vehicle in accordance with the invention would be to provide the barrier section 300 with a predetermined amount of mass, e.g., sand, and then provide additional sand in the path of movement of the barrier section after impact by a vehicle. The quantity or mass of the additional sand could be designed to gradually slow the vehicle, e.g., placed in increments.

[0165] An alternate design is to use a receptacle or box structure 318 to hold the sand or gravel as shown in FIG. 13C. A combination of these designs can be used at a given installation. For example, it may be desirable to place particularly heavy barrier sections at the ends of an installation to serve as anchors with the interior barrier sections made much lighter. Also, the distribution of mass in the barrels or boxes can be made such that the center of gravity of the mass can be at any desired vertical location. This then minimizes the tendency of higher center of gravity vehicles to override the barrier by placing the center of force higher on the barrier.

[0166] The face of the barrier 298 can be made from steel and supported with supporting flanges. Alternately, the non-impacted side of the barrier 298 can comprise a box which can be filled with sand, gravel or other material to increase the mass of the barrier 298. Since the face of the barrier 298 is relatively high compared with guard rails, the center of gravity of all but the largest trucks is below the top of the barrier 298. Since the lower flange 310 of the barrier section 300 engages the wheels of an impacting vehicle, the barrier section 300 will not tip over. Even if the front part of the horizontal portion 310 is covered by dirt, the vehicle will still be over the front part of the horizontal portion 310 and will prevent the barrier section 300 from tipping over. The lower portion of the barrier face goes all the way to the ground and thus underrides are also prevented. Thus this design prevents, overrides, underrides and does not create a rollover situation.

[0167] The bottom of the impacted face of the barrier 298 can be provided with a sloping section, not shown, to redirect a vehicle back onto the roadway when a vehicle strays slightly to where it glances off of the barrier much in the same manner as with the so-called New Jersey or GM barriers, the concrete barriers that are found in many work zones. In this embodiment, however, the vehicle is more carefully introduced back into the traffic flow since the barrier will give somewhat and thus minimize the accidents that can occur from an impact off of a GM or NJ barrier. As the impact angle increases, there is less of a chance of the vehicle rebounding off of the barrier again making this design far safer than the NJ or GM designs.

[0168] FIG. 14 shows a detail of the linking system whereby an errant vehicle is captured by a linked barrier and brought to a stop. The linked barrier 330 comprises a number of individual barrier sections 300 as described with respect to FIGS. 13A, 13B and 13C and each being provided with a link 322 at one end. The links 322 of adjacent barrier section 300 are joined together as shown to form the linked barrier 330. As such, the length of the linked barrier 330 can be selected as desired, e.g., by providing the necessary number of barrier sections 300 until the desired length is attained. Other cooperating mechanisms for joining the edges of the adjacent barrier sections 300 can also be used, including some mechanisms which are not formed in connection with the barrier sections 300 themselves.

[0169] This is a particular feature of this design in that it automatically accommodates impacting vehicles 324 having different masses. They will not all see the same deceleration but a small light vehicle and a relatively large truck will both be safely brought to a stop providing there is sufficient space available. As the vehicle 324 penetrates the barrier 330 further, it picks up more mass and thus a greater force tending to slow it down first by the transfer of momentum effect and then by the friction effect of the barrier sections 300 being dragged along with the vehicle.

[0170] The barrier sections 300 can merely sit on the ground where with the weight of much of the vehicle 324 resting on the barrier flange 310 causes a deceleration from friction with the ground that can slow the vehicle at a very gradual deceleration, perhaps at 1 G. This is permissible if there is sufficient space for the barrier 330 to travel. The initial impact with the barrier 330 will slow the impacting vehicle by virtue of the conservation of momentum. The initial mass of the barrier 330 can be controlled and the barrier 330 can be designed to accumulate mass as it travels thus creating any reasonable desired force onto the impacting vehicle.

[0171] Furthermore, as shown in FIG. 14, one barrier section 300 can be linked to others so that mass can be added as more and more barrier sections 300 are involved. Finally, a variety of projections or protrusions can extend down into the earth from the barrier sections 300 and plow up the earth as the barrier 330 travels. This would generally only work in places where the ground does not freeze. However, in northern climates, the barrier 330 can be placed on a bed of gravel that has sufficient drainage to prevent water accumulation and freezing.

[0172] FIG. 15 illustrates an alternate design employing an energy absorbing expandable metal joint between the sections 300 of the barrier. The linkages that join two or more barrier sections 300 can be a normal pin type hinge or a section of expandable metal 320 or other structure such as a rod and die design can be used. As such, when an errant vehicle strikes one barrier section 300 and begins moving it, the metal that joins the adjacent barrier section will begin to expand (see FIG. 15A). This will dissipate some energy before the adjacent barrier section begins moving. It will also expand the area covered by the barrier sections and help to form a pocket to trap the errant vehicle. Expandable metal is made by partially slitting a metal sheet (See FIG. 15B) so that when the ends are pulled the metal expands forming diamond shaped holes. After a point, the metal stops expanding and begins to pull on the adjacent barrier section. This also helps to form pockets that trap the vehicle.

[0173] FIG. 16 illustrates the use of sensors 342 that communicates with a control location such as the local police 344 via a wireless communication system 346 when an impact into the barrier 300 occurs. This communication can be via a cell phone in which case either a direct electrical power or a solar battery is necessary to provide long term uninterrupted service.

[0174] An alternate approach is to use the Skybitz or equivalent satellite based system as described in co-pending U.S. provisional patent application 60/387,792 filed Jun. 11, 2002. In this case, an up to 10 year lifetime battery is used and the sensor communicates once per day to verify that it is operational and additionally whenever an event such as an impact with the barrier 300 occurs. Thus, the remote monitoring and control station can monitor on a daily basis that the sensor(s) 342 is operational and learn within a few minutes or less when an impact has occurred. In addition to permitting a rapid response to an accident where there may be injuries, this system also alerts the authorities to any accident with the barrier 300 permitting them to quickly find the impacting vehicle and assess repair costs. Today, many vehicles drive away after damaging barriers, particularly crash cushions, leaving the repair costs to be paid for by the taxpayers. This added feature will go along way to paying the costs of installing and maintaining the barriers of this invention.

[0175] The sensors 342 used with this system can be simple motion sensors such as an inertial switch or deformation sensor or they can be more sophisticated inertial sensors, for example, such as a MEMS accelerometer. In the latter case, the authorities can get a feeling for the severity of the accident. Cameras, chemical, temperature and other sensors and equipment can also be added to the Skybitz type system, for example. If vibration sensors are placed in the ground, for example, even unauthorized median crossing can, in some cases, be sensed. Such sensors can also switch on a video camera if desired. They may be installed rather deep in the ground so that they are safe from the environment and vandals.

[0176] A sensor system including the sensors 342 can be situated on the barrier section 300, under the barrier section 300, behind the barrier section 300 such as in a path of movement of the barrier section 300 after impact, or, as in particular with the case when the sensor system includes cameras, with a field of view encompassing the barrier section 300.

[0177] It is important to note that now that the sensor systems described herein have been disclosed, there are many other road-mounted structures such as stop signs etc. or other devices that are frequently destroyed long before the police become aware of an event. Now all such structures can be monitored for events and provide immediate notification to the authorities in time to catch the vandal or impacting vehicle or other perpetrator.

[0178] An important teaching of this invention is the use of a barrier as an inertial damper on the errant vehicle. The weight of the barrier is not so large as to cause the errant vehicle to experience a barrier crash and in most cases, the airbag will not deploy. It will look like a relatively soft crash to the airbag sensors. As the crash progresses and the vehicle slows down, additional mass can be added to continue the process. Simultaneously, the barrier is rubbing against the ground that also dissipates energy and gradually the vehicle is brought to a stop.

[0179] Although shown as straight sections, the barrier need not be flat and in some cases a curved shape is preferable. For example, when protecting a vehicle from an impact with a pole, a curved shape can be used to help deflect the vehicle away from the pole. For some end treatments of guard rail substitutions, the last section can contain a 90 degree curve to minimize the damage to vehicles that slide sideways into the end.

[0180] Another important advantage of the barrier of this invention is that is most cases, the barrier is displaced by the accident but not destroyed or even damaged. Thus, the repair and maintenance costs are minimal.

[0181] Since all portions of an installation are designed to be impacted, there is no need for a special lead-in structure as is common with guardrails. These lead-in sections are known for causing a vehicle to flip or rollover under certain types of accident. Although several preferred embodiments are illustrated and described above, there are possible combinations using other geometries, sensors, materials and different dimensions for the components that perform the same functions. This invention is not limited to the above embodiments and should be determined by the following claims.

[0182] It will be understood that numerous modifications and substitution can be made to the above-described embodiments without deviating from the scope and spirit of the invention. Accordingly, the above-described embodiments are intended for the purpose of illustration and not as limitation.

[0183] The preferred embodiments of the invention are described above and unless specifically noted, it is the applicant's intention that the words and phrases in the specification and claims be given the ordinary and accustomed meaning to those of ordinary skill in the applicable art(s). If applicants intend any other meaning, they will specifically state they are applying a special meaning to a word or phrase.

[0184] Likewise, applicant's use of the word function here is not intended to indicate that the applicant seeks to invoke the special provisions of 35 U.S.C. 112, sixth paragraph, to define their invention. To the contrary, if applicant wishes to invoke the provisions of 35 U.S.C. 112, sixth paragraph, to define his invention, he will specifically set forth in the claims the phrases means for or step for and a function, without also reciting in that phrase any structure, material or act in support of the function. Moreover, even if applicant invokes the provisions of 35 U.S.C. 112, sixth paragraph, to define his invention, it is the applicant's intention that his inventions not be limited to the specific structure, material or acts that are described in the preferred embodiments herein. Rather, if applicant claims his inventions by specifically invoking the provisions of 35 U.S.C. 112, sixth paragraph, it is nonetheless his intention to cover and include any and all structure, materials or acts that perform the claimed function, along with any and all known or later developed equivalent structures, materials or acts for performing the claimed function.